Gek97310 PDF

GE Industrial AeroDerivative
Gas Turbines
1 Neumann Way
MD S133
Cincinnati, Ohio 45215
FAX: (513) 552-5009
15 August 2003
Subject: Revision, dated 30 June 2003 to LM2500 Industrial Gas

Generator/Gas Turbine ON-Site Operation and Maintenance
Manual GEK 97310.
This revision replaces the Operation and Maintenance Manual GEK 97310,
dated 1 April 1998, Change 1, dated 15 August 1990, Change 2, dated 15 April
1993, Change 3, dated 31 March 1994, Change 4, dated 15 December 1995.
The following ICN’s are incorporated: ICN NO. GEK 97310-30, dated 31
December 1996, ICN NO. GEK 97310-31, dated 31 December 1996, ICN NO.
GEK 97310-32, dated 30 June 1997, ICN NO. GEK 97310-33, dated 8 October
1997, ICN NO. GEK 97310-34, dated 1 June 1998, ICN NO. GEK 97310-35
dated 29 June 1998, ICN NO. GEK 97310-36 dated 29 January 1999, ICN NO.
GEK 97310-37 dated 14 August 2000, ICN NO. GEK 97310-38 dated 28 October
2000, ICN NO. GEK 97310-39 dated 22 March 2002, ICN NO. GEK 97310-40
dated 5 August 2002 supporting the LM2500-G and P Series, Industrial Gas
Generators/Gas Turbines.
This printing replaces the entire GEK 97310 Operation and Maintenance Manual.
No filing is necessary.
Questions and/ or comments on the technical content of this publication

should be directed to the Customer Service Representative.
Corrections or additions to the distribution requirements of this manual should be

made on the attached form and return to Customer Service Representative.
Gas Turbines
DISTRIBUTION LIST UPDATES

If there were any corrections to the distribution of GEK ____________ (write in
manual Number from letter) please fill in information below and fax completed
form to address below. For request for other manuals or change in quantity
contact your Customer Service Manager.
GE Industrial Aero-Derivative & Marine Gas Turbines

Attn. Customer Service Representative
Fax (513) 552-5009
DATE: ________________
Company Name:
__________________________________________
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Gas Turbines
GEK 97310
Volume I
ON-SITE OPERATION AND MAINTENANCE MANUAL
FOR GE
LM2500 G SERIES GAS GENERATORS
AND
LM2500 P SERIES GAS TURBINES
INDUSTRIAL AERODERIVATIVE
GAS TURBINES
GE Industrial Aeroderivative Gas Turbines

Mail Drop S-133
One Neumann Way
P.O. Box 156301
Cincinnati, Ohio 45215-6301, USA
Gas Turbines
GEK 97310
Volume I
FOR GE
AND
GAS TURBINES
GE PROPRIETARY INFORMATION
The information contained in this document is GE proprietary information and is
disclosed in confidence. It is the property of GE and shall not be used, disclosed to
others, or reproduced without the express written consent of GE, including, but
without limitation, it is not to be used in the creation, manufacture, development, or
derivation of any repairs, modifications, spare parts, design, or configuration
changes or any other government or regulatory approval to do so. If consent is given
for reproduction in whole or in part, this notice and the notice set forth on each page
of this document shall appear in any such reproduction in whole or in part. The
information contained in this document may also be controlled by U.S. export control
laws. Unauthorized export or re-export is prohibited.
COPYRIGHT 1989-2003 General Electric Company, USA
NOTE: THIS REVISION REPLACES GEK 97310 VOLUME I DATED 1 APRIL 1988,
CHANGE 1 DATED 15 AUGUST 1990, CHANGE 2 DATED 15 APRIL 1993,
CHANGE 3 DATED 31 MARCH 1994, CHANGE 4 DATED 15 DECEMBER 1995,
ICN GEK 97310-34 DATED 1 JUNE 1998, ICN GEK 97310-35 DATED
29 JUNE 1998, ICN 97310-37 DATED 14 AUGUST 2000, ICN GEK 97310-38
DATED 28 OCTOBER 2000, ICN GEK 97310-39 DATED 22 MARCH 2002,
ICN GEK 97310-40 DATED 5 AUGUST 2002

Mail Drop S-133
One Neumann Way
P.O. Box 156301
30 JUNE 2003
GEK 97310
VOLUME I
LIST OF EFFECTIVE PAGES
This On-Site Operation and Maintenance Manual is part of an industrial LM2500 set which includes:
GEK 50336 LM2500 IPB
GEK 97310 O&M Vol II
GEK 99418 LM2500 IRM
GEK 108730 CD-LM2500 Series Gas Generator/Gas Turbine
While this manual has been carefully prepared, there may be occasions when inconsistencies occur with respect to
a given gas generator. If such event occurs, contact GE Aircraft Engines, Marine & Industrial Engines and Service
Division for clarification. In no event is this manual to be considered a part of the gas generator Specification under
which any gas generator is purchased nor is it to be otherwise considered a part of any purchase contract except to
the extent specifically referenced therein and then subject to obtaining clarification of inconsistencies as pointed
out above.
Insert latest change pages (if required); dispose of the superseded pages in accordance with applicable regulations.
NOTE: On a change page, the portion of text affected by the latest change is indicated by a vertical line (change
bar) in the outer margin of the page. Changes to wiring diagrams are indicated by shaded areas.
Dates of issue for original and changed pages are:
Original . . . . . . . . . . . 0 . . . . . . . . . .30 June 2003
Total number of pages in this manual is 1586 consisting of the following:
Page * Change Page * Change Page * Change

Number No. Number No. Number No.
Title . . . . . . . . . . . . . . . 0 B-1 - B-31 . . . . . . . . . . . 0 M-32, blank . . . . . . . . . 0

A-B . . . . . . . . . . . . . . . . 0 B-32, blank . . . . . . . . . . 0 N-1 - N-41 . . . . . . . . . . 0
C, blank . . . . . . . . . . . . 0 C-1 - C-32 . . . . . . . . . . . 0 N-42, blank. . . . . . . . . . 0
i-xiv . . . . . . . . . . . . . . . 0 D-1 - D-34 . . . . . . . . . . . 0 O-1 - O-41 . . . . . . . . . . 0
1-1 - 1-32 . . . . . . . . . . . 0 E-1 - E-31 . . . . . . . . . . . 0 O-42, blank . . . . . . . . . 0
2-1 - 2-126 . . . . . . . . . . 0 E-32, blank . . . . . . . . . . 0 P-1 - P-31. . . . . . . . . . . 0
3-1 - 3-4 . . . . . . . . . . . . 0 F-1 - F-45 . . . . . . . . . . . 0 P-32, blank . . . . . . . . . . 0
4-1 - 4-34 . . . . . . . . . . . 0 F-46, blank . . . . . . . . . . 0 Q-1 - Q-35 . . . . . . . . . . 0
5-1 - 5-218 . . . . . . . . . . 0 G-1 - G-36. . . . . . . . . . . 0 Q-36, blank . . . . . . . . . 0
APPENDIX A H-1 - H-43 . . . . . . . . . . . 0 R-1 - R-34 . . . . . . . . . . 0
A-1 . . . . . . . . . . . . . . . . 0 H-44, blank . . . . . . . . . . 0 S-1 - S-36. . . . . . . . . . . 0
A-2, blank. . . . . . . . . . . 0 I-1 - I-33 . . . . . . . . . . . . 0 T-1 - T-43 . . . . . . . . . . . 0
A-3 - A-21 . . . . . . . . . . 0 I-34, blank . . . . . . . . . . . 0 T-44, blank . . . . . . . . . . 0
A-22, blank. . . . . . . . . . 0 J-1 - J41 . . . . . . . . . . . . 0 U-1 - U-34 . . . . . . . . . . 0
A-23 - A-26 . . . . . . . . . 0 J-42, blank . . . . . . . . . . 0 V-1 - V-47 . . . . . . . . . . . 0
ADDENDUMS K-1 - K-36 . . . . . . . . . . . 0 V-48, blank . . . . . . . . . . 0
L-1 - L-30 . . . . . . . . . . . 0 W-1 - W-48 . . . . . . . . . . 0
A-1 - A-39 . . . . . . . . . . 0
M-1 - M-31 . . . . . . . . . . 0 X-1 - X-42. . . . . . . . . . . 0
A-40, blank. . . . . . . . . . 0
* Zero in this column indicates an original page.
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Y-1 - Y-32 . . . . . . . . . . . 0
Z-1 - Z-38 . . . . . . . . . . . 0
AA-1 - AA-40 . . . . . . . . 0
AB-1 - AB-39 . . . . . . . . 0
AB-40, blank . . . . . . . . 0
AC-1 - AC-38 . . . . . . . . 0
AD-1 - AD-34 . . . . . . . . 0
B/(C, blank)
GEK 97310
VOLUME 1
TABLE OF CONTENTS
Chapter Title Page

1 INTRODUCTION .......................................................................................................................... 1-1
1-1 GENERAL INFORMATION........................................................................................................... 1-1
1-1.1 Purpose and Scope of Technical Manual ..................................................................................... 1-1
1-1.2 Levels of Maintenance .................................................................................................................. 1-1
1-1.3 Special Inspections....................................................................................................................... 1-1
1-1.4 Arrangement and Use of This Technical Manual .......................................................................... 1-2
1-1.5 Notes, Cautions, and Warnings .................................................................................................... 1-3
1-1.6 Changes to Technical Manual....................................................................................................... 1-3
1-1.7 Change Symbols .......................................................................................................................... 1-3
1-1.8 Text Changes ................................................................................................................................ 1-3
1-1.9 Page Changes .............................................................................................................................. 1-3
1-1.10 Changes to Illustrations ................................................................................................................ 1-3
1-1.11 Equipment Points of Reference .................................................................................................... 1-3
1-2 SAFETY........................................................................................................................................ 1-5
1-2.1 General ......................................................................................................................................... 1-5
1-2.2 Reference ..................................................................................................................................... 1-5
1-2.3 Safety Precautions........................................................................................................................ 1-8
1-3 EQUIPMENT DESCRIPTION ....................................................................................................... 1-9
1-3.1 General ......................................................................................................................................... 1-9
1-4 RELATIONSHIP OF MEASUREMENT UNITS ............................................................................. 1-29
1-5 REFERENCE DATA ...................................................................................................................... 1-29
1-5.1 General ......................................................................................................................................... 1-29
2 FUNCTIONAL DESCRIPTION ..................................................................................................... 2-1
2-1 INTRODUCTION .......................................................................................................................... 2-1
2-1.1 General ......................................................................................................................................... 2-1
2-2 GAS TURBINE ASSEMBLY.......................................................................................................... 2-1
2-2.1 General ......................................................................................................................................... 2-1
2-3 GAS GENERATOR ASSEMBLY ................................................................................................... 2-2
2-3.1 Inlet Section .................................................................................................................................. 2-2
2-3.2 Compressor Section ..................................................................................................................... 2-2
2-3.3 General ......................................................................................................................................... 2-2
2-3.4 Air Flow ......................................................................................................................................... 2-2
2-3.5 Support ......................................................................................................................................... 2-2
2-3.6 Front Frame Assembly .................................................................................................................. 2-2
2-3.7 Compressor Rotor ........................................................................................................................ 2-4
2-3.8 Compressor Stator........................................................................................................................ 2-4
2-3.9 Compressor Rear Frame .............................................................................................................. 2-14
2-3.10 Combustor Section ....................................................................................................................... 2-16
2-3.11 General ......................................................................................................................................... 2-16
2-3.12 Cowl Assembly ............................................................................................................................. 2-16
2-3.13 Combustor Mounting .................................................................................................................... 2-16
2-3.14 Swirl Cups..................................................................................................................................... 2-16
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2-3.15 Combustor Liners ......................................................................................................................... 2-16
2-3.16 High Pressure Turbine Section - Twin Shank Rotor Configuration................................................ 2-16
2-3.17 General ......................................................................................................................................... 2-16
2-3.18 Component Mounting ................................................................................................................... 2-17
2-3.19 High Pressure Turbine - Twin Shank Rotor Configuration............................................................. 2-17
2-3.20 Stage 1 Turbine Nozzle Assembly (Twin Shank Rotor Configuration) .......................................... 2-21
2-3.21 Stage 2 Turbine Nozzle Assembly (Twin Shank Rotor Configuration) .......................................... 2-21
2-3.22 High Pressure Turbine Section - Single Shank Rotor Configuration............................................. 2-24
2-3.23 General ......................................................................................................................................... 2-24
2-3.24 Component Mounting ................................................................................................................... 2-24
2-3.25 High Pressure Turbine Rotor - Single Shank Rotor Configuration ................................................ 2-24
2-3.26 Stage 1 Turbine Nozzle Assembly (Single Shank Rotor Configuration) ....................................... 2-28
2-3.27 Stage 2 Turbine Nozzle Assembly (Single Shank Rotor Configuration) ....................................... 2-30
2-3.28 Turbine Mid Frame ........................................................................................................................ 2-30
2-3.29 Accessory Drive Section............................................................................................................... 2-34
2-3.30 General ......................................................................................................................................... 2-34
2-3.31 Accessory Drive Train ................................................................................................................... 2-34
2-3.32 Inlet Gearbox ................................................................................................................................ 2-34
2-3.33 Radial Drive Shaft......................................................................................................................... 2-34
2-3.34 Accessory Gearbox ...................................................................................................................... 2-37
2-3.35 Air-Oil Separator ........................................................................................................................... 2-37
2-4 POWER TURBINE........................................................................................................................ 2-37
2-4.1 Power Turbine Rotor ..................................................................................................................... 2-37
2-4.2 General ......................................................................................................................................... 2-37
2-4.3 Blades and Seals.......................................................................................................................... 2-37
2-4.4 Power Turbine Stator..................................................................................................................... 2-42
2-4.5 General ......................................................................................................................................... 2-42
2-4.6 Shrouds and Seals ....................................................................................................................... 2-42
2-4.7 Turbine Rear Frame ...................................................................................................................... 2-42
2-4.8 General ......................................................................................................................................... 2-42
2-5 EXHAUST DUCT .......................................................................................................................... 2-42
2-5.1 General ......................................................................................................................................... 2-42
2-6 HIGH SPEED FLEXIBLE COUPLING SHAFT (TYPICAL) ........................................................... 2-42
2-6.1 General ......................................................................................................................................... 2-42
2-6.2 Operation ...................................................................................................................................... 2-42
2-7 BEARINGS ................................................................................................................................... 2-45
2-7.1 General ......................................................................................................................................... 2-45
2-7.2 Gas Generator .............................................................................................................................. 2-45
2-7.3 Power Turbine ............................................................................................................................... 2-45
2-7.4 Mounting ....................................................................................................................................... 2-45
2-8 SEALS .......................................................................................................................................... 2-46
2-8.1 Oil Seals ....................................................................................................................................... 2-46
2-8.2 Air Seals ....................................................................................................................................... 2-46
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2-9 AIRFLOW...................................................................................................................................... 2-49
2-9.1 Primary Airflow.............................................................................................................................. 2-49
2-9.2 Stage 8 Bleed Air.......................................................................................................................... 2-49
2-9.3 Stage 9 Bleed Air.......................................................................................................................... 2-49
2-9.4 Stage 13 Bleed Air........................................................................................................................ 2-49
2-9.5 Compressor Discharge Bleed Air ................................................................................................. 2-58
2-10 ENGINE SYSTEMS...................................................................................................................... 2-58
2-10.1 Fuel System.................................................................................................................................. 2-58
2-10.2 General ......................................................................................................................................... 2-58
2-10.3 Fuel Manifold ................................................................................................................................ 2-58
2-10.4 Fuel Nozzles ................................................................................................................................. 2-58
2-10.5 Speed Governing System ............................................................................................................. 2-58
2-10.6 General ......................................................................................................................................... 2-58
2-10.7 Fuel Flow ...................................................................................................................................... 2-58
2-10.8 Electrical System .......................................................................................................................... 2-58
2-10.9 General ......................................................................................................................................... 2-58
2-10.10 Ignition System ............................................................................................................................. 2-58
2-10.11 Exhaust Gas (T5.4) Temperature Indication ................................................................................. 2-67
2-10.12 Speed Indication ........................................................................................................................... 2-69
2-10.13 Vibration Indication ....................................................................................................................... 2-69
2-10.14 Oil Temperature Indications .......................................................................................................... 2-69
2-10.15 Lubrication System ....................................................................................................................... 2-71
2-10.16 General ......................................................................................................................................... 2-71
2-10.17 Lube Supply Subsystem ............................................................................................................... 2-71
2-10.18 Lube Scavenge Subsystem .......................................................................................................... 2-82
2-10.19 Oil Seal Pressurization Subsystem............................................................................................... 2-83
2-10.20 Sump Vent Subsystem ................................................................................................................. 2-83
2-10.21 Starting System ............................................................................................................................ 2-86
2-10.22 General ......................................................................................................................................... 2-86
2-10.23 Accessory Drive System............................................................................................................... 2-88
2-10.24 Variable Stator Control System..................................................................................................... 2-90
2-10.25 General ......................................................................................................................................... 2-90
2-10.26 Components ................................................................................................................................. 2-90
2-10.27 Operation ...................................................................................................................................... 2-99
2-10.28 Flame Sensing System (Optional) ................................................................................................ 2-100
2-10.29 Compressor Inlet Temperature (T2) Sensor Kit (Optional) ........................................................... 2-100
2-10.30 Inlet Seal Kit (Optional)................................................................................................................. 2-100
2-10.31 Hydraulic Supply System (Optional) ............................................................................................. 2-100
2-11 AUXILIARY SYSTEM REQUIREMENTS...................................................................................... 2-103
2-11.1 Mounting Systems ........................................................................................................................ 2-103
2-11.2 Optional Gas Turbine Assembly/ Installation Mounting Kit ........................................................... 2-103
2-11.3 Alignment Coupling (Gas Turbine Models) ................................................................................... 2-103
2-11.4 Anti-icing ....................................................................................................................................... 2-103
2-11.5 Exhaust Gas System (Gas Turbine Models) ................................................................................. 2-109
2-11.6 Heat Rejection .............................................................................................................................. 2-109
2-11.7 Engine Control .............................................................................................................................. 2-109
2-11.8 Electrical Services ........................................................................................................................ 2-110
2-11.9 Electrical Interlocks....................................................................................................................... 2-110
2-11.10 Electrical Systems ........................................................................................................................ 2-111
2-11.11 Instrumentation ............................................................................................................................. 2-112
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Chapter Title Page

2-12 MECHANICAL SERVICES ........................................................................................................... 2-113
2-12.1 Fuel............................................................................................................................................... 2-113
2-12.2 Lubrication Oil............................................................................................................................... 2-113
2-12.3 Starter ........................................................................................................................................... 2-113
2-12.4 Compressor Cleaning ................................................................................................................... 2-113
2-12.5 Bleed Air ....................................................................................................................................... 2-114
2-12.6 Air Vents ....................................................................................................................................... 2-114
2-12.7 Liquid Drains ................................................................................................................................. 2-114
2-13 FUEL SYSTEM............................................................................................................................. 2-114
2-13.1 Fuel Pump And Filter Assembly (Optional)................................................................................... 2-129
2-14 WINDMILLING.............................................................................................................................. 2-129
2-14.1 Gas Generator .............................................................................................................................. 2-129
2-14.2 Power Turbine ............................................................................................................................... 2-131
2-15 ACCESSORY DRIVE PAD............................................................................................................ 2-131
2-16 SHIPPING AND HANDLING ........................................................................................................ 2-131
3 GENERAL INSTALLATION ........................................................................................................... 3-1
3-1 INSTALLATION ............................................................................................................................. 3-1
3-1.1 General ......................................................................................................................................... 3-1
3-1.2 Site Information............................................................................................................................. 3-1
3-1.3 Tools ............................................................................................................................................. 3-1
3-1.4 Installation Procedure ................................................................................................................... 3-2
3-1.5 Customer Furnished Power Shaft Installation Requirements ....................................................... 3-2
3-2 INSTALLATION CHECKOUT ........................................................................................................ 3-3
3-2.1 Inspection and Pre-Energizing...................................................................................................... 3-3
3-2.2 Turn-On and Preliminary Tests ..................................................................................................... 3-3
3-2.3 Verification Test............................................................................................................................. 3-3
4 GENERAL OPERATION AND TROUBLESHOOTING ................................................................. 4-1
4-1 OPERATION ................................................................................................................................. 4-1
4-1.1 General ......................................................................................................................................... 4-1
4-2 PERFORMANCE RATINGS AND OPERATING LIMITS .............................................................. 4-1
4-2.1 General ......................................................................................................................................... 4-1
4-3 PREPARATION............................................................................................................................. 4-1
4-3.1 General ......................................................................................................................................... 4-1
4-4 GAS FUEL REQUIREMENTS ...................................................................................................... 4-1
4-4.1 General ......................................................................................................................................... 4-1
4-5 LIQUID FUEL REQUIREMENTS.................................................................................................. 4-1
4-5.1 General ......................................................................................................................................... 4-1
4-5A LUBRICATING OIL REQUIREMENTS ......................................................................................... 4-1
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4-6 NOX SUPPRESSION WATER REQUIREMENT .......................................................................... 4-2
4-6.1 General ......................................................................................................................................... 4-2
4-7 INITIAL OPERATION.................................................................................................................... 4-2
4-7.1 General ......................................................................................................................................... 4-2
4-8 NORMAL OPERATION................................................................................................................. 4-2
4-8.1 General ......................................................................................................................................... 4-2
4-9 SPECIAL INSTRUMENTATION .................................................................................................... 4-2
4-9.1 General ......................................................................................................................................... 4-2
4-10 EMERGENCY OPERATIONS ...................................................................................................... 4-2
4-10.1 Emergency Shutdown................................................................................................................... 4-2
4-10.2 Post Shutdown Fire....................................................................................................................... 4-3
4-11 RESTART PROCEDURE FOLLOWING EMERGENCY SHUTDOWN ......................................... 4-3
4-12 ENGINE TROUBLESHOOTING ................................................................................................... 4-3
4-12.1 Introduction ................................................................................................................................... 4-3
4-12.2 Gas Generator Fails to Motor ....................................................................................................... 4-4
4-12.3 Gas Generator Fails to Reach Maximum Motoring Speed ........................................................... 4-7
4-12.4 Fuel Manifold Pressure Too High or Too Low ............................................................................... 4-7
4-12.5 Gas Generator Fails to Light Off ................................................................................................... 4-7
4-12.6 Hot Starts...................................................................................................................................... 4-7
4-12.7 Gas Generator Starts, But Fails to Accelerate to Idle ................................................................... 4-8
4-12.8 Idle RPM Not Within Limits ........................................................................................................... 4-8
4-12.9 Gas Generator Speed Unstable/Hunting ...................................................................................... 4-8
4-12.10 Slow Acceleration ......................................................................................................................... 4-8
4-12.11 Compressor Stall or High T5.4 During Acceleration or Deceleration............................................ 4-8
4-12.12 High Gas Generator Speed, Low Power, Low T5.4 ...................................................................... 4-9
4-12.13 High Gas Generator Speed, Low Power, High T5.4 ..................................................................... 4-9
4-12.14 Performance Loss Greater Than 25°F (17°C) .............................................................................. 4-9
4-12.15 High Vibration in Gas Generator................................................................................................... 4-9
4-12.16 High Vibrations in Power Turbine. ................................................................................................. 4-9
4-12.17 Variable Stator Vane (VSV) System Malfunction .......................................................................... 4-10
4-12.18 High or Low Lube Oil Pressure ..................................................................................................... 4-10
4-12.19 High Scavenge Oil Temperature ................................................................................................... 4-10
4-12.20 High Lube Oil Consumption.......................................................................................................... 4-11
4-12.21 Incorrect or Fluctuating T5.4......................................................................................................... 4-11
4-12.22 Variable Stator Control System Troubleshooting Procedure......................................................... 4-11
4-12.23 Gas Generator Speed Instrumentation Troubleshooting Procedure ............................................. 4-13
4-12.24 Gearbox Troubleshooting Procedure ............................................................................................ 4-14
4-12.25 Ignition System Troubleshooting Procedure ................................................................................. 4-15
4-12.26 Start Stall Troubleshooting Procedure .......................................................................................... 4-16
4-12.27 Power Turbine Inlet T5.4 Thermocouple System Troubleshooting Procedure .............................. 4-17
4-12.27A Power Turbine Inlet T5.4 Thermocouple System Temperature Spread Troubleshooting Procedure ....... 4-23
4-12.28 Adjustment of Engine High Pressure (HP) Recoup Cavity Pressure............................................ 4-23
4-12.29 Power Turbine Transducer Motional Pickup Troubleshooting........................................................ 4-34
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TABLE OF CONTENTS
Chapter Title Page

5 PERIODIC INSPECTION, SERVICING AND PREVENTATIVE MAINTENANCE......................... 5-1
5-1 GENERAL INSPECTION INSTRUCTIONS.................................................................................. 5-1
5-1.1 Shop Practices.............................................................................................................................. 5-1
5-1.2 Evaluation of Engine Part Serviceability Using The Borescope ................................................... 5-1
5-1.3 Special Inspections....................................................................................................................... 5-2
5-2 USE OF INSPECTION TABLES AND INSTRUCTIONS............................................................... 5-4
5-2.1 Extent and Methods of Inspection ................................................................................................ 5-4
5-2.2 Form of Inspection Tables............................................................................................................. 5-4
5-2.3 Definition of Terms ........................................................................................................................ 5-5
5-3 PERIODIC INSPECTIONS ........................................................................................................... 5-9
5-3.1 Tools and Parts ............................................................................................................................. 5-9
5-3.2 Lube Scavenge Filter Check ......................................................................................................... 5-9
5-3.3 Lube Supply Filter Check.............................................................................................................. 5-9
5-3.4 Engine Inlet Inspection ................................................................................................................. 5-12
5-3.5 Borescope Inspection of the Engine ............................................................................................. 5-17
5-3.6 Compressor Blades and Vanes .................................................................................................... 5-37
5-3.7 Combustor and Fuel Nozzles ....................................................................................................... 5-38
5-3.8 High Pressure Turbine Nozzles .................................................................................................... 5-38
5-3.9 High Pressure Turbine Twin Shank Rotor Blades ......................................................................... 5-56
5-3.10 High Pressure Turbine Single Shank Rotor Blades ...................................................................... 5-61
5-3.11 Turbine Mid Frame ........................................................................................................................ 5-72
5-3.12 Power Turbine Nozzles ................................................................................................................. 5-73
5-3.13 Power Turbine Rotor Blades ......................................................................................................... 5-75
5-3.14 Engine Enclosure Inspection ........................................................................................................ 5-78
5-3.15 Gas Turbine Exhaust Inspection ................................................................................................... 5-78
5-3.16 Variable Stator System Inspection ................................................................................................ 5-78
5-3.16 Variable Stator System Inspection ................................................................................................ 5-78
5-3.18 Lube And Scavenge Pump Inlet Screens Inspection And Cleaning ............................................. 5-110
5-3.18A Lube and Scavenge Pump Screen and Electronic Chip Detector Inspection and Cleaning......... 5-114
5-3.19 Lube Oil Test................................................................................................................................. 5-119
5-3.20 Fuel Nozzle Inspection ................................................................................................................. 5-121
5-3.21 Engine Exterior Inspection And Cleaning ..................................................................................... 5-121
5-3.22 Gas Turbine Gas Generator External Inspection .......................................................................... 5-122
5-3.23 Spark Igniter Inspection ................................................................................................................ 5-142
5-3.24 Vibration Transducer Inspection and Verification .......................................................................... 5-142
5-3.25 Engine Special Inspections........................................................................................................... 5-143
5-3.26 Engine Stalls - Below 7500 RPM Gas Generator Speed.............................................................. 5-145
5-3.27 Engine Stalls - Above 7500 Rpm Gas Generator Speed.............................................................. 5-146
5-3.28 Removal Of Fire Extinguishing Agents From Engine External Surfaces ...................................... 5-147
5-3.29 Removal Of Fire Extinguishing Agents From Engine Internal Surfaces........................................ 5-149
5-3.30 High Pressure Recoup Pressure Preferred Operating Range (GE, PE And PH Series) .............. 5-149
5-3.31 Lube Oil Pressure Corrections For Industrial LM2500 Gas Turbines And Gas Generators.......... 5-149
5-3.32 Lube Supply Pressure at Pressure Tap for Temperature vs Gas Generator Speed ..................... 5-166
5-4 SERVICING .................................................................................................................................. 5-175
5-4.1 Oil Tank ......................................................................................................................................... 5-175
5-4.2 Water Servicing and Pumping Requirements (NOx Suppression) ............................................... 5-175
5-4.3 Compressor Efficiency Trending ................................................................................................... 5-175
vi
GEK 97310
VOLUME 1
TABLE OF CONTENTS
Chapter Title Page

5-4.4 Compressor Cleaning ................................................................................................................... 5-180
5-4.5 Gas Generator Pneumatic Starter Servicing ................................................................................ 5-188
5-5 STANDARD MAINTENANCE PRACTICES .................................................................................. 5-190
5-5.1 Purpose ........................................................................................................................................ 5-190
5-5.2 Point of Reference ........................................................................................................................ 5-190
5-5.3 Performance Of Maintenance Within The Enclosure.................................................................... 5-190
5-5.4 Maintenance Practices ................................................................................................................. 5-191
5-6 PREVENTATIVE MAINTENANCE PROCEDURES...................................................................... 5-217
5-6.1 Tools And Parts............................................................................................................................. 5-217
5-6.2 Lube Filter Cleaning...................................................................................................................... 5-217
5-6.3 Thermocouple System Test .......................................................................................................... 5-217
5-6.4 Ignition System Test...................................................................................................................... 5-217
5-6.5 Oil Sampling And Analysis............................................................................................................ 5-218
APPENDIX A ............................................................................................................................................... A-1
NATURAL GAS FUEL.................................................................................................................................. A-3
1. APPLICABLE DOCUMENTS........................................................................................................ A-4
2. REQUIREMENTS ......................................................................................................................... A-4
LIQUID FUEL............................................................................................................................................... A-7
1. FUEL SPECIFICATIONS .............................................................................................................. A-8
2. ADDITIONAL REQUIREMENTS .................................................................................................. A-9
3. FUEL HANDLING ......................................................................................................................... A-10
4. FUEL SAMPLING ......................................................................................................................... A-11
NOX SUPPRESSION WATER PURITY SPECIFICATION........................................................................... A-13
1. SCOPE ......................................................................................................................................... A-14
3. REQUIREMENTS ......................................................................................................................... A-14
COMPRESSOR CLEANING WATER PURITY SPECIFICATION................................................................ A-15
1. SCOPE ......................................................................................................................................... A-16
3. REQUIREMENTS ......................................................................................................................... A-16
LIQUID DETERGENT FOR COMPRESSOR CLEANING........................................................................... A-17
1. SCOPE ......................................................................................................................................... A-18
3. MATERIAL COMPOSITION.......................................................................................................... A-18
4. TEST REQUIREMENTS............................................................................................................... A-18
5. TEST METHODS.......................................................................................................................... A-20
6. MATERIAL COMPATIBILITY......................................................................................................... A-21
7. NOTES.......................................................................................................................................... A-21
LUBRICATING OIL SPECIFICATION .......................................................................................................... A-23
1.0 Oil Specifications .......................................................................................................................... A-24
2.0 Applicable Documents .................................................................................................................. A-24
3.0 Requirements ............................................................................................................................... A-24
4.0 Qualification .................................................................................................................................. A-25
vii
GEK 97310
VOLUME 1
TABLE OF CONTENTS
Addendum Title
Addendum A Industrial Gas Turbine Model 7LM2500PC101C
Addendum B Industrial Gas Turbine Model 7LM2500PC102
Addendum C Industrial Gas Turbine Model 7LM2500PC103
Addendum D Industrial Gas Turbine Model 7LM2500PC103B
Addendum E Industrial Gas Turbine Model 7LM2500PC104
Addendum F Industrial Gas Turbine Model 7LM2500PC104A
Addendum G Industrial Gas Turbine Model 7LM2500PC104B
Addendum H Industrial Gas Turbine Model 7LM2500PC104C
Addendum I Industrial Gas Turbine Model 7LM2500PC101B
Addendum J Industrial Gas Turbine Model 7LM2500PC101A
Addendum K Industrial Gas Turbine Model 7LM2500PC101D
Addendum L Industrial Gas Turbine Model 7LM2500-PD-MG
Addendum M Industrial Gas Turbine Model 7LM2500-PE-MG
Addendum N Industrial Gas Turbine Model 7LM2500-PE-ND
Addendum O Industrial Gas Turbine Model 7LM2500-PE-MD
Addendum P Industrial Gas Turbine Model 7LM2500-PE-NG
Addendum Q Industrial Gas Turbine Model 7LM2500-PE-NX
Addendum R Industrial Gas Turbine Model 7LM2500-PE-MGX
Addendum S Industrial Gas Turbine Model 7LM2500PC104D
Addendum T Industrial Gas Generator Model 7LM2500GA101
Addendum U Industrial Gas Turbine Model 7LM2500-PE-ML
Addendum V Industrial Gas Generator Model 7LM2500GB101
Addendum W Industrial Gas Generator Model 7LM2500GB104
Addendum X Industrial Gas Generator Model 7LM2500-20GB104
Addendum Y Industrial Gas Generator Model 7LM2500-GE-MG
Addendum Z Industrial Gas Generator Model 7LM2500-GD-MG
Addendum AA Industrial Gas Generator Model 7LM2500-GE-MGX
Addendum AB Industrial Gas Turbine Model 7LM2500-PH-NGA/MGA (STIG)
Addendum AC Industrial Gas Turbine Model 7LM2500-PL-MGA
Addendum AD Industrial Gas Turbine Model 7LM2500-PE-MGA
viii
GEK 97310
VOLUME 1
LIST OF TABLES
Table Title Page

2-1 LM2500 ENGINE FUEL SYSTEMS.............................................................................................. 2-115
3-1 INSTALLATION TOOLS ................................................................................................................ 2-1
4-1 ENGINE TROUBLESHOOTING INDEX ....................................................................................... 4-5
4-2 ELECTRICAL TEST - T5.4 SYSTEM COMPONENTS ................................................................ 4-17
4-3 ELECTRICAL TEST - POWER TURBINE TRANSDUCER MOTIONAL PICKUP ........................ 4-34
5-1 MAINTENANCE CHECKS............................................................................................................ 5-9
5-2 CATEGORIES OF WEAR CONDITIONS. (SEE FIGURE 5-3.) ..................................................... 5-14
5-3 BORESCOPE INSPECTION REQUIREMENTS .......................................................................... 5-25
5-4 COMPRESSOR BLADES AND VANES ....................................................................................... 5-28
5-5 COMBUSTION LINER ASSEMBLY AND FUEL NOZZLES.......................................................... 5-44
5-6 HIGH PRESSURE TURBINE NOZZLES...................................................................................... 5-51
5-7 HIGH PRESSURE TURBINE TWIN SHANK ROTOR BLADES................................................... 5-58
5-8 HIGH PRESSURE TURBINE SINGLE SHANK ROTOR BLADES............................................... 5-63
5-9 TURBINE MID FRAME................................................................................................................. 5-72
5-10 POWER TURBINE NOZZLES ...................................................................................................... 5-73
5-11 POWER TURBINE ROTOR BLADES........................................................................................... 5-75
5-12 COMPRESSOR STATOR CASE AND VARIABLE VANE COMPONENTS .................................. 5-93
5-12A POSSIBLE CAUSES OF FOREIGN MATERIAL .......................................................................... 5-117
5-13 ENGINE TUBES, HOSES, TUBE/HOSE FITTINGS, ELECTRICAL CABLE
ASSEMBLIES AND ELECTRICAL CONNECTORS..................................................................... 5-123
5-14 INLET DUCT AND CENTERBODY .............................................................................................. 5-127
5-15 TRANSFER GEARBOX ................................................................................................................ 5-129
5-16 COMPRESSOR FRONT FRAME ................................................................................................. 5-130
5-17 COMPRESSOR REAR FRAME (CRF) ........................................................................................ 5-131
5-18 TURBINE MID FRAME EXTERIOR ............................................................................................. 5-134
5-19 POWER TURBINE STATOR CASE .............................................................................................. 5-137
5-20 TURBINE REAR FRAME (TRF) ................................................................................................... 5-140
5-21 SPECIAL INSPECTION................................................................................................................ 5-143
5-22 LUBE OIL PRESSURE CORRECTION FOR INDUSTRIAL LM2500 GAS TURBINES.
MIL-L-23699 OIL WITH V.G. CONTROL PN L34379 AND 3R DAMPER BEARING.................... 5-150
MIL-L-7808 OIL WITH V.G. CONTROL PN L34379 AND 3R DAMPER BEARING...................... 5-152
5-24 LUBE OIL PRESSURE CORRECTION FOR INDUSTRIAL LM2500 GAS GENERATORS.
MIL-L-23699 OIL WITH V.G. CONTROL PN L34379 AND 3R DAMPER BEARING.................... 5-154
MIL-L-7808 OIL WITH V.G. CONTROL PN L34379 AND 3R DAMPER BEARING...................... 5-156
MIL-L-23699 OIL WITH V.G. CONTROL PN L34379 ................................................................... 5-158
MIL-L-7808 OIL WITH V.G. CONTROL PN L34379 ..................................................................... 5-160
MIL-L-23699 OIL WITH V.G. CONTROL PN L34379 ................................................................... 5-162
MIL-L-7808 OIL WITH V.G. CONTROL PN L34379 ..................................................................... 5-164
5-30 STANDARD DAY TEMPERATURE CORRECTION FACTOR....................................................... 5-178
ix
GEK 97310
VOLUME 1
LIST OF TABLES
Table Title Page

5-31 Deleted ......................................................................................................................................... 5-185
5-32 TORQUE WRENCH SIZE ............................................................................................................ 5-193
5-33 MINIMUM BREAKAWAY TORQUE FOR SELF–LOCKING NUTS............................................... 5-193
5-34 TORQUE VALUES FOR STEEL BOLTS, NUTS, AND SELF-LOCKING NUTS ........................... 5-193
5-35 TORQUE VALUES FOR PLUGS AND UNIONS .......................................................................... 5-194
5-36 TORQUE VALUES FOR TUBING NUTS AND HOSE FITTINGS................................................. 5-195
5-37 TORQUE VALUES FOR PLUGS AND UNIONS USED IN BOSSES AND
FOR UNIVERSAL BULKHEAD FITTING LOCKNUTS ................................................................. 5-196
5-38 HOSE MINIMUM BEND RADII..................................................................................................... 5-210
x
GEK 97310
VOLUME 1
LIST OF ILLUSTRATIONS
Figure Title Page

1-1 Change Symbols .......................................................................................................................... 1-4
1-2 LM2500 Gas Turbine-Right Side (Sheet 1 of 4) ............................................................................ 1-11
1-2 LM2500 Gas Turbine-Left Side (Sheet 2 of 4) .............................................................................. 1-12
1-2 LM2500 Gas Generator-Right Side (Sheet 3 of 4) ....................................................................... 1-13
1-2 LM2500 Gas Generator-Left Side (Sheet 4 of 4) .......................................................................... 1-14
1-3 Gas Turbine Assembly Cross Section........................................................................................... 1-15
1-4 Gas Generator Assembly Cross Section (Typical)........................................................................ 1-21
1-5 Gas Turbine Components ............................................................................................................. 1-25
1-6 Gas Generator Components (Typical) .......................................................................................... 1-27
1-7 General Conversion Factors ......................................................................................................... 1-30
1-8 Conversion Inches (Fractions to Decimals) .................................................................................. 1-31
1-9 Temperature Conversion Chart..................................................................................................... 1-32
2-1 Front Frame Assembly .................................................................................................................. 2-3
2-2 Compressor Rotor Assembly ........................................................................................................ 2-5
2-3 Compressor Stator Assembly ....................................................................................................... 2-6
2-4 Compressor Stator Variable Vanes-Steel Front Casing ................................................................ 2-9
2-5 Compressor Rear Frame .............................................................................................................. 2-15
2-6 Combustor .................................................................................................................................... 2-17
2-7 High Pressure Turbine Rotor (Twin Shank)................................................................................... 2-18
2-8 High Pressure Turbine Rotor Cooling (Twin Shank) ..................................................................... 2-19
2-9 High Pressure Turbine Rotor Blade Cooling (Twin Shank) ........................................................... 2-20
2-10 First Stage High Pressure Turbine Nozzle (Twin Shank Rotor Configuration) .............................. 2-22
2-11 First Stage High Pressure Turbine Nozzle Cooling (Twin Shank Rotor Configuration)................. 2-22
2-12 Second Stage High Pressure Turbine Nozzle (Twin Shank Rotor Configuration)......................... 2-23
2-13 High Pressure Turbine Rotor (Single Shank) ................................................................................ 2-25
2-14 High Pressure Turbine Rotor Assembly (Single Shank) ............................................................... 2-25
2-15 High Pressure Turbine Rotor Air Flow (Single Shank) .................................................................. 2-26
2-16 High Pressure Turbine Rotor Blade Cooling (Single Shank) ........................................................ 2-27
2-17 Stage One Turbine Nozzle Assembly (Single Shank Rotor Configuration)................................... 2-29
2-18 Stage One HPT Nozzle Cooling (Single Shank Rotor Configuration) .......................................... 2-29
2-19 Stage Two HPT Nozzle Assembly (Single Shank Rotor Configuration)........................................ 2-31
2-20 Stage Two High Pressure Turbine Nozzle Cooling (Single Shank Rotor Configuration)............... 2-32
2-21 Turbine Mid Frame ........................................................................................................................ 2-33
2-22 Accessory Drive Section (Except GA101 Models)........................................................................ 2-35
2-23 Inlet Gearbox ................................................................................................................................ 2-36
2-24 Accessory Gearbox (Except GA101 Models) ............................................................................... 2-38
2-25 Air-Oil Separator ........................................................................................................................... 2-40
2-26 Power Turbine Rotor and Stator Casings...................................................................................... 2-41
2-27 Turbine Rear Frame ...................................................................................................................... 2-43
2-28 Exhaust Duct Assembly (Typical).................................................................................................. 2-44
2-29 High Speed Flexible Coupling Shaft (Typical) ............................................................................... 2-45
2-30 Gas Turbine Bearings ................................................................................................................... 2-46
2-31 Typical Oil Seals ........................................................................................................................... 2-47
2-32 Typical Air Seals ........................................................................................................................... 2-48
2-33 Typical Gas Turbine Air Flow......................................................................................................... 2-50
2-34 Typical Gas Generator Air Flow .................................................................................................... 2-55
2-35 Typical Electric System Schematic ............................................................................................... 2-59
2-36 Ignition System ............................................................................................................................. 2-66
2-37 Thermocouple Schematic ............................................................................................................. 2-68
2-38 Engine Speed Pickups.................................................................................................................. 2-70
2-39 Typical Gas Generator Lubrication System Schematic................................................................. 2-72
xi
GEK 97310
VOLUME 1
Figure Title Page

2-40 Lube and Scavenge Pump (Gas Generator/Gas Turbine Models with
Five Scavenge Elements Pump) .......................................................................................... 2-80
2-41 Lube and Scavenge Pump (Gas Generator/Gas Turbine Models with Six
Scavenge Elements Pump) ............................................................................................... 2-81
2-42 Forward Scavenge Pump (GA101 Models) .................................................................................. 2-84
2-43 Lube and Scavenge Pump (GA101 Model) .................................................................................. 2-85
2-44 Pneumatic Starter ......................................................................................................................... 2-87
2-45 Hydraulic Starter ........................................................................................................................... 2-89
2-46 Variable Stator Control System (Early Configuration)................................................................... 2-91
2-47 Variable Stator Control Functional Schematic (Early Configuration) ............................................ 2-92
2-48 Variable Stator Control PN L34379 System (Current Configuration) ............................................ 2-93
2-52 Variable Stator Control PN L34379 Functional Schematic (Current Configuration)...................... 2-97
2-53 Variable Stator Vane Actuators ..................................................................................................... 2-98
2-54 Flame Sensing System - Optional (Kit 537L358).......................................................................... 2-101
2-55 Hydraulic Pump - Optional (Kit 537L162G02) .............................................................................. 2-102
2-56 Mounting Arrangements - LM2500 Series Gas Turbine................................................................ 2-104
2-56A Anti-Icing System Requirements .................................................................................................. 2-107
2-57 Mounting Arrangements - LM2500 Gas Generator ...................................................................... 2-108
2-58 Natural Gas Fuel System.............................................................................................................. 2-117
2-59 Natural Gas Fuel System with Water Injection for NOx Suppression ........................................... 2-118
2-60 Natural Gas Fuel System with Fuel Nozzle Premix Steam Injection for NOx Suppression .......... 2-119
2-61 Natural Gas Fuel System with Direct Fuel Nozzle Steam Injection for NOx Suppression............ 2-120
2-62 Natural Gas Fuel System with Water Injection for NOx Suppression and Steam Injection
into CDP Ports for Power Enhancement....................................................................................... 2-121
2-63 Natural Gas Fuel System with Steam Injection for NOx Suppression and
Power Augmentation (STIG) ................................................................................................ 2-122
2-64 Liquid Fuel System ....................................................................................................................... 2-123
2-65 Liquid Fuel System with Water Injection for NOx Suppression..................................................... 2-124
2-66 Liquid Fuel System with Water Injection for NOx Suppression and Steam Injection into
CDP Ports for Power Enhancement.............................................................................................. 2-125
2-67 Dual Fuel System ......................................................................................................................... 2-126
2-68 Dual Fuel System with Water Injection for NOx Suppression ....................................................... 2-127
2-69 Dual Fuel System with Steam Injection for NOx Suppression ...................................................... 2-128
2-70 Fuel Pump - Optional (Kit L24093G01) ........................................................................................ 2-130
4-1 Hookup for Variable Stator Vane System Actuation (Early Configuration).................................... 4-12
4-2 T5.4 Thermocouple System Schematic - P and G Series (Except GA101) ................................. 4-20
4-2A Thermocouple Probe (Sheet 1 of 3) ............................................................................................. 4-21
4-3 High Pressure Recoup Air Metering Spacer Configuration - Left Side Pneumatic System .......... 4-24
4-4 High Pressure Recoup Orifice Selection Worksheet .................................................................... 4-28
4-5 Typical Excel Spreadsheet Based on Figure 4-5 Worksheet ........................................................ 4-29
4-6 Preferred Operating Range for High Pressure Recoup (GE, PE, and PL Models) ....................... 4-31
5-1 Definition of Terms ........................................................................................................................ 5-6
5-2 Hookup for Variable Stator Vane System Actuation...................................................................... 5-13
5-3 Inspection of VSV Shrouds and Bushings .................................................................................... 5-15
5-4 Borescope Inspection ................................................................................................................... 5-18
5-5 Motor Drive, 1C8067G01, For Gas Generator Borescope Inspection .......................................... 5-19
xii
GEK 97310
VOLUME 1
Figure Title Page

5-6 Removal/Installation of Transfer Gearbox Gearshaft Seal Assembly, L21431G02 ....................... 5-21
5-7 Zero Indexing Gas Generator Rotor ............................................................................................. 5-24
5-8 Compressor Blade and Vane Damage Examples ........................................................................ 5-32
5-9 Compressor Rotor Blades ............................................................................................................ 5-33
5-10 Tip Clanging Contact (Rotor Stages 3 through 6)......................................................................... 5-33
5-11 Inspection of Tip Trailing Edge...................................................................................................... 5-34
5-12 Stage 1 Mid Span Damper Inspection Limits................................................................................ 5-34
5-13 Variable Stator Vane Inner Trunnions and Platforms - Dimensions .............................................. 5-35
5-14 Fixed and Variable Compressor Vanes......................................................................................... 5-36
5-15 Combustor .................................................................................................................................... 5-39
5-16 Fuel Nozzle (Liquid Fuel).............................................................................................................. 5-42
5-17 Fuel Nozzle (Natural Gas Fuel) .................................................................................................... 5-43
5-18 Fuel Nozzle (Dual Fuel) ................................................................................................................ 5-43
5-19 High Pressure Turbine Nozzles (Twin Shank Configuration) ........................................................ 5-48
5-20 First-Stage High Pressure Turbine Nozzle (Single Shank Configuration)..................................... 5-49
5-21 Second-Stage High Pressure Turbine Nozzle (Single Shank Configuration)................................ 5-50
5-22 High Pressure Turbine (Twin Shank) Rotor Blades....................................................................... 5-57
5-23 High Pressure Turbine (Single Shank) Rotor Blades .................................................................... 5-62
5-24 Power Turbine Nozzles ................................................................................................................. 5-74
5-25 Power Turbine Blades ................................................................................................................... 5-77
5-26 Variable Stator System ................................................................................................................. 5-79
5-27 Compressor Variable Stator Vanes............................................................................................... 5-80
5-28 Compressor Stator Variable Vanes-Steel Front Casing ................................................................ 5-83
5-29 Variable Stator Vane Actuating Mechanism.................................................................................. 5-88
5-30 Vane Actuation Ring Segment Inspection Areas .......................................................................... 5-90
5-31 Variable Stator Vane Lever Arm Inspection .................................................................................. 5-91
5-32 Actuation Ring Spacer Nut Stabilized with RTV ........................................................................... 5-92
5-33 Actuation Ring Spacer Clearance................................................................................................. 5-92
5-34 Lube and Scavenge Pump Inlet Screens (All Models Except GA101) ......................................... 5-111
5-34A Five Element Lube and Scavenge Pump Screens ....................................................................... 5-115
5-34B Six Element Lube and Scavenge Pump Screens ......................................................................... 5-115
5-34C Electronic Chip Detector Tip Buildup ............................................................................................ 5-117
5-35 Transient Temperature Limits........................................................................................................ 5-144
5-36 Lube Oil Pressure Correction for Industrial LM2500 Gas Turbines.
MIL-L-23699 Oil with V.G. Control PN L34379 and 3R Damper Bearing ..................................... 5-151
MIL-L-7808 Oil with V.G. Control PN L34379 an 3R Damper Bearing ......................................... 5-153
5-38 Lube Oil Pressure Correction for Industrial LM2500 Gas Generator.
MIL-L-23699 Oil with V.G. Control PN L34379 and 3R Damper Bearing ..................................... 5-155
5-39 Lube Oil Pressure Correction for Industrial LM2500 Gas Generators.
MIL-L-7808 Oil with V.G. Control PN L34379 and 3R Damper Bearing ....................................... 5-157
MIL-L-23699 Oil with V.G. Control PN L34379 ............................................................................. 5-159
MIL-L-7808 Oil with V.G. Control PN L34379 ............................................................................... 5-161
MIL-L-23699 Oil with V.G. Control PN L34379 ............................................................................. 5-163
MIL-L-7808 Oil with V.G. Control PN L34379 ............................................................................... 5-165
5-44 LM2500 Gas Turbine Lube Supply Pressure at Pressure Tap vs Gas Generator
Speed Using MIL-L-7808 Lube Oil and V.G. Control PN L34379 ................................................. 5-167
xiii
GEK 97310
VOLUME 1
Figure Title Page

5-45 LM2500 Gas Generator Lube Supply Pressure at Pressure Tap vs Gas Generator
Speed Using MIL-L-7808 Lube Oil and V.G. Control PN L34379 ................................................. 5-168
5-46 LM2500 Gas Turbine Lube Supply Pressure at Pressure Tap vs Gas Generator
Speed Using MIL-L-23699 Lube Oil and V.G. Control PN L34379 ............................................... 5-169
5-47 LM2500 Gas Generator Lube Supply Pressure at Pressure Tap vs Gas Generator
Speed Using MIL-L-23699 Lube Oil and V.G. Control PN L34379 ............................................... 5-170
5-48 LM2500 Gas Turbine Lube Supply Pressure at Pressure Tap vs Gas Generator Speed Using
MIL-L-7808 Lube Oil with V.G. Control PN L34379 and 3R Damper Bearing .............................. 5-171
5-49 LM2500 Gas Generator Lube Supply Pressure at Pressure Tap vs Gas Generator Speed Using
MIL-L-7808 Lube Oil with V.G. Control PN L34379 and 3R Damper Bearing .............................. 5-172
5-50 LM2500 Gas Turbine Lube Supply Pressure at Pressure Tap vs Gas Generator Speed Using
MIL-L-23699 Lube Oil with V.G. Control PN L34379 and 3R Damper Bearing ............................ 5-173
5-51 LM2500 Gas Generator Lube Supply Pressure at Pressure Tap vs Gas Generator Speed Using
MIL-L-23699 Lube Oil with V.G. Control PN L34379 and 3R Damper Bearing ............................ 5-174
5-52 Sample Trend Curve of Discharge Gas Temperature at a Constant Pressure Ratio vs.
Operating Time .................................................................................................................... 5-176
5-53 Sample Curve of Discharge Gas Temperature vs. Pressure Ratio............................................... 5-179
5-54 Deleted ......................................................................................................................................... 5-183
5-55 Deleted ......................................................................................................................................... 5-184
5-56 Pneumatic Starter ......................................................................................................................... 5-189
5-57 Sequence of Tightening Threaded Fasteners............................................................................... 5-197
5-58 Determining Torque Wrench Correction Factor ............................................................................ 5-198
5-59 Installation of Universal Fittings .................................................................................................... 5-201
5-60 Safety-Wiring Practices................................................................................................................. 5-202
5-61 Flexible Coupling Assembly .......................................................................................................... 5-209
5-62 Installation of Hose Assemblies .................................................................................................... 5-211
5-63 Factory Preformed Hoses ............................................................................................................. 5-212
5-64 Routing and Clamping Techniques ............................................................................................... 5-212
5-65 Installation of Cushion Clamps, Series J1153 and J1162 ............................................................ 5-213
xiv
GEK 97310
VOLUME I
CHAPTER 1
INTRODUCTION
1-1 GENERAL INFORMATION meters. These will eventually replace

the conventional metric torque wrench
1-1.1 Purpose and Scope of Technical calibrated in kilogram meters (kgm) and
Manual. This manual is to be used for on-site will be given in specifications of N·m or
installation, operation, maintenance, repair, Nm. To convert kilogram meters (kgm)
and parts support of the 7LM2500 series gas to newton meters (N·m) simply discard
generators and gas turbines designed and man- the decimal point. For example,
ufactured by GE Aircraft Engines, Cincinnati 3.5 kgm would become 35 N·m. To con-
(Evendale), Ohio 45215. This manual contains vert kilogram centimeters (kg cm) to
all authorized maintenance tasks that may be newton meters, round off to one decimal
performed on site. The extent of maintenance place. For example, 50 kg cm would
to be performed at any particular site depends become 5.0 N·m. Although the above
on the installation, available tooling, and the values are not mathematically precise
depth of maintenance desired by the operator. (3.5 kgm actually equals 34.3 N·m) they
are considered adequate for general
1-1.2 Levels of Maintenance. Level 1 purposes.
maintenance tasks cover all work on the exte-
rior of an installed engine plus scheduled 1-1.3 Special Inspections. The mainte-
inspection, compressor cleaning (water wash) nance of the gas generator or gas turbine
and engine changeout. Level 2 modular main- requires that inspection checks be made peri-
tenance tasks cover removal and reinstallation odically. The inspection requirements and lim-
of one or more major sections down to the its throughout this manual are based on
B-sump bearing (gas generator thrust bearing). operation within specified limits. In addition to
the regular inspections there are those neces-
NOTE sary when the gas generator or gas turbine has
• The System Internationale (S.I.) been operated outside of the specified limits,
units shown in this chapter are direct for example, off-schedule variable geometry
mathematical conversions and may operation, overspeed, or overtemperature.
be rounded off in most instances at There are also special inspections necessary
the user's discretion. Examples of for gas generators or gas turbines exposed to
units that may be rounded off are abnormal conditions. These may include, for
those utilized for temperatures, example, failures with significant damage and
torque values, pressures, etc. Exam- other abnormal exposure such as an installa-
ples where S.I. units may not be tion fire or mishap during transportation, han-
rounded off are those utilized for dling, or storage. This manual describes the
drop checks, rigging adjustments, inspection checks necessary following over-
runouts, etc. limit operation and the criteria for special
inspection checks necessary for gas generators
• Commensurate with the adoption of the exposed to abnormal conditions.
S.I. system has been the introduction of
torque wrenches calibrated in newton
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

1-1
GEK 97310
VOLUME I
1-1.4 Arrangement and Use of This c. The chapters contained in Volume I

Technical Manual. are numbered with Arabic numerals. Tables
are numbered with Arabic numerals to indicate
a. This technical manual consists of two the chapter followed by Arabic numerals to
volumes and is arranged to provide ease of identify sequence within the chapter. Figures
accessing the information contained in each and pages are numbered with Arabic numerals
volume according to the on-site task require- separated by a dash to indicate chapter and
ments. During the initial installation of an sequence within the chapter. Paragraphs are
engine, normal on-site operation or during the numbered in Arabic using a combination of
performance of routine preventative (sched- dashes and decimals.
uled) maintenance tasks, Volume I of this man-
ual is required to support the on-site activities. d. Volume II of this manual is of the work
In the event level 1 or 2 corrective mainte- package format and contains the procedures
nance, preservation, storage maintenance or encompassing levels 1 and 2 corrective main-
complete gas generator, power turbine or gas tenance including gas generator, power tur-
turbine change-out is required then Volume II bine, and gas turbine change-out. Also
of this manual is required to support the on-site included in Volume II is the complete recom-
task requirements. mended tooling and spare parts provisioning
for level 1 and 2 corrective maintenance plus
b. Volume I of this manual is of the con- the preparation for storage or shipment of the
ventional format and contains five chapters, engine.
for coverage of all LM2500 series engines.
Chapters 1 through 5 contain information that e. Each work package or subordinate
is applicable to all models. The information work package is arranged as follows:
contained is unique and relates to model refer-
ence data, control system differences, optional (1) Introduction
hardware kits available and the complete
instructions for operating the engine. The (2) Applicable Support Equipment
arrangement of Volume I is as follows:
(3) Consumable Materials
Chapter Title
1 Introduction (4) Removal (component)
2 Functional Description (5) Installation (component)
3 General Installation
4 General Operation and (6) Component Inspection
Troubleshooting
(7) Parts Repair
5 Periodic Inspection. Servic-
ing and Preventative
(8) Parts Replacement
Maintenance

1-2
GEK 97310
VOLUME I
1-1.5 Notes, Cautions, and Warnings. 1-1.8 Text Changes. Changes are indi-
Notes, Cautions, and Warnings will be found cated by a vertical line in the margin along side
throughout this publication. It is important that the text change. Changes to illustrations are
the significance of each is thoroughly under- indicated by miniature pointing hands.
stood by personnel using this technical man- Changes to diagrams and schematics are indi-
ual. Their definitions are as follows: cated by shaded areas.
a. NOTE highlights an essential proce- 1-1.9 Page Changes. Insert latest change
dure to assure correct maintenance. pages and dispose of superseded pages. Page
changes are designated by the change number
b. CAUTION indicates a procedure, prac- and date of effective change at the bottom of
tice, etc., which if not strictly observed, could each affected page. Refer to list of effective
result in damage or destruction of equipment. pages.
c. WARNING indicates a procedure, 1-1.10 Changes to Illustrations. Illustra-

practice, etc., which could result in personal tions (line art and photographs) represent the
injury or loss of life if not followed correctly. equipment configuration at time of inclusion in
this technical manual. They will not necessar-
1-1.6 Changes to Technical Manual. ily be changed to represent all and/or the latest
equipment configuration. They are to be used
1-1.7 Change Symbols. Changes (includ- only as an aid in performing maintenance
ing addition of new data to text, tables, and actions in accordance with the text and the
illustrations) are indicated by use of change parts list.
symbols shown by figure 1-1. Previous change
symbols are deleted when a page is subse- 1-1.11 Equipment Points of Reference.
quently changed, so that the symbols show lat- All engine references to left, right, forward,
est changes only. aft, top, bottom, and clock positions apply
when viewing the engine from the aft (exhaust
end) looking forward.

1-3
GEK 97310
VOLUME I
Figure 1-1. Change Symbols

1-4
GEK 97310
VOLUME I
1-2 SAFETY WILL CAUSE SERIOUS DETERIO-

RATION OF THE BODY NERVOUS
1-2.1 General. This technical manual is SYSTEMS AND POSSIBLE DEATH,
designed to provide safe procedures and pro- IF BREATHED FREQUENTLY.
cesses for accomplishing the operation and AVOID FREQUENT OR PRO-
maintenance herein described. It is therefore LONGED EXPOSURE TO THE
important that the Warnings and Cautions be SKIN. WASH THOROUGHLY WITH
thoroughly understood and observed by the SOAP AND WARM WATER AS
users of his manual. Changes or additions SOON AS POSSIBLE AFTER COM-
deemed necessary for proper operation, main- PLETING USE OF SUCH MATERI-
tenance, and safety improvements should be ALS. TAKE SPECIAL
submitted to PRECAUTIONS TO PREVENT
MATERIALS FROM ENTERING
THE EYES. IF EXPOSED, RINSE
THE EYES IN AN EYE BATH
GE Aircraft Engines FOUNTAIN IMMEDIATELY AND
Marine & Industrial Engines REPORT TO A PHYSICIAN. AVOID
Customer Service SPILLING FREON OR SIMILAR
Mail Drop S155 SOLVENTS ON THE SKIN.
Cincinnati, Ohio 45215 EXTREMELY RAPID EVAPORA-
TION OF THESE SOLVENTS HAS A
1-2.2 Reference. The following are gen- REFRIGERATING EFFECT AND
eral safety precautions that are not related to MAY CAUSE SERIOUS FROST-
any specific procedures, and therefore do not BITE. DO NOT ALLOW ADHE-
appear elsewhere in the manual. Personnel SIVES TO CONTACT THE SKIN.
must understand and apply these precautions RAPID BONDING OF CERTAIN
during many phases of operation and ADHESIVES WILL CAUSE
maintenance. INSTANT ADHESION TO BODY
MEMBERS OR OBJECTS. DO NOT
ATTEMPT TO FORCEFULLY SEPA-
RATE BODY MEMBERS IF
HEALTH HAZARDS: BONDED TOGETHER. CONSULT
THE AREA SUPERVISOR OR A
PHYSICIAN FOR PROCEDURES
WARNING
FOR SEPARATION.
USE ALL CLEANING SOLVENTS,
FUELS, OILS, ADHESIVES, AND
EPOXYS AND CATALYSTS IN A
WELL VENTILATED AREA. AVOID
FREQUENT AND PROLONGED
INHALATION OF FUMES. CON-
CENTRATIONS OF FUMES OF
MANY CLEANERS, ADHESIVES
AND ESTERS ARE TOXIC AND

1-5
GEK 97310
VOLUME I
FIRE HAZARDS: FROM PARTS, ENSURE THAT

APPROVED SAFETY EQUIPMENT
IS WORN, AND MOVE TO AN ISO-
WARNING
LATED AREA. BE SURE THAT THE
KEEP ALL CLEANING SOLVENTS, INCREASED AIR PRESSURE IS
OILS, ESTERS AND ADHESIVES NOT DETRIMENTAL OR DAMAG-
AWAY FROM OPEN FLAME SPACE ING TO THE PARTS BEFORE
HEATERS, EXPOSED ELEMENT APPLYING HIGH PRESSURE JETS
ELECTRIC HEATERS, SPARKS OR OF AIR.
FLAME. DO NOT SMOKE WHEN
USING, OR WHEN IN THE VICIN- HEATED/CHILLED PARTS HAZARDS:
ITY OF FLAMMABLE MATERIALS,
OR WHEN IN AREAS WHERE
FLAMMABLES ARE STORED. WARNING
PROVIDE ADEQUATE VENTILA- USE THERMALLY INSULATED
TION TO DISPERSE CONCENTRA- GLOVES WHEN HANDLING
TIONS OF POTENTIALLY EITHER HEATED OR CHILLED
EXPLOSIVE FUMES OR VAPORS. PARTS, TO PREVENT BURNS OR
PROVIDE APPROVED CONTAIN- FREEZING OF HANDS. PARTS
ERS FOR BULK STORAGE OF CHILLED TO SUPER-COLD [-40 TO
FLAMMABLE MATERIALS; AND -65ºF (-40 -55ºC)] TEMPERATURES
FOR DISPENSERS IN THE WORK- CAN CAUSE INSTANT FREEZING
ING AREAS. KEEP ALL CONTAIN- OF HANDS IF PARTS ARE HAN-
ERS TIGHTLY CLOSED WHEN DLED WITHOUT PROTECTIVE
NOT IN USE. GLOVES.
COMPRESSED AIR HAZARDS:
WARNING
AIR PRESSURE, USED IN WORK
AREAS FOR CLEANING OR DRY-
ING OPERATIONS, SHALL BE
REGULATED TO 29 PSIG (200 KPA)
OR LESS. USE APPROVED
SAFETY EQUIPMENT (GOGGLES,
FACE SHIELD) TO PREVENT
INJURY TO THE EYES. DO NOT
DIRECT THE JET OF COM-
PRESSED AIR AT SELF OR OTHER
PERSONNEL OR SO THAT REFUSE
IS BLOWN ONTO ADJACENT
WORKSTATIONS. IF ADDITIONAL
AIR PRESSURE IS REQUIRED TO
DISLODGE FOREIGN MATERIALS

1-6
GEK 97310
VOLUME I
ELECTRICAL HAZARDS: PROCEDURAL HAZARDS:
WARNING WARNING
LETHAL OUTPUT VOLTAGES ARE OBSERVE ALL SPECIFIED AND
GENERATED BY THE IGNITION LOGICAL SAFETY PRACTICES
EXCITER. DO NOT ENERGIZE THE WHEN ASSEMBLING OR DISAS-
EXCITER UNLESS THE OUTPUT SEMBLING THE GAS TURBINE.
CONNECTION IS PROPERLY ISO- WEAR SAFETY GLASSES OR
LATED. IF THE IGNITION OTHER APPROPRIATE EYE PRO-
EXCITER IS GAS TURBINE TECTION AT ALL TIMES. DO NOT
MOUNTED, BE SURE ALL LEADS ALLOW SAFETY WIRE OR WIRE
ARE CONNECTED AND PLUG IS CLIPPINGS TO FLY FROM THE
INSTALLED BEFORE FIRING THE CUTTER WHEN REMOVING OR
EXCITER, OR ALL PERSONNEL INSTALLING WIRE. DO NOT USE
ARE CLEARED AT LEAST 5 FEET FINGERS AS GUIDES WHEN
(1.5 M) FROM THE ENGINE. IF THE INSTALLING PARTS OR TO
EXCITER IS REMOVED, FIRE CHECK ALIGNMENT OF HOLES.
ONLY IN THE ISOLATION CHAM- USE ONLY CORRECT TOOLS AND
BER OF THE TESTER. EXCITER FIXTURES, AND USE AS RECOM-
INPUT VOLTAGES ARE NOT CON- MENDED. AVOID SHORT CUTS,
SIDERED LETHAL, BUT MAY SUCH AS USING FEWER THAN
CAUSE SEVERE DISCOMFORT IF RECOMMENDED ATTACHING
EXPOSED. BOLTS; SHORTER, OR THE
INCORRECT QUALITY OF BOLTS.
PAINTS AND FINISHES HAZARDS: HEED ALL WARNINGS IN THE
MANUAL TEXT TO AVOID INJURY
TO PERSONNEL OR DAMAGE TO
WARNING
ENGINE PARTS.
APPLY PAINTS, FINISHES AND
PRESERVATIVES IN APPROVED
SPRAY BOOTHS OR ISOLATED
AREAS EQUIPPED WITH AIR
CLEANING AND SPRAY EVACUA-
TION EQUIPMENT. ENSURE ALL
LIGHTING AND ELECTRICAL
GEAR IS EXPLOSION PROOF.
WEAR APPROPRIATE BREATHING
FILTERS AND EYE PROTECTION,
AND SUCH CLOTHING AS IS
REQUIRED TO PROTECT THE
SKIN.

1-7
GEK 97310
VOLUME I
TOOLING HAZARDS: CAUTION
WARNING ALL HARDWARE ITEMS HAVE

BEEN MANUFACTURED TO
IMPROPERLY MAINTAINED ENGLISH MEASUREMENT UNITS.
TOOLS AND SUPPORT EQUIP- USE OF SUBSTITUTE METRIC
MENT CAN BE DANGEROUS TO SIZES IS NOT RECOMMENDED
PERSONNEL AND CAN DAMAGE AND WILL VOID WARRANTY FOR
ENGINE PARTS. OBSERVE REC- INTERFACING PARTS. TOOLS IN
OMMENDED INSPECTIONS AND METRIC SIZES SHOULD BE FUR-
SCHEDULES FOR INSPECTIONS NISHED WITH SUITABLE ADAPT-
TO AVOID UNANTICIPATED FAIL- ERS TO MATE WITH ENGLISH
URES. USE TOOLING ONLY FOR MEASUREMENT UNIT SIZES
THE PURPOSE FOR WHICH IT GIVEN. LIMITS, FITS, AND
WAS DESIGNED, AND AVOID CLEARANCES MAY BE INTER-
ABUSE. BE CONSTANTLY ALERT PRETED IN EITHER ENGLISH OR
FOR DAMAGED EQUIPMENT AND METRIC UNITS AS SHOWN IN
INITIATE APPROPRIATE ACTION THE TABLES.
FOR APPROVED REPAIR
IMMEDIATELY. 1-2.3 Safety Precautions. Although the
7LM2500 series engines are safe and reliable,
WARNING certain safety considerations should be
WHEN USING EQUIPMENT PRO- observed.
VIDED WITH OR ASSOCIATED
WITH HIGH FREQUENCY POWER a. The outside surfaces of the engines are
GENERATORS, BE SURE THAT not insulated. Adequate precautions should be
ALL COMPONENTS ARE ADE- taken to prevent operating personnel from
QUATELY ISOLATED FROM NON- inadvertently coming in contact with the hot
INVOLVED PERSONNEL, AND surfaces.
ARE INSULATED TO PREVENT
SERIOUS INJURY TO THE OPERA- b. The engine is a source of considerable
TOR. BE SURE THE GENERATOR noise. It will be necessary for personnel work-
POWER IS OFF WHEN CONNECT- ing on or in its vicinity to wear proper ear pro-
ING OR POSITIONING CONNEC- tection equipment when the engine is
TORS AND CABLES, AND WHEN operating.
ADJUSTING THE HEATER c. The engine is a high-speed machine. In
ELEMENTS. the remote case of parts failure, the casing of
the engine would contain compressor blade
and turbine blade failures, but might not con-
tain major failures of compressor or turbine
disks. Operating personnel should not be per-
manently stationed in or near the plane of the
rotating parts.

1-8
GEK 97310
VOLUME I
d. Rotating parts of the starter operate at a OBSERVER SHALL BE STA-

very high speed. In the remote case of a parts TIONED AT THE ENCLOSURE
failure personnel should not be stationed in the DOOR AND CONFINED SPACE
plane of the starter during the start cycle. ENTRY PROCEDURES SHALL
BE FOLLOWED.
e. The low pressure and high velocity cre-
ated by the compressor of the engine can draw z ALLOW THE GAS TURBINE TO
objects and personnel into the gas generator. COOL DOWN. AVOID CONTACT
The use of an inlet screen or other protective WITH HOT PARTS, AND WEAR
measures is recommended. THERMALLY INSULATED
GLOVES AS NECESSARY.
f. Suitable fire protection equipment
should be provided. z EAR PROTECTION SHALL BE
WORN IF GAS TURBINE IS
WARNING OPERATING.
WHEN ENTERING THE GAS z DO NOT REMAIN IN THE
TURBINE ENCLOSURE THE ENCLOSURE OR IN THE PLANE
FOLLOWING REQUIREMENTS OF ROTATION OF THE
SHALL BE MET: STARTER WHEN STARTING OR
z THE GAS TURBINE SHALL BE MOTORING THE GAS TURBINE.
SHUT DOWN. 1-3 EQUIPMENT DESCRIPTION
z ENCLOSURE ENTRY DURING 1-3.1 General. The following informa-
ENGINE OPERATION IS PRO- tion describes, in general detail, the 7LM2500
HIBITED IN GENERAL. IF series engines. See figures 1-2, 1-3, 1-4, 1-5,
ENTRY SHOULD BE REQUIRED and 1-6.
DURING ENGINE OPERATION,
a. The 7LM2500 series gas generator/tur-
CONTACT GE FIELD SERVICE
bine consists of the following:
FOR A REPRESENTATIVE WHO
IS TRAINED TO ENTER THE (1) Gas generator
ENCLOSURE UNDER SUCH (1) Power turbine
CONDITIONS.
(1) Inlet duct with water wash
z THE FIRE EXTINGUISHING manifold
SYSTEM SHALL BE MADE
INACTIVE ACCORDING TO THE (1) Centerbody
CUSTOMER’S PROCEDURES. (1) Exhaust duct (provided as a cus-
z SECONDARY AIR TO THE tomer option) (gas turbines only)
ENCLOSURE SHALL BE SHUT (1) Flexible coupling forward adapter
OFF. HIGH SECONDARY AIR- (G/T only)
FLOW MAY PREVENT OPENING (1) Lubrication system (less oil tank,
OR CLOSING THE ENCLOSURE cooler and filters)
DOOR.
(2) Ignition units
z THE ENCLOSURE DOOR SHALL
BE KEPT OPEN. IF THE GAS (1) Set of instrumentation sensors
TURBINE IS OPERATING, AN

1-9
GEK 97310
VOLUME I
(30) Fuel nozzles and one or two fuel (4) Individually replaceable compres-
manifold(s) sor stator vanes
NOTE (5) Replaceable 1st and 2nd stage

For a complete functional description high pressure turbine stator vanes in pairs
of the engine and its systems, refer to
Chapter 2 of this manual. (6) Horizontally split compressor sta-
tor and power turbine casings to facilitate
b. The engine is completely assembled repair and/or detailed inspection
and factory tested. All items listed above are
mounted on the gas turbine except for the igni- (7) Externally replaceable gearbox
tion units. The ignition units are shipped loose bearings and seals
for mounting by the Buyer. The gas generator
and power turbine are shipped as an assembled (8) Bolted outer races on all main
unit in a metal reusable container. The remain- bearings
der of the equipment is shipped in wooden
crates. (9) The LM2500 engine has incorpo-
rated a number of ports, specifically located to
c. The LM2500 engine is designed to sep- facilitate borescope inspection. In total, there
arate into major modules and structural units. are 40 different ports which provide access to
See figures 1-5 and 1-6. Modular construction the engine's interior. Using the borescope pro-
is specifically oriented to provide maximum cedure, complete inspection of the LM2500
flexibility for maintenance programs. The engine's gas path can be accomplished with the
engine can be disassembled into interchange- engine installed.
able logical modules. This capability provides
for modular repair or replacement.
d. The LM2500 engine is constructed

with a high degree of accessibility. Detail fea-
tures are specifically aimed at individual com-
ponent replacements, most of which can be
accomplished on an installed engine.
e. Features of the engine include the

following:
(1) Controls and accessories exter-

nally mounted for ease of replacement
(2) Individually replaceable compres-

sor rotor blades
(3) Individually replaceable high

pressure turbine rotor blades or blade pairs

1-10
GEK 97310
VOLUME I
Figure 1-2. LM2500 Gas Turbine-Right Side (Sheet 1 of 4)

1-11
GEK 97310
VOLUME I
Figure 1-2. LM2500 Gas Turbine-Left Side (Sheet 2 of 4)

1-12
GEK 97310
VOLUME I
Figure 1-2. LM2500 Gas Generator-Right Side (Sheet 3 of 4)

1-13
GEK 97310
VOLUME I
Figure 1-2. LM2500 Gas Generator-Left Side (Sheet 4 of 4)

1-14
GEK 97310
VOLUME I
Figure 1-3. Gas Turbine Assembly Cross Section (Sheet 1 of 6)

1-15
GEK 97310
VOLUME I

1-16
GEK 97310
VOLUME I

1-17
GEK 97310
VOLUME I

1-18
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VOLUME I

1-19
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VOLUME I

1-20
GEK 97310
VOLUME I
Figure 1-4. Gas Generator Assembly Cross Section (Typical) (Sheet 1 of 4)

1-21
GEK 97310
VOLUME I

1-22
GEK 97310
VOLUME I

1-23
GEK 97310
VOLUME I

1-24
GEK 97310
VOLUME I
Figure 1-5. Gas Turbine Components (Sheet 1 of 2)

1-25
GEK 97310
VOLUME I
Figure 1-5. Gas Turbine Components (Sheet 2 of 2)

1-26
GEK 97310
VOLUME I
Figure 1-6. Gas Generator Components (Typical) (Sheet 1 of 2)

1-27
GEK 97310
VOLUME I
Figure 1-6. Gas Generator Components (Typical) (Sheet 2 of 2)

1-28
GEK 97310
VOLUME I
1-4 RELATIONSHIP OF MEASURE-

MENT UNITS. See figures 1-7, 1-8, and 1-9.
1-5 REFERENCE DATA.
1-5.1 General. Reference data relating to

equipment performance ratings, component
weights and applicable drawing lists are pro-
vided in the applicable addendum for a spe-
cific gas generator or gas turbine model.

1-29
GEK 97310
VOLUME I
Figure 1-7. General Conversion Factors

1-30
GEK 97310
VOLUME I
Figure 1-8. Conversion Inches (Fractions to Decimals)

1-31
GEK 97310
VOLUME I
Figure 1-9. Temperature Conversion Chart

1-32
GEK 97310
VOLUME I
CHAPTER 2
FUNCTIONAL DESCRIPTION
2-1 INTRODUCTION. 2-2 GAS TURBINE ASSEMBLY.
2-1.1 General. This chapter contains NOTE

detailed functional and physical descriptions The following information describes,
of the 7LM2500 Series gas generator and gas in general detail, the functional
turbine equipment and systems. For a general description of the 7LM2500 Series gas
description of the equipment refer to generators and gas turbines.
Chapter 1.
2-2.1 General. See Chapter 1, figures 1-6
NOTE thru 1-9. The gas turbine assembly consists of
• The System Internationale (S.I.) units a gas generator, a power turbine, a high-speed
shown in this chapter are direct mathe- coupling shaft adapter, and inlet and exhaust
matical conversions and may be rounded components. The gas generator is composed
off in most instances at the user’s discre- of a variable geometry compressor, an annular
tion. Examples of units that may be combustor, a high pressure turbine, an acces-
rounded off are those utilized for tem- sory drive system, and controls and accesso-
peratures, torque values, pressures, etc. ries. The power turbine is composed of a six
Examples where S.I. units may not be stage low pressure turbine rotor, a low pressure
rounded off are those utilized for drop turbine stator, and a turbine rear frame. It is
checks, rigging adjustments, runouts, aerodynamically coupled to the gas generator
etc. and is driven by the gas generator exhaust gas.
• Commensurate with the adoption of the The high-speed coupling shaft adapter is con-
S. I. system has been the introduction of nected to the power turbine rotor and provides
torque wrenches calibrated in newton shaft power to the connected load. The inlet
meters. These will eventually replace duct and centerbody are the engine inlet com-
the conventional metric torque wrench ponents; the exhaust duct, outer cone, and
calibrated in kilogram-meters (kgm) and inner deflector are the engine exhaust
will be given in specifications of N·m or components.
Nm. To convert kilogram-meters (kgm)
to newton meters (N·m) simply discard
the decimal point. For example,
3.5 kgm would become 35 N·m. To con-
vert kilogram centimeters (kg cm) to
newton meters (N·m), round off to one
decimal place. For example, 50 kg cm
would become 5.0 N·m. Although the
above values are not mathematically
precise (35 kgm actually equals
34.3 N·m) they are considered adequate
for general purposes.

2-1
GEK 97310
VOLUME I
2-3 GAS GENERATOR ASSEMBLY. 2-3.5 Support. The front of the compres-
sor stator is supported by the front frame cas-
2-3.1 Inlet Section. The inlet section ing, and the front of the compressor rotor is
directs airflow into the compressor inlet of the supported by the No. 3 roller bearing, which is
engine. It provides a smooth, nonturbulent air- housed in the front frame hub (A sump). The
flow into the compressor. This section con- rear of the compressor stator is supported by
sists of an inlet duct and a centerbody. The the compressor rear frame casing, and the rear
inlet duct is bolted to the forward, outer flange of the rotor is supported by the No. 4 ball and
of the compressor front frame and contains the No. 4 roller bearings, which are housed in the
water wash manifold for injecting liquid clean- compressor rear frame hub (B sump).
ing solutions into the compressor. The center-
body is bolted to the front of the hub of the 2-3.6 Front Frame Assembly. See
compressor front frame. The inlet duct and figure 2-1. The front frame assembly forms a
centerbody are made of aluminum. flow path for compressor inlet air. Struts
between the hub and outer case provide lubri-
2-3.2 Compressor Section. cation supply and scavenge for the A sump
components. The frame also supports the
2-3.3 General. The compressor is a compressor rotor front bearing, inlet duct, cen-
16 stage, high-pressure ratio, axial flow terbody, forward end of the compressor casing,
design. Major components of the compressor compressor inlet seals, inlet gearbox, and the
are compressor front frame, compressor rotor, A sump end cover. It provides mounting of
compressor stator, and compressor rear frame. attachment provisions for the gas generator
The primary purpose of the compressor section front mounts, handling mounts, compressor
is to compress air for combustion; however, inlet temperature (CIT) sensor, inlet total pres-
some of the air is extracted for engine cooling sure (P2) probe, inlet temperature sensor, and
and customer use. transfer gearbox mounts. In the frame are air
passages for sump and seal pressurization and
2-3.4 Air Flow. Air, taken in through the ventilation. A seal oil drain connection is pro-
front frame, passes through successive stages vided at the bottom of the casing. The lower
of compressor rotor blades and compressor frame strut houses the radial drive shaft which
stator vanes and is compressed as it passes transfers power from the inlet gearbox to the
from stage to stage. After passing through transfer gearbox mounted on the bottom of the
16 stages, the air has been compressed in the frame.
ratio of 18 to 1. The inlet guide vanes and the
first 6 stages of stator vanes are variable; their
angular position is changed as a function of
compressor inlet temperature (CIT) and com-
pressor speed. This provides stall-free opera-
tion of the compressor throughout a wide
range of speed and inlet temperatures.

2-2
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VOLUME I
Figure 2-1. Front Frame Assembly

2-3
GEK 97310
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2-3.7 Compressor Rotor. See figure 2-2. b. Rotor spool/disk materials are titanium
for stages one through 10 and Inconel 718 for
a. The compressor rotor is a spool/disk the remainder. Close vane-to-rotor spool and
structure. It is supported at the forward end by blade-to-stator casing clearances are obtained
the No. 3 roller bearing, which is housed in the with metal spray rub coating. Thin squealer
compressor front frame (A sump). The aft end tips on the blades and vanes contact the
of the rotor is supported by the No. 4 ball and sprayed material. Abrasive action on the tips
roller bearings, which are housed in the com- prevents excessive rub while obtaining mini-
pressor rear frame (B sump). Use of spools mum clearance. The first and second stage
makes it possible for several stages of blades disks have a series of single blade axial dove-
to be carried on a single piece of rotor struc- tails, while each of stages 3 through 16 have
ture. There are seven major structural ele- one circumferential dovetail groove in which
ments and three main bolted joints. The first blades are retained. Blades in stages one
stage disk, the second stage disk (with integral through 14 are titanium. Blades in stages 15
front stub shaft), and the stages 3 through 9 and 16 are A286. The first stage blades have
spool are jointed by a single bolted joint at mid span shrouds to reduce blade tip vibration.
stage 2. The stages 3 through 9 spool is bolted
through the stage 10 disk to the stages 11 2-3.8 Compressor Stator. See figures 2-3
through 13 spool with the joint at stage 10. and 2-4. The compressor stator consists of two
The stages 11 through 13 spool is followed by titanium or M-152 steel front casing halves
the rear shaft and an overhung stages 14 and two rear casing halves of Inconel 718,
through 16 spool, with a single bolted joint at each split horizontally with all four pieces
stage 13. Interfering rabbets are used in all bolted together. They house the compressor
flange joints for good positioning of parts and variable and fixed vanes and provide a struc-
for rotor stability. An air duct, supported by tural shell between the compressor front frame
the front and rear shafts, routes stage 8 air aft and the compressor rear frame. The compres-
through the center of the rotor for pressuriza- sor stator has one stage of inlet guide vanes
tion of the B sump seals. (IGV) and 16 stages of stator vanes. The
IGV’s and stages 1 through 6 are variable and
their angular positions change as a function of
compressor inlet temperature and gas genera-
tor speed. This variability gives the vane air-
foil the optimum angle of attack for efficient
operation without compressor stall.
The vane positions are controlled by a speed

sensor and servo valve. The material of the
IGV’s and vanes of stages 1 and 2 is titanium,
while stages 3 through 16 are A286. Stage 8
vanes are A286 airfoils with a stainless steel
base.

2-4
GEK 97310
VOLUME I
Figure 2-2. Compressor Rotor Assembly

2-5
GEK 97310
VOLUME I
Figure 2-3. Compressor Stator Assembly

2-6
GEK 97310
VOLUME I
LEGEND FOR FIGURE 2-4
1. Self Locking Nut (1 ea) 27. Glass Bushing, Stg-3 (46 ea)
2. Vane Arm, Stg-IGV (30 ea) 28. Glass Bushing, Stg-4 (50 ea)
4. Vane Arm, Stg-1 (32 ea) 30. Glass Bushing, Stg-6 (64 ea)
5. Vane Arm, Stg-2 (4 ea) 31. Flanged Bushing, Stg-IGV (34 ea)
6. Vane Arm, Stg-2 (36 ea) 32. Flanged Bushing, Stg-1 (36 ea)
8. Vane Arm, Stg-3 (42 ea) 34. Flanged Washer, Stg-3 (40 ea)
12. Vane Arm, Stg-5 (50 ea) 38. Spacer, Stg-3 (46 ea)
16. Alignment Sleeve, Stg-IGV thru 2 42. Connecting Link, Stg-IGV (2 ea)
17. Alignment Sleeve, Stg-3 (46 ea) 43. Connecting Link, Stg-1 (2 ea)
21. Spacer, Stg-IGV (34 ea) 47. Connecting Link, Stg-5 (2 ea)
22. Spacer, Stg-1 (36 ea) 48. Connecting Link, Stg-6 (2 ea)
23. Spacer, Stg-2 (40 ea) 49. Act. Arm Sleeve, Stg-IGV (30 ea)
24. Washer, Stg-IGV (34 ea) 50. Act. Arm Sleeve, Stg-1 (32 ea)
25. Washer, Stg-1 (36 ea) 51. Act. Arm Sleeve, Stg-2 (36 ea)
26. Washer, Stg-2 (40 ea) 52. Act. Arm Sleeve, Stg-3 (42ea)

2-7
GEK 97310
VOLUME I
LEGEND FOR FIGURE 2-4 - Continued
53. Act. Arm Sleeve, Stg-4 (46 ea) 78. Self Locking Nut, Stg-2 (14 ea)
54. Act. Arm Sleeve, Stg-5 (50 ea) 79. Bushing, Stg-IGV (34 ea)
55. Act. Arm Sleeve, Stg-6 (56 ea) 80. Bushing, Stg-1 (36 ea)
56. Ring Segment, Stg-IGV (2 ea) 81. Bushing, Stg-2 (40 ea)
57. Ring Segment, Stg-1 (2 ea) 82. Plain Nut, Stg-5 (8 ea)
59. Ring Segment, Stg-3 (2 ea) 84. Self Locking Nut, Stg-5 (8 ea)
61. Ring Segment, Stg-5 (2 ea) 86. Alignment Sleeve, Stg-5 (8 ea)
62. Ring Segment, Stg-6 (2 ea) 87. Alignment Sleeve, Stg-6 (8 ea)
63. Vane, Stg-IGV (34 ea) 88. Vane, Stg-7 (72 ea)
64. Vane, Stg-1 (36 ea) 89. Vane, Stg-8 (34 ea)
68. Vane, Stg-5 (58 ea) 93. Vane Dovetail Liner (4 ea Stage)
69. Vane, Stg-6 (64 ea) 94. Vane Dovetail Liner (4 ea Stage)
70. Vane Shroud, Stg-IGV (2 ea) 95. Act. Arm Sleeve (36 ea)
71. Vane Shroud, Stg-1 (2 ea) 96. Machine Bolt (56 ea)
72. Vane Shroud, Stg-2 (2 ea) 97. Flat Washer (56 ea)
73. Shear Bolt, Stg-IGV (12 ea) 98. Straight Pin (28 ea)
74. Shear Bolt, Stg-1 (14 ea) 99. Safety Wire (AR)
75. Shear Bolt, Stg-2 (14 ea) 100. Act. Ring Spacer (56 ea)
76. Self Locking Nut, Stg-IGV (12 ea) 101. Self Locking Nut (56 ea)
77. Self Locking Nut, Stg-1 (14 ea) 102. Flat Washer (56 ea)

2-8
GEK 97310
VOLUME I
Figure 2-4. Compressor Stator Variable Vanes-Steel Front Casing

(Sheet 1 of 5)

2-9
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VOLUME I

(Sheet 2 of 5)

2-10
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VOLUME I

(Sheet 3 of 5)

2-11
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VOLUME I

(Sheet 4 of 5)

2-12
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VOLUME I

(Sheet 5 of 5)

2-13
GEK 97310
VOLUME I
a. Three bleed manifolds are welded to a. Bearing axial and radial loads and a
the stator casings. Bleed air is extracted from portion of the first stage nozzle load are taken
the inner annulus area at the tips of the stage in the hub and transmitted through 10 radial
eight vanes and is used for sump pressurization struts: to the case. The hub is a casting which
and cooling. Bleed air, extracted at the stage provides about half of the radial lengths of the
nine vanes, is used for power turbine cooling, 10 struts. The outer strut ends are castings
power turbine forward seal pressurization, and which are welded to the hub to complete the
power turbine balance piston cavity pressur- struts. The hub and strut assembly is welded
ization. Bleed air, extracted at the stage thir- to the case, a sheet metal and machined ring
teen vanes, is used for cooling the second stage weldment that is the combustor outer case as
high pressure turbine nozzle. well as the structural load path between the
compressor casing and the turbine mid frame.
b. The IGV’s and stages 1 and 2 are To provide the customer with compressor dis-
shrouded. These shrouds, which are aluminum charge air, an internal manifold within the
extrusions split into forward and aft halves, are frame extracts air from the combustion area
held together with bolts. The first and second and routes it through struts 3, 4, 8, and 9. Six
stage vane shrouds mate with rotor seal teeth. borescope ports located in the case just for-
ward of the mid flange permit inspection of the
c. Borescope ports are provided in the combustor, fuel nozzles, and the first stage tur-
casing at several stages of vanes to permit bine nozzle. Two borescope ports are provided
internal inspection of the compressor. in the aft portion of the case for inspection of
the turbine blades and nozzles.
d. The variable vanes are actuated by a
pair of master levers. The aft ends of the mas- b. The B sump housing is fabricated from
ter levers are attached to pivot posts near the an Inconel 718 casting that forms the sump
tenth stage on each side of the casing. Each of cavity and supports the sump seals, an Inconel
the master lever forward ends is positioned by 718 sheet support cone, and a machined cir-
a hydraulic actuator. Adjustable linkages con- cumferential flange. Sump service tubing
nect directly from the master levers to the actu- attachment points are made with standard fit-
ating rings of the variable vanes. tings, which allow the housing to be removed
from the frame without breaking permanent
2-3.9 Compressor Rear Frame. See connections. To provide for differential ther-
figure 2-5. The compressor rear frame assem- mal growth between sump service tubing and
bly is made of Inconel 718 and consists of the the surrounding structure, the tubes are
outer case, the struts, the hub, and the B sump attached only at the sump and have slip joints
housing. Its outer case supports the combus- where they pass through the outer strut ends.
tor, the fuel manifold(s), the 30 fuel nozzles,
two spark igniters, and the second stage tur-
bine nozzle support.

2-14
GEK 97310
VOLUME I
Figure 2-5. Compressor Rear Frame

2-15
GEK 97310
VOLUME I
2-3.10 Combustor Section. 2-3.14 Swirl Cups. Thirty vortex-induc-

ing axial swirl cups in the dome (one at each
2-3.11 General. See figure 2-6. The com- fuel nozzle tip) provide flame stabilization and
bustor is annular and consists of four major mixing of the fuel and air. The interior surface
components riveted together: cowl (diffuser) of the dome is protected from the high temper-
assembly, dome, inner liner, and outer liner. ature of combustion by a cooling-air film.
Accumulation of carbon on the fuel nozzle tips
2-3.12 Cowl Assembly. The cowl assem- is prevented by venturi-shaped spools attached
bly, in conjunction with the compressor rear to the swirler.
frame, serves as a diffuser and distributor for
the compressor discharge air. It furnishes uni- 2-3.15 Combustor Liners. The combus-
form air flow to the combustor throughout a tor liners are a series of overlapping rings
large operating range providing uniform com- joined by resistance-welded and brazed joints.
bustion and even temperature distribution at They are protected from the high combustion
the turbine. The cowl assembly consists of a heat by circumferential film-cooling. Primary
machined ring and inner and outer cowl inlets combustion and cooling air enters through
welded to the inner and outer cowl wall. closely spaced holes in each ring. These holes
Strength and stability of the cowl ring section help to center the flame and admit the balance
are provided with a truss structure consisting of the combustion air. Dilution holes are
of 40 box sections welded to the cowl walls. employed on the outer and inner liners for
The box sections also serve as aerodynamic additional mixing to lower the gas temperature
diffuser elements. To provide a short overall at the turbine inlet. Combustor/turbine nozzle
combustor system length, the cowl assembly air seals at the aft end of the liners prevent
leading edge fits with and around the compres- excessive air leakage while providing for ther-
sor rear frame struts. mal growth.
2-3.13 Combustor Mounting. The com- 2-3.16 High Pressure Turbine Section -
bustor is mounted in the compressor rear frame Twin Shank Rotor Configuration.
on 10 equally spaced mounting pins in the for-
ward (low temperature) section of the cowl 2-3.17 General. The high pressure turbine
assembly. These pins provide positive axial section consists of the high pressure turbine
and radial location and assure centering of the rotor, first and second stage turbine nozzle
cowl assembly in the diffuser passage. The assemblies, and the turbine mid frame. The
mounting hardware is enclosed within the turbine rotor extracts energy from the gas
compressor rear frame struts so that it will not stream to drive the compressor rotor to which
affect airflow. it is mechanically coupled. The turbine noz-
zles direct the hot gas from the combustor onto
the rotor blades at the optimum angle and
velocity.

2-16
GEK 97310
VOLUME I
Figure 2-6. Combustor

2-3.18 Component Mounting. The for- a. The conical forward turbine shaft
ward end of the turbine rotor is attached to the transmits energy to the compressor rotor.
compressor rotor rear shaft and is supported by Torque is transmitted through the spline joint
the No. 4 ball and roller bearings (B sump). at the forward end of the shaft. Two air seals
The aft end of the turbine rotor is supported by are attached to the forward end of the shaft.
the No. 5 roller bearing in the turbine mid The forward seal prevents compressor dis-
frame (C sump). The turbine nozzles are con- charge pressure (CDP) from directly entering
tained in and supported by the compressor rear the B sump. The other seal maintains CDP in
frame. The turbine mid frame, besides sup- the plenum formed by the rotor and the com-
porting the aft end of the turbine rotor, also bustor. This plenum is a balance chamber that
supports the front end of the power turbine. It provides force that maintains the proper thrust
contains the transition duct through which the load on the No. 4 ball bearing. The inner rab-
hot gas flows from the high pressure turbine bet diameter on the rear flange provides a posi-
section into the power turbine. tive radial location for the stage 1 blade
retainer and a face seal for the rotor internal
2-3.19 High Pressure Turbine - Twin
cooling air. The outer rabbet diameter on the
Shank Rotor Configuration. See
flange provides positive location for the stage
figure 2-7. The high pressure turbine rotor
1 disk and stability for the rotor assembly.
consists of a conical forward shaft, two disks
with air cooled blades and blade retainers, a
conical rotor spacer, a catenery shaped thermal
shield, and a rear shaft.

2-17
GEK 97310
VOLUME I
Figure 2-7. High Pressure Turbine Rotor (Twin Shank)
b. The high pressure turbine rotor is c. Turbine blades in both stages are long
cooled by a continuous flow of compressor shanked and internally air cooled. Use of the
discharge air that passes through holes in the long shank blades provides thermal isolation
first stage nozzle support and forward turbine of dovetails, cooling air flow paths, high
shaft. See figure 2-8. This air cools the inside damping action for low vibration and low disk
of the rotor and both disks before passing rim temperature. The blades are brazed
between the paired dovetails and out to the together in pairs. Channel shaped tip caps are
blades. inserted into the blade tips and are held by
crimping the blade tips and by brazing. The
turbine blades are coated to improve corrosion,
erosion and oxidation resistance. The type of
coating employed (marinized or nonmarin-
ized) depends on the type of environment in
which the engine will be operated.

2-18
GEK 97310
VOLUME I
Figure 2-8. High Pressure Turbine Rotor Cooling (Twin Shank)
d. Both first and second stage high pres- e. The stage 1 disk is forged premium
sure turbine blades are cooled by compressor Inco 718. There are 54 bolt holes and blade
discharge air which flows through the dovetail slots in the rim. The stage 2 disk is also forged
and the blade shanks into the airfoil. See premium Inco 718. There are 58 bolt holes
figure 2-9. First stage blades are cooled by and blade slots in the rim. Bosses around the
internal convection and external film cooling. rim bolt holes on both sides of each disk rim
The convection cooling of the center area is provide resistance to low cycle fatigue. The
accomplished through a labyrinth passage bottom tangs and the bottom of the slots are
within the blade. The leading edge circuit pro- enclosed in the cooled region of the rotor. The
vides internal convection cooling by airflow inner bolt circle has twenty-four 3/8 inch
through the labyrinth then out through the diameter bolts. The aft shaft is rabbeted to the
leading edge, tip and gill holes. Convection disk. See figure 2-8.
cooling of the trailing edge is provided by air
flowing through the trailing edge exit holes.
Stage 2 blades are cooled by convection, with
all the cooling air discharged at the blade tips.

2-19
GEK 97310
VOLUME I
Figure 2-9. High Pressure Turbine Rotor Blade Cooling (Twin Shank)

2-20
GEK 97310
VOLUME I
2-3.20 Stage 1 Turbine Nozzle Assembly c. The stage 1 nozzle assembly is air-
(Twin Shank Rotor Configuration). See cooled by convection and film cooling with
figure 2-10. The stage 1 high pressure turbine compressor discharge air that flows through
nozzle directs high pressure gases from the each vane. See figure 2-11. Internally, the
combustion section onto the first stage turbine vane is divided into two cavities. Air flowing
blades at the optimum angle and velocity. The into the forward cavity is discharged through
first stage nozzle vanes are air-cooled by con- holes in the leading edge and through gill holes
vection and film cooling. The major compo- on each side close to the leading edge to form a
nents of the first stage turbine nozzle assembly thin film of cool air over the length of the
are the nozzle support, nozzle vane assembly, vane. Air flowing into the aft cavity is dis-
inner and outer seals, air baffles, thermal charged through trailing edge slots.
shield, pressure balance seal support, and a
shim to be used with the thin flange nozzle 2-3.21 Stage 2 Turbine Nozzle Assembly
support. (Twin Shank Rotor Configuration). See
figure 2-12. The stage 2 high pressure turbine
a. The nozzles are coated to improve cor- nozzle directs the high pressure gases exiting
rosion, erosion and oxidation resistance. They from the first stage turbine blades onto the sec-
are bolted to the first stage nozzle support and ond stage blades at the optimum angle and
receive axial support from the second stage velocity. The major parts of the second stage
nozzle support. There are 33 nozzle segments nozzle assembly are the nozzle vane assembly,
in the assembly, each segment consisting of nozzle support, first and second stage turbine
two vanes. The vanes are cast and then welded shrouds, and interstage seal.
into pairs (segments) to decrease the number
of gas leakage paths. These welds are partial- a. The nozzle support is a conical section
penetration welds to allow easy separation of with a flange that is bolted between the flanges
the segments for repair and replacement of of the compressor rear frame and the turbine
individual vanes. mid frame. The support mounts the nozzles,
cooling air feeder tubes, and the first and sec-
b. The stage 1 nozzle support, in addition ond stage turbine shrouds.
to supporting the first stage nozzle segments,
forms the inner flow path wall from the com- b. The nozzle vanes are cast then coated.
pressor rear frame to the nozzle segments and The nozzle vanes (two per nozzle segment)
is bolted to the aft end of the pressure balance direct the gas stream onto the second stage tur-
seal support. bine blades. The inner ends of the nozzles
form a mounting circle for the interstage seal
attachment.

2-21
GEK 97310
VOLUME I
Figure 2-10. First Stage High Pressure Turbine Nozzle (Twin Shank Rotor Configuration)
Figure 2-11. First Stage High Pressure Turbine Nozzle Cooling

(Twin Shank Rotor Configuration)

2-22
GEK 97310
VOLUME I
Figure 2-12. Second Stage High Pressure Turbine Nozzle (Twin Shank Rotor Configuration)
c. The stage 2 nozzle assembly is air- e. The interstage seal is composed of six
cooled by convection. See figure 2-12. The segments bolted to the nozzles. It minimizes
nozzle vane center area and leading edge are the gas leakage between the second stage noz-
cooled by internal air (stage 13) which enters zle and the turbine rotor. The sealing surface
through the cooling air tubes. Some of the air has four steps for maximum effectiveness of
is discharged through holes in the trailing each sealing tooth. The seal backing material
edge, while the remainder flows out through and the honeycomb sealing surface are Hastel-
the bottom of the vanes and is used for cooling loy X. The seals are pregrooved to preclude
the interstage seals and the turbine blade seal rub under emergency shutdown
shanks. conditions.
d. The turbine shrouds form a portion of

the outer aerodynamic flow path through the
turbine. They are located radially in line with
the turbine blades and form a pressure seal to
prevent excessive gas leakage over the blade
tips. The sealing (rubbing) surface is nickel-
aluminide compound. The first stage consists
of 24 segments, the second stage, 11 segments.

2-23
GEK 97310
VOLUME I
2-3.22 High Pressure Turbine Section - bustor. This plenum is a balance chamber that
Single Shank Rotor Configuration. provides a force that maintains the proper
thrust load on the No. 4 ball bearing. The
2-3.23 General. The high pressure turbine
inner rabbet diameter on the rear flange pro-
section consists of the high pressure turbine
vides a positive radial location for the stage 1
rotor, first and second stage turbine nozzle
blade retainer and a face seal for the rotor
assemblies, and the turbine mid frame. The
internal cooling air. The outer rabbet diameter
turbine rotor extracts energy from the gas
on the flange provides positive location for the
stream to drive the compressor rotor to which
stage 1 disk and stability for the rotor
it is mechanically coupled. The turbine noz-
assembly.
zles direct the hot gas from the combustor onto
the rotor blades at the optimum angle and b. The high pressure turbine rotor is
velocity. cooled by a continuous flow of compressor
discharge air that passes through holes in the
2-3.24 Component Mounting. The for-
first stage nozzle support and forward turbine
ward end of the turbine rotor is attached to the
shaft. See figures 2-14 and 2-15. This air
compressor rotor rear shaft and is supported by
cools the inside of the rotor and both disks
the No. 4 ball and roller bearings (B sump).
before passing between the dovetails and out
The aft end of the turbine rotor is supported by
to the blades.
the No. 5 roller bearing in the turbine mid
frame (C sump). The turbine nozzles are con- c. The turbine blades are coated to
tained in and supported by the compressor rear improve corrosion, erosion and oxidation
frame. The turbine mid frame, besides sup- resistance. The type of coating employed
porting the aft end of the turbine rotor also (marinized or nonmarinized) depends on the
supports the forward end of the power turbine. type of environment in which the engine will
It contains the transition duct through which be operated.
the hot gas flows from the high pressure tur-
d. Both first and second stage high pres-
bine section into the power turbine.
sure turbine blades are cooled by compressor
2-3.25 High Pressure Turbine Rotor - discharge air which flows through the dovetail
Single Shank Rotor Configuration. See and the blade shanks into the airfoil. See
figure 2-13. The high pressure turbine rotor figure 2-16. First stage blades are cooled by a
consists of a conical forward shaft, two disks combination of internal convection, leading
with air cooled blades and blade retainers, a edge internal impingement and external film
conical rotor spacer, a catenery shaped thermal cooling. The convection cooling of the mid
shield, and a rear shaft. chord region is accomplished through serpen-
tine passages within the blade. The leading
a. The conical forward turbine shaft
edge circuit provides internal convection cool-
transmits energy to the compressor rotor.
ing by impingement of air against the inside
Torque is transmitted through the spline joint
surface and flow through the leading edge and
at the forward end of the shaft. Two air seals
gill holes. Convection cooling of the trailing
are attached to the forward end of the shaft.
edge is provided by air flowing over pinned
The forward seal prevents compressor dis-
fins and finally through the trailing edge exit
charge pressure (CDP) from directly entering
slots. Stage 2 blades are cooled by convection,
the B sump. The other seal maintains CDP in
with all the cooling air discharged at the blade
the plenum formed by the rotor and the com-
tips.

2-24
GEK 97310
VOLUME I
Figure 2-13. High Pressure Turbine Rotor (Single Shank)
Figure 2-14. High Pressure Turbine Rotor Assembly (Single Shank)

2-25
GEK 97310
VOLUME I
Figure 2-15. High Pressure Turbine Rotor Air Flow (Single Shank)

2-26
GEK 97310
VOLUME I
Figure 2-16. High Pressure Turbine Rotor Blade Cooling (Single Shank)

2-27
GEK 97310
VOLUME I
e. The stage 1 disk is forged premium a. The nozzles are coated to improve ero-
Inco 718 as is the twin shank disk. The disk sion, corrosion, and oxidation resistance.
geometry is similar to the twin shank except They are bolted to the first stage nozzle sup-
there are 88 bolts holes and blade slots in the port and receive axial support from the second
rim compared to 54 bolt holes and blade slots stage nozzle support. There are 33 nozzle seg-
in the twin shank configuration. The outer ments in the assembly, each segment consist-
diameter of the disk has been increased by ing of two vanes. The vanes are cast and then
0.50 inch (12.7 mm) to accommodate the welded into pairs (segments) to decrease the
shorter shank and blade. The bore area of the number of gas leakage paths. These welds are
disk has been modified to accommodate the partial-penetration welds to allow easy separa-
longer chord blade. See figure 2-16. tion of the segments for repair and replacement
of individual vanes.
f. The stage 2 disk is also forged pre-
mium Inco 718 as is the twin shank disk. The b. The stage 1 nozzle support, in addition
disk geometry is similar to the twin shank to supporting the first stage nozzle segments,
except there are 90 bolt holes and blade slots in forms the inner flow path wall from the com-
the rim compared to 58 bolt holes and blade pressor rear frame to the nozzle segments and
slots in the twin shank configuration. The is bolted to the aft end of the pressure balance
outer diameter of the disk has been increased seal support.
by 0.30 inch (7.8 mm) and the bore area of the
disk has been strengthened. The inner bolt cir- c. The stage 1 nozzle assembly is air
cle has twenty-four 7/16 inch diameter bolts. cooled by convection and film cooling with
The aft shaft is rabbeted to the disk. See compressor discharge air that flows through
figure 2-14. each vane. See figure 2-18. Internally, the
vane is divided into two cavities. Air flowing
2-3.26 Stage 1 Turbine Nozzle Assembly into the forward cavity is discharged through
(Single Shank Rotor Configuration). See holes in the leading edge and through gill holes
figure 2-17. The stage 1 high pressure turbine on each side close to the leading edge to form a
nozzle directs high pressure gases from the thin film of cool air over the length of the
combustion section onto the first stage turbine vane. Air flowing into the aft cavity is dis-
blades at the optimum angle and velocity. The charged through additional film holes and
stage 1 nozzle vanes are air cooled by convec- trailing edge slots.
tion and film cooling. The major components
of the first stage turbine nozzle assembly are
the nozzle support, nozzle vane assembly,
inner and outer seals, air baffle, pressure bal-
ance seal support, and channel cover. The
assembly incorporates a number of structural
and cooling geometry improvements for
increased life and compatibility with the single
shank turbine.

2-28
GEK 97310
VOLUME I
Figure 2-17. Stage One Turbine Nozzle Assembly (Single Shank Rotor Configuration)
Figure 2-18. Stage One HPT Nozzle Cooling (Single Shank Rotor Configuration)

2-29
GEK 97310
VOLUME I
2-3.27 Stage 2 Turbine Nozzle Assembly nickel-aluminide compound. The first stage
(Single Shank Rotor Configuration). See consists of 48 segments, the second stage has
figure 2-19. The stage 2 high pressure turbine 11 segments.
nozzle directs the high pressure gases exiting
from the first stage turbine blades onto the sec- d. The interstage seal is composed of
ond stage blades at the optimum angle and eleven segments bolted to the nozzles. It mini-
velocity. The major components of the second mizes the gas leakage between the second
stage nozzle assembly are the nozzle support, stage nozzle and the turbine rotor. The sealing
nozzle vane assembly, first and second stage surface has four steps for maximum effective-
turbine shrouds, and interstage seal. The ness of each sealing tooth. The seal backing
assembly incorporates a number of structural material and the honeycomb sealing surface
and cooling geometry improvements for are Hastelloy X. The seals are pregrooved to
increased life and compatibility with the single preclude seal rub under emergency shutdown
shank turbine rotor. conditions.
a. The nozzle support is a conical section 2-3.28 Turbine Mid Frame. See
with a flange that is bolted between the flanges figure 2-21. The turbine mid frame supports
of the compressor rear frame and the turbine the aft end of the high pressure turbine rotor
mid frame. The support mounts the nozzles, and the forward end of the power turbine rotor.
cooling air feeder tubes, and the first and sec- It is bolted between the rear flange of the com-
ond stage turbine shrouds. pressor rear frame and the front flange of the
power turbine stator. The frame provides a
b. The nozzle vanes are cast then coated. smooth diffuser flow passage for high pressure
The nozzle vanes (two per nozzle segment) turbine discharge air into the power turbine.
direct the gas stream onto the second stage tur- Piping for bearing lubrication and seal pressur-
bine blades. The inner ends of the nozzles ization is located within the frame struts. The
form a mounting circle for the interstage seal frame contains ports for the low pressure tur-
attachment. The stage 2 nozzle assembly is air bine inlet thermocouples and pressure probes.
cooled by convection. See figure 2-20. The These ports also provide access for borescope
nozzle vane center area and leading edge are inspection of the power turbine inlet area. The
cooled by internal air (stage 13) which enters power turbine first stage nozzles assemble to
through the cooling air tubes. Some of the air the turbine mid frame.
is discharged through holes in the trailing
edge, while the remainder flows out through a. The frame hub is a one-piece casting
the bottom of the vanes and is used for cooling with flanges to support the sump housing, sta-
the interstage seals and the turbine blade tionary seals, inner liner support, and power
shanks. turbine first stage nozzle support. It has eight
gusseted pads spaced around the circumfer-
c. The turbine shrouds form a portion of ence for attaching the struts.
the outer aerodynamic flow path through the
turbine. They are located radially in line with
the turbine blades and form a pressure seal to
prevent excessive gas leakage over the blade
tips. The sealing (rubbing) surface is

2-30
GEK 97310
VOLUME I
Figure 2-19. Stage Two HPT Nozzle Assembly (Single Shank Rotor Configuration)

2-31
GEK 97310
VOLUME I
Figure 2-20. Stage Two High Pressure Turbine Nozzle Cooling (Single Shank Rotor
Configuration)

2-32
GEK 97310
VOLUME I
Figure 2-21. Turbine Mid Frame

2-33
GEK 97310
VOLUME I
b. The bearing support cone and the sump 2-3.31 Accessory Drive Train. Power to
housing are bolted to the forward flange of the drive the accessories is extracted from the
hub. The sump housing is of double-wall con- compressor rotor through a large diameter hol-
struction so that the inner or wetted wall can be low shaft which is spline-connected to the
cooled with air to prevent coking. The sump rotor front shaft. A set of bevel gears in the
vent tube also is double-walled to prevent inlet gearbox transfers this power to the radial
coking within the vent tube. drive shaft, which transmits the power to
another set of bevel gears in the forward sec-
c. The liner assembly consists of an inner tion of the transfer gearbox. A short horizontal
and outer liner held together with airfoil- drive shaft transmits the power to the acces-
shaped strut fairings butt-welded to both lin- sory drive adapters in the accessory gearbox.
ers. This assembly guides the gas flow and
shields the main structure from high tempera- 2-3.32 Inlet Gearbox. See figure 2-23.
ture. The liner assembly is supported at the The inlet gearbox assembly consists of a cast
forward end by inner and outer liner supports. aluminum casing, a shaft, a pair of bevel gears,
Seals at both ends of the inner and outer liners bearings, and oil jets. The casing, which is
are provided to prevent excessive leakage of bolted inside the front frame hub, mounts two
cooling air from behind the liner assembly. duplex ball bearings and a roller bearing. It
has internal oil passages and jets to provide
d. The power turbine first stage turbine lubrication for the gears and bearings. The
nozzle consists of 14 segments of six vanes shaft, which rotates on a horizontal axis, is
each. The inner end is attached to the nozzle splined at the aft end to mate with the second
support, and the outer end is secured to the stage disk of the compressor rotor. The for-
outer nozzle support ring which is secured ward end of the shaft mounts the upper bevel
between the frame aft flange and the power gear and is supported by a duplex ball bearing.
turbine stator front flange. The lower bevel gear, which rotates on a verti-
cal axis, is supported at its upper end by a
2-3.29 Accessory Drive Section. roller bearing and at its lower end by a duplex
ball bearing. The lower end is also splined to
2-3.30 General. See figure 2-22. The mate with the radial drive shaft.
accessory drive section consists of an inlet
gearbox located in the hub of the front frame, a 2-3.33 Radial Drive Shaft. The radial
radial drive shaft inside the 6 o’clock strut of drive shaft, a hollow shaft externally splined
the front frame, and a transfer/accessory gear- on each end, mates with the bevel gears in the
box bolted underneath the front frame. The inlet and transfer gearboxes. Its function is to
pneumatic or hydraulic starter and the tube and transmit power from the inlet gearbox to the
scavenge pump are mounted on the aft side of forward section (bevel gearbox) of the transfer
the accessory gearbox. The air-oil separator gearbox. The shaft contains a shear section to
and the variable stator control are mounted on prevent damage to the accessory drive system.
the front of the accessory gearbox. Two gas
generator speed sensors are located on the
accessory gearbox.

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Figure 2-22. Accessory Drive Section (Except GA101 Models) (Sheet 1 of 2)

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Figure 2-22. Accessory Drive Section (Except GA101 Models) (Sheet 2 of 2)
Figure 2-23. Inlet Gearbox

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2-3.34 Accessory Gearbox. See box. To prevent oil and oil vapors from escap-
figure 2-24. The accessory gearbox assembly ing past the end of the impeller, the separator
consists of a two-piece aluminum casing, air- has two labyrinth seals, with the cavity
oil separator, gears, bearings, seals, oil noz- between the two seals pressurized with stage 8
zles, and accessory adapters. The forward sec- ejector air.
tion (bevel or transfer gearbox) contains a set
of right-angle bevel gears and a horizontal 2-4 POWER TURBINE.
drive shaft which transmits the power to the
gear train in the rear section (accessory gear- 2-4.1 Power Turbine Rotor.
box). Each bevel gear is supported by a
duplex ball bearing and a roller bearing. An 2-4.2 General. See figure 2-26. The
access cover in the bottom of the casing facili- power turbine rotor is a six stage low pressure
tates installation of the radial drive shaft. The turbine rotor mounted between the No. 6 roller
plug-in gear concept is used on all accessory bearing, housed in the turbine mid frame
adapters and idler gears in the aft (accessory) (C sump), and the No. 7 ball and roller bear-
section. This permits an entire gear, bearing, ings, housed in the turbine rear frame
seal, and adapter assembly to be removed and (D sump). It consists of six disks, each having
replaced without disassembling the gearbox. two integral spacers, one on each side (except
Each spur gear is supported by a casing- for stages 1 and 6). Stage 1 has a seal at the
mounted roller bearing on one end and an forward end. Each disk spacer is attached to
adapter-mounted ball bearing on the other end. the adjacent disk spacer by close-fitting bolts.
The accessory drive spur gears are internally The front shaft is secured between stages 2 and
splined. Internal tubes and oil nozzles provide 3 spacers, and the rear shaft between stages 5
lubrication of the gears and bearings. Gearbox and 6 spacers.
carbon face seals are retained from the outside
of the gearbox and can be replaced without 2-4.3 Blades and Seals. Blades of all six
disassembly of the gearbox. stages contain interlocking tip shrouds for low
vibration levels and are retained in the disks by
2-3.35 Air-Oil Separator. See figure 2- dovetails. Replaceable rotating seals, secured
25. The air-oil separator consists of a fabri- between the disk spacers, mate with stationary
cated sheet metal impeller with a cast alumi- seals to prevent excessive gas leakage between
num housing. It is mounted on the front of the stages. The first three stages of blades are
accessory section of the gearbox and is an coated for corrosion protection.
optional part of the gearbox. To prevent exces-
sive oil loss from venting oil vapor overboard,
all sumps are vented to the air-oil separator.
The sump vent air is discharged after passing
through the separator. Oil is collected on the
inside of the impeller as the oil-laden sump air
passes through the separator. Small holes in
the segments of the impeller allow the col-
lected oil to be discharged to the separator
outer housing. Vanes on the housing wall are
used to collect and direct the oil to the gear-

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Figure 2-24. Accessory Gearbox (Except GA101 Models)

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Figure 2-24. Accessory Gearbox (GA101 Models) (Sheet 2 of 2)

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Figure 2-25. Air-Oil Separator

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Figure 2-26. Power Turbine Rotor and Stator Casings

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2-4.4 Power Turbine Stator. 2-5 EXHAUST DUCT.

2-4.5 General. See figure 2-26. The
power turbine stator consists of two casing 2-5.1 General. See figure 2-28. The
halves split horizontally, stages 2 through 6 exhaust duct consists of the inner and outer
turbine nozzles, and six stages of blade duct forming the diffusing passage from the
shrouds. The first stage nozzle is assembled to power turbine rear frame. The diffusing sec-
the turbine mid frame assembly. Stages 2 and tion recovers a portion of the kinetic energy of
3 nozzles have welded segments of six vanes the exhaust gases leaving the power turbine,
each. Stages 4, 5 and 6 nozzles have segments before the 90 degree turn in the exhaust duct.
of two vanes each. The first three stages of The inner diffuser duct can be moved aft to
vanes are coated for corrosion protection. obtain access to the coupling shaft. The
exhaust duct is independently supported from
2-4.6 Shrouds and Seals. Honeycomb the gas turbine base structure and piston-ring-
shrouds, mounted in casing channels, mate type expansion joints are used to accommodate
with the shrouded blade tips to provide close- the thermal growth between the turbine rear
clearance seals and also to act as a casing heat frame and the exhaust duct.
shield. The stationary interstage seals are
attached to the inner ends of the nozzle vanes NOTE
to maintain low air leakage between stages. The exhaust duct may not be supplied
Insulation is installed between nozzles/shrouds as part of the gas turbine.
and casing to protect the casing from the high
temperature of the gas stream. 2-6 HIGH SPEED FLEXIBLE COU-
PLING SHAFT (TYPICAL).
2-4.7 Turbine Rear Frame.
2-4.8 General. See figure 2-27. The tur- 2-6.1 General. See figure 2-29. The high
bine rear frame consists of an outer casing, speed coupling shaft consists of a forward
eight equally spaced radial struts, and a single- adapter (Inco 718) which mates with the power
piece cast steel hub. It forms the power tur- turbine, two flexible couplings, a distance
bine exhaust flow path and supports the aft end piece, and an aft adapter which mates with the
of the power turbine and the forward adapter connected load.
of the high-speed coupling shaft. The turbine NOTE
rear frame hub supports the inner deflector of
the exhaust system. It also contains a bearing Couplings, distance piece, and aft
housing for the No. 7 ball and No. 7 roller adapter may not be supplied as part of
bearings. The bearing housing is a one-piece the gas turbine.
casting of 17-4 PH stainless steel material. 2-6.2 Operation. The forward and aft
The hub and the bearing housings have flanges adapters are connected to the distance piece by
to which air and oil seals are attached to form the flexible couplings. The flexible couplings
the D sump. The frame casing supports the allow for axial and radial deflections between
outer cone of the exhaust system and provides the gas turbine and the connected load during
attaching points for the gas turbine rear sup- operation. Inside the aft adapter and the rear
ports. The struts contain service lines for flexible coupling is an axial damper system
lubrication supply, and sump scavenging and consisting of a cylinder and a piston assembly.
venting. The power turbine speed pickups are The damper system prevents excessive cycling
mounted in the struts. of the flexible couplings. Anti-deflection rings
restrict radial deflection of the couplings dur-
ing shock loads.

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Figure 2-27. Turbine Rear Frame

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Figure 2-28. Exhaust Duct Assembly (Typical)

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Figure 2-29. High Speed Flexible Coupling Shaft (Typical)
2-7 BEARINGS. 2-7.3 Power Turbine. The power turbine

rotor support consists of three bearings: the
2-7.1 General. See figure 2-30. The No. 6R, 7B, and 7R bearings. The No. 6R and
engine assembly bearings support two separate 7R bearings are roller bearings mounted on the
rotating systems: the gas generator and the forward and aft rotor shafts respectively. The
power turbine. Seven bearings are used: No. 7B bearing is a ball bearing mounted on
No. 3R (A sump), 4R and 4B (B sump), the rear shaft, just forward of the No.7R bear-
5R and 6R, (C sump), 7B and 7R (D sump). ing. It carries the thrust load of the power tur-
No. 1 and 2 bearings are not used in this bine rotor.
application.
2-7.4 Mounting. All bearing outer races,
2-7.2 Gas Generator. Support for the except No. 4B, 5R and 7R are flanged. The
gas generator rotors consists of a four-bearing No. 4B bearing is retained by a spanner nut
system: the No. 3R and 4R bearings are roller across its outer face. The No. 5R and 7R bear-
bearings mounted on the forward and aft coming is retained by a tabbed ring which engages
pressor shafts respectively. Bearing No. 4B is slots in the outer race. Bearings No. 3R and
a ball bearing and is used to carry the thrust 5R, under some conditions, can be lightly
load of the gas generator rotors. The No. 5R loaded. To prevent skidding of the rollers
bearing is a roller bearing supporting the rear under these conditions, the outer race is very
shaft of the gas generator turbine rotor. slightly elliptical to keep the rollers turning.

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Figure 2-30. Gas Turbine Bearings
2-8 SEALS. shafts of the starter, fuel pump, VSV control,

and auxiliary drive pad.
2-8.1 Oil Seals. See figure 2-31. The oil
seals are of two types: labyrinth windback 2-8.2 Air Seals. See figure 2-32. The gas
used in the sump areas, and carbon seals used turbine air seals are of two types: labyrinth/
in the transfer gearbox. The labyrinth/wind- honeycomb used in the sump and turbine
back seal combines a rotating seal having oil areas, and fishmouth used in the combustor
slingers and a serrated surface with a station- and turbine mid frame. The labyrinth/honey-
ary seal having windback threads and a smooth comb seal combines a rotating seal having a
rub surface. The oil slingers throw oil into the serrated surface with a stationary seal having a
windback threads which direct the oil back to honeycomb surface. The serrations cut into
the sump area. The serrations cut grooves into the honeycomb to maintain close clearances
the smooth surface of the stationary seal to over a large temperature range. The fishmouth
maintain close clearances throughout a large seals are circular, sheet metal, stationary, inter-
temperature range. This seal allows a small locking type seals used to prevent excessive
amount of seal pressurization air to leak into leakage of hot combustion gas from the pri-
the sump, thereby preventing oil leakage. The mary gas stream.
carbon seal consists of a stationary spring-
loaded carbon sealing ring and a rotating
highly polished steel mating ring. It prevents
oil in the gearbox from leaking past the drive

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Figure 2-31. Typical Oil Seals

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Figure 2-32. Typical Air Seals

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2-9 AIRFLOW. D sump is bled into the flexible coupling shaft

tunnel for cooling. It then passes out the aft
2-9.1 Primary Airflow. See figure 2-33 end of the exhaust duct. Some of the air passes
and 2-34. The gas generator compressor through holes in the power turbine rear shaft
draws air through the inlet duct, and the front rotor air tube and holes in the rotor front shaft,
frame. After being compressed to an approxi- where it pressurizes and cools the C sump.
mate ratio of 18 to 1, the air enters the combus-
tion section where some of it is mixed with 2-9.3 Stage 9 Bleed Air. See figure 2-33.
fuel, and the mixture burned. The remainder Ninth-stage air is bled from the compressor
of the air is used for centering the flame in the through holes in the compressor casing at the
combustor and for cooling the combustor and stage nine vanes and is piped to the turbine
some parts of the high pressure turbine. Some mid frame and aft balance piston ejector. The
of the energy in the hot combustion gas is used air to the turbine mid frame enters the frame
to turn the high pressure turbine rotor which is through 5 of the struts. Some of the air exits
coupled to and turns the compressor rotor. through holes in the frame hub to cool the
Upon leaving the high pressure turbine sec- frame inner liner. The rest of the air enters
tion, the gas passes into the power turbine sec- through the tubes of the HPT cooling and vent
tion. Most of the remaining energy is seal and three holes in the aft hub face to the
extracted by the power turbine rotor which forward side of the LP rotor. This air is used
drives the high speed flexible coupling shaft. for rotor cooling and passes through the power
The shaft transmits the power from the turbine turbine. The air to the aft balance piston ejec-
rotor through the turbine rear frame and tor is added to stage 13 air and enters the frame
through the exhaust duct. through struts 2 and 8 and passes into an area
between the forward air seals. This area acts
2-9.2 Stage 8 Bleed Air. See figure 2-33. as a balance chamber to reduce the aft loading
Stage 8 air is bled from the compressor of the No. 7 ball bearing.
through hollow eighth-stage vanes into an
external manifold. From the manifold, the air 2-9.4 Stage 13 Bleed Air. See
is piped forward and aft to ejector nozzles. figure 2-33. Thirteenth-stage air is bled from
Each ejector contains a venturi through which the compressor through holes in the casing into
the eighth-stage air passes. The air passing a manifold. The air is piped through the com-
through the venturi draws external air into the pressor rear frame casing and into the second-
ejector. This gives the ejector a high volume stage high pressure turbine shrouds and flows
output of low pressure and low temperature through and cools the second-stage nozzles.
air. Air from the forward ejector is piped into Some of the air exits through nozzle trailing
the front frame hub where it pressurizes and edge holes, and the remainder is used for cool-
cools the A sump. Some of the A sump air ing the interstage seal, the aft side of the
passes through holes in the compressor rotor stage 1 blade shanks, and the front side of the
front shaft, through the rotor air duct, and stage 2 blade shanks. Some stage 13 air is
through holes in the rotor rear shaft, where it added to stage 9 air through an ejector and is
pressurizes and cools the B sump. Air from used for No. 7B bearing pressure balance.
the aft air ejector is piped into the turbine rear
frame hub, where it is used to pressurize and
cool the D sump. Part of the air entering the

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Figure 2-33. Typical Gas Turbine Air Flow (Sheet 1 of 5)

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Figure 2-34. Typical Gas Generator Air Flow (Sheet 1 of 3)

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2-9.5 Compressor Discharge Bleed Air. 2-10.4 Fuel Nozzles. The fuel nozzles are
See figure 2-33. Bleed air is available for cus- individually removable. Thirty fuel nozzles are
tomer use from the stage 16 of the compressor. utilized in each engine assembly.
This bleed air is taken through holes in the
inner wall of the compressor rear frame and 2-10.5 Speed Governing System.
out through frame struts No. 3, 4, 8, and 9. If
customer bleed air is used, it must be extracted 2-10.6 General. The speed governing sys-
uniformly from the four ports. Compressor tem or fuel control regulates fuel flow to the
discharge air used for high pressure turbine combustion section of the gas generator to
blade cooling is taken off through the stage 1 control gas generator speed. The power tur-
high pressure turbine nozzle support. The bine speed is not directly controlled, but is
remaining compressor discharge bleed air is established by the gas stream energy level pro-
used for cooling the combustion liner and the duced by the gas generator.
stage 1 high pressure turbine nozzle vanes.
2-10.7 Fuel Flow. Fuel flow is regulated
2-10 ENGINE SYSTEMS. by the off-engine mounted fuel control which
senses various parameters to provide stable
2-10.1 Fuel System. operation of the engine at the throttle setting
selected.
NOTE
The following information describes in 2-10.8 Electrical System.
general detail, the fuel system
employed on the 7LM2500 series 2-10.9 General. The electrical system
engines. Different configurations are consists of ignition system, exhaust gas tem-
available as customer selected options. perature indication, speed indication, vibration
Refer to Section 2-13, Fuel System indication, and oil temperature indication. See
Configurations, for particular details of figure 2-35.
the engine model selected.
2-10.10 Ignition System. See figure 2-36.
2-10.2 General. The fuel system consists During start, the ignition system produces the
of a fuel manifold, and 30 fuel nozzles, which high energy sparks that ignite the fuel-air mix-
are engine mounted, and a fuel control, which tune in the combustor. It consists of 2 ignition
is off-engine mounted and is not supplied as a exciters, 2 ignition leads, and 2 spark igniters.
part of the fuel system. Once ignition has been accomplished, com-
bustion will continue without additional igni-
2-10.3 Fuel Manifold. The fuel manifold tion from the spark igniters until the engine is
is the split ring type and incorporates a pres- shut down.
sure tap for troubleshooting or continuous
read-out. It distributes fuel to the fuel nozzles.

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Figure 2-35. Typical Electric System Schematic (Sheet 1 of 7)

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Figure 2-36. Ignition System

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a. The ignition exciters are the capacitor c. The ignition leads are low-loss connec-
discharge type. The exciters are off-engine tions between the ignition exciters and the
mounted. Design characteristics are as spark igniters. They are coaxial, having metal-
follows: lic shielding which incorporates copper inner
braid, sealed flexible conduit, and nickel outer
Normal Duty 75 sec. on, 90 sec. off braid.
Cycle 75 sec. on, 90 sec. off
75 sec. on, 30 min. off d. The spark igniters are surface gap type.
or They have internal passages for air-cooling
45 sec. on, 120 sec. off and air vents to prevent the accumulation of
for 4 cycles followed by carbon in interior passages.
30 minutes off
2-10.11 Exhaust Gas (T5.4) Temperature
Power input 115 Volts @ 50-60 Hz Indication.
Stored energy 14.5-16.0 joules
a. Current Configuration. Gas generator
Spark rate 2/sec. exhaust gas temperature is sensed by 11 ther-
mocouples installed in the turbine mid frame.
Output voltage 15-20 KV See figure 2-37. There are four thermocouple
Output energy harnesses, three of which have three thermo-
couples each and one of which has two
Total 2.0 joules min. thermocouples.
Duration 20 micro-seconds min.
b. Early (GA101) Configuration. The
Peak power 100,000 watts min. thermocouple harness consists of two sections.
The right half has six probe assemblies, the left
Peak current 2000 amp. min.
half has five assemblies. The separate probe
assemblies are connected in a parallel configu-
NOTE ration by using equal length leads. The electri-
Ignition exciter, L21454P03, contains a cal leads are contained in swaged, stainless
20 megohm bleed resistor located steel sheathing which is filled with magnesium
across the exciter storage capacitor. oxide for insulation. Each dual-immersion
This bleed resistor reduces the voltage probe assembly consists of two single junction
on the storage capacitor to a safe han- thermocouples which are enclosed in swaged,
dling level for maintenance or storage stainless steel tubes with magnesium oxide
conditions. A bleed time of 50-75 sec- insulation.
onds will reduce the exciter tank volt-
age by approximately 2/3rds.
b. The exciters operate on 115v. 60 Hz

input. The power is transformed, rectified, and
discharged in the form of capacitor discharge
energy pulses through the coaxial shielded
leads to spark igniters.

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Figure 2-37. Thermocouple Schematic

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c. A thermocouple junction is formed flange (CRFV) to indicate gas generator vibra-

when two dissimilar metals are joined. tion. The second pickup is installed on the for-
Chromel and Alumel are used as the dissimilar ward flange of the turbine rear frame to
metals. A complete circuit is formed when indicate power turbine vibration (TRFV).
both ends of the Chromel and Alumel wires Also available is an optional on-engine accel-
are joined. The junctions are termed hot and erometer signal conditioning package and high
cold. When the cold junction is maintained at impedance cables. All of the accelerometers
a known reference temperature and the hot are oriented to sense vibration in the vertical
junction is exposed to a high temperature, an direction. Salient features of the accelerome-
electromotive force (EMF) will be generated ters are as follows:
which is proportional to the temperature of the
hot junction. The EMF is extremely small. At • Piezo-electric operating principle with no
a hot junction temperature of 1560°F (850°C) moving parts.
and cold junction temperature of 32°F (0°C),
• High signal output of 50 pico coulomb/G.
approximately 0.035 volts will be generated.
The electrical output of each of the 22 junc- • High thermal capability of 1150°F
tions is averaged electrically by successively (621°C)
paralleling conductors of equal resistance. • Rugged construction.
The resultant output signal represents the aver-
age temperature of the turbine discharge gas. 2-10.14 Oil Temperature Indications.
Iron-Constantan thermocouples are available
d. Thermocouple leads are available to replace the standard tube and scavenge sys-
which allow each thermocouple probe to be tem RTD's at the purchaser's request. Temper-
read individually. This system allows monitor- ature-electromotive force relationship and
ing exhaust gas temperature (T5.4 spread). accuracy conforms to Instrument Society of
America (ISA) standards for Type J Iron-
2-10.12 Speed Indication. See figure 2-38. Constantan Thermocouples. The time con-
The speed pickups are magnetic, reluctance- stant of the sensors is 3.5 seconds for a step
type, pulse generators which supply electrical change in temperature of lubricating oil flow-
signals proportional to gas generator and ing at a velocity at 2 feet/sec (0.61 m/sec).
power turbine speeds. The gas generator gas Five thermocouples or RTD's are used to mea-
speed sensors are mounted on the accessory sure oil scavenge temperature (one for each
gearbox and the power turbine speed sensors sump, one for the accessory gearbox). One is
are mounted in the turbine rear frame. used to measure supply oil temperature.
2-10.13 Vibration Indication. The vibra-

tion pickups are self-generating, velocity type
transducers used to indicate gas generator or
power turbine vibration. On early configura-
tions, one sensor is installed at the 12 o'clock
position on the forward flange of the compres-
sor front stator case (FFV). On current config-
urations, the sensor is installed at the 6 o'clock
position on the compressor rear stator case aft

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Figure 2-38. Engine Speed Pickups

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2-10.15 Lubrication System. enge element is used to scavenge the

accessory gearbox.
2-10.16 General. See figure 2-39. The
lubrication system is of the recirculating dry b. Early Gas Turbines. Early gas turbine
sump type with an 18 GPM maximum flow five scavenge element pumps are similar to the
rate. The oil flow in the system varies directly gas generators described above except that the
with gas generator speed. Lube oil from a cus- D sump and accessory gearbox each have one
tomer provided storage tank is fed to the tube scavenge element similar to the A, B, and C
element of the engine mounted lube and scav- sumps.
enge pump. The lube element supplies oil to c. Current gas turbines utilize lube pumps
the engine sumps and gearboxes via a cus- with six scavenge elements where the addi-
tomer provided lube supply duplex filter, anti- tional element scavenges the air-oil separator
static check valve and individual oil jets. The directly.
lube oil is scavenged from the bearing sumps
and gearboxes via individual scavenge pump d. GA101 Models. Oil is distributed to
elements. The combined scavenge oil flow is components requiring lubrication and cooling
returned to the lube storage tank via an anti- by the supply element of the lube and scavenge
static check valve, customer provided lube pump. Distribution is controlled by nozzles,
scavenge filters and an oil cooler. Since the which direct oil to each component. Five sep-
scavenge pump elements have a combined arate scavenge elements (three in one pump,
flow rating larger than the supply element, the two in another) remove the oil from the gas
scavenge oil is mixed with air which is generator cavities and return it to the cus-
removed in the lube storage tank de-aerator tomer's tank. The gas generator lubrication
system. Sump air and oil is vented to an system is connected with and depends on the
engine gearbox mounted air-oil separator packager-provided lubrication system, which
where the oil is removed from the mixture and includes such components as the oil tank, fil-
returned to the lube storage tank de-aerator ters, coolers, etc. Refer to the packager's
system. The air is vented overboard via a cus- instruction manual for information on the cus-
tomer provided air-oil demister or into the tomer's system and its components.
exhaust duct via a flame arrestor.
2-10.17 Lube Supply Subsystem. See
a. Gas Generators (except GA101) and figure 2-39. The lube supply subsystem con-
Gas Turbines. Gas generators utilize pumps sists of the following:
with five scavenge elements: one for each of
• Oil tank (packager supplied)
the A sump, B sump and C sump plus two ele-
ments for the accessory gearbox. The acces- • Lube and scavenge pump supply element
sory gearbox is scavenged with the A sump and relief valve
and the air-oil separator is scavenged with the • Lube supply duplex filter (packager
accessory gearbox. supplied)
NOTE • Lube supply anti-static check valve
The D sump, which is located in the • C and D sump supply check valve (early
power turbine, is not included in gas gas turbine only)
generator models. The D sump scav-
• Lube supply RTD's or thermocouples

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Figure 2-39. Typical Gas Generator Lubrication System Schematic (Sheet 1 of 7)

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a. Lube oil from the supply tanks enters Reseat

the lube and scavenge pump through an inlet
screen which prevents particles larger than Gas generators 275 psid (1898 kPa) min
0.030 inch (0.76 mm) in size from entering. Gas turbines 90 psid (621 kPa) min
Output of the supply element is routed to the
customer provided lube supply filter. From the Pumping capacity. All flows are determined
filter, the oil flows through an anti-static check at the following conditions:
valve to the inlet gearbox, the stator vane con-
trol, the transfer and accessory gearbox, and Pump speed 6000 RPM
the gas turbine sumps. On early gas turbines
only, oil going to the C and D sump passes Oil temperature 150°+/-51°F
through an additional check valve in the C and (66°+/-28°C)
D sump supply line. Lube discharge oil is also Oil pressure 12-15 psia
piped to a port near the forward end of the lube (83-104 kPa)
and scavenge pump to lubricate the drive Oil specification MIL-L-23699 or
spline. MIL-L-7808
Lube supply 16.0-18.3 gpm
b. The lube and scavenge pump
(60.6-69.3 lpm)
(see figure 2-40 or 2-41) is a six or seven ele-
ment, positive displacement, vane type pump. AGB scavenge 4.8-5.4 gpm
One element is used for the lube supply, and (18.2-20.4 lpm)
five or six elements are used for lube scaveng- A sump plus
ing. Within the pump are inlet screens, one for AGB scavenge 18.0-20.2 gpm
each element, and a lube supply pressure limit- (68.1-70.5 lpm)
ing valve. Design characteristics of the pump
are as follows: B sump 10.6-12.1 gpm
scavenge (40.1-45.8 lpm
Rotation Clockwise when viewed C sump 7.6-8.5 gpm
from drive end scavenge (28.8-32.2 lpm)
D sump 3.6-4.1 gpm
Shear section 1500-2000 1b in.
scavenge (13.6-15.5 lpm)
(1730 -2306 kg cm) torque
(Gas Turbine
Models only)
Pressure limiting valve
Air-Oil separa- 4.8-5.4 gpm
Cracking pressure tor scavenge (18.2-20.5 lpm)
Gas generators 300 psid (2070 kPa) min Discharge pressure
Gas turbines 100 psid (690 kPa) min Lube supply 25-75 psia (173-518 kPa)
normal, 75-100 psia
Full flow
(518-690 kPa) extreme
Gas generators 400 psid (2760 kPa) min Scavenge 25-85 psia (173-586 kPa)
Gas turbines 200 psid (1380 kPa) min normal, 85-100 psia

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Figure 2-40. Lube and Scavenge Pump

(Gas Generator/Gas Turbine Models with Five Scavenge Elements Pump)

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Figure 2-41. Lube and Scavenge Pump

(Gas Generator/Gas Turbine Models with Six Scavenge Elements Pump)

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c. Oil enters the lube inlet port and passes removes particles larger than 0.037 inch
through a removable, non-bypassing inlet (0.94 mm). A pressure relief valve, which is
screen which traps particles larger than part of the pump protects the system. From the
0.030 inch (0.76 mm). A lube supply pressure pump, oil flows through a packager-supplied
limiting valve is provided to limit supply pres- filter, through an anti-static leakage check
sure. It is located between the inlet and outlet valve through the seal air-to-oil cooler, to the
of the supply element. On gas generators and three bearing areas, and to the gearboxes. The
early gas turbines, the air-oil separator drains lube supply subsystem also supplies oil to the
into the aft section of the accessory gearbox variable stator system and to the starter.
and is scavenged with the gearbox oil. On cur-
rent gas turbines, oil from the air-oil separator 2-10.18 Lube Scavenge Subsystem. See
is scavenged directly by a lube and scavenge figure 2-39. The lube scavenge subsystem
pump element. This feature can be added to consists of the following:
early gas turbines if necessary.
• Lube and scavenge pump scavenge
d. The lube supply check valve is located elements.
on the engine at the supply interface. It will • Lube scavenge duplex filter (packager
open and flow 20 gpm (76 lpm) with a maxi- supplied).
mum differential pressure of 15 psid
(104 kPa). The purpose of the check valve is • Lube scavenge check valve.
to prevent the oil in the tank from draining into • Temperature control valve (packager
the sumps and gearbox when the engine is shut supplied).
down under gravity head conditions.
• Heat exchanger/oil cooler (packager
e. Early Gas Turbines. A check valve is supplied).
located in the lube oil supply line to the C and • Scavenge system relief valve (packager
D sumps. The check valve isolates the C and supplied).
D sumps from the gas generator lube oil sys-
tem when an external lube supply and scav- a. Scavenge oil enters the pump through
enge system is used for the power turbine. five or six scavenge oil ports, passes through
Both the C and D sump scavenge lines and the an inlet screen in each port, and enters the
C and D sump oil supply lines are equipped scavenge elements. The output of five scav-
with access ports to facilitate the application of enge elements is connected inside the pump
an external lube system for the power turbine. and discharges through a common scavenge
During normal engine operation, lube oil is discharge port. The sixth scavenge element
supplied from the lube pump, to the C and D discharge is external to the pump body and is
sumps. The check valve then opens at a 2 psi connected by tubing to the common scavenge
(14 kPa) pressure differential. discharge line from the pump to the scavenge
check valve.
f. Lube Supply Subsystem (GA101
Models). See figure 2-39. Oil flows from the
customer's oil tank to the lube supply element
of the lube and scavenge pump. It enters the
pump through a lube inlet screen, which

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b. The scavenge check valve is located in (2) The lube and scavenge pump
the lube and scavenge pump discharge line. It scavenges oil from the B and C sumps.
will open and flow 20 gpm (76 lpm) with a Because of the large quantity of oil supplied to
maximum differential pressure of 15 psi the B sump bearings, a dual, side-by-side ele-
(104 kPa). The purpose of this check valve is ment is used to scavenge the B sump. See
to prevent the oil in the scavenge lines from figure 2-43.
draining back into the sumps and gearbox
when the engine is shut down. (3) Scavenge discharge from both
pumps is routed through an anti-static leakage
c. Lube Scavenge Subsystem (GA101 check valve and back to the customer's system.
Models). The scavenge subsystem consists of
five elements, five inlet screens with magnetic, (4) The scavenge subsystem and the
chip detectors, an anti-static leakage check sump vent subsystem use flexible line cou-
valve, and associated piping. The scavenge plings to compensate for gas generator thermal
elements and associated areas are as follows: expansion.
No. of 2-10.19 Oil Seal Pressurization

Area Elements Pump Subsystem. Refer to paragraph 2-9.2, Eighth-
Stage Bleed Air.
Transfer Gear- 1 Fwd. Scavenge
box - Fwd.
Transfer gear- 1 Fwd. Scavenge
box - Aft. 2-10.20 Sump Vent Subsystem. See
figure 2-39.
A Sump 1 Fwd. Scavenge
B Sump 1 Lube and a. The sump vent subsystem consists of
Scavenge one major part, the air-oil separator, and the
piping and tubing. The air-oil separator is
C Sump 1 Lube and mounted on the accessory gearbox.
Scavenge
b. To prevent oil leakage, main bearing
(1) The forward scavenge pump scav- oil seals use pressurization air to cause air to
enges the rear portion of the A sump. The cen- flow across the seals into the sumps. Seal
ter portion of the A sump drains into the pressurizing air is extracted from the eighth
transfer gearbox-forward and is scavenged by stage of the compressor and distributed to the
the transfer gearbox-forward scavenge ele- oil seals. To remove the air which enters the
ment. The forward scavenge pump also scav- sump through the oil seals, the sump air is
enges the transfer gearbox-aft. Scavenge oil vented. Each sump area is connected to a
from all elements of the forward scavenge sump vent manifold through frame struts. The
pump is discharged into a common port and is manifold connects to the air-oil separator
then routed to a scavenge discharge manifold which extracts oil from the air before venting
in the lube and scavenge pump. See the air into the exhaust duct. Extracted oil is
figure 2-42. returned to the scavenge system.

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Figure 2-42. Forward Scavenge Pump (GA101 Models)

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Figure 2-43. Lube and Scavenge Pump (GA101 Model)

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2-10.21 Starting System. • Inlet air pressure 35 to 41 psig starting

(241 to 284 kPa gage)
2-10.22 General.
• Peak power 135 horse power
a. The engine is equipped with a pad on (100 kw)
the accessory gearbox for a starter. Pneumatic • Turbine wheel 75,000 rpm
(either air or natural gas) or hydraulic starters speed (Normal maximum)
may be used. The starter drives the gas gener-
• Lubrication Oil sump splash
ator to a speed which, after light-off, will per-
(continuous lube
mit it to continue to accelerate to idle
optional)
unassisted. In addition the starter is used peri-
odically to motor the gas generator for water-
washing. (c) The starter is equipped with a
cutout switch of the normally closed type,
(1) Pneumatic starter (air or natural which opens when cutout speed is reached.
gas). See figure 2-44. The switch has a contact rating of 5 amps
inductive and 5 amps resistive on 115 volt,
(a) The starter system consists of 60 Hz power, and 2.5 amps inductive and 4
a pneumatic turbine starter, which can be used amps resistive on 24 volts dc.
with air or natural gas. An optional starter reg-
ulator valve is available for use with air start- (d) The maximum supply tem-
ing systems only. The starter drives the gas perature is 475°F (246°C). Air or gas must be
generator compressor rotor through the gear- dry and filtered to 40 micron nominal. If it is
box to start the engine. The starter can also be desired to purge and, without stopping, go into
used to motor the engine for water-washing. a start cycle, the gas generator may be motored
The optional starter regulator valve permits or at 1200 rpm (approximately 15 psig [103 kPa
interrupts flow of air to the starter and regu- gage] for 2 minutes then increasing the pres-
lates the flow of the pneumatic medium to the sure to 38 psig (262 kPa gage) and at 1700 rpm
proper pressure and flow. The customer is energizing the fuel and ignition system.
responsible for interconnecting piping, electri-
cal connections and mounting of off-engine (e) The starter is energized dur-
components. See installation drawings pro- ing normal start for approximately 40 to
vided with the engine. 70 seconds. The consumption per start is
about 120 to 250 pounds (54 to 113 kg),
(b) Design features and require- depending on the medium and conditions used.
ments of the starter are:
• Reduction gear 16 to 1
ratio
• Cutout speed 4300-4700 rpm
• Shaft rotation Counterclockwise
when viewed from
output shaft

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Figure 2-44. Pneumatic Starter

(f) The starter duty cycle is as NOTE
follows:
The above starter duty cycle limits
Starting— shall apply during all normal operating
45 seconds on, 2 minutes off for any conditions. When performing an
number of cycles. engine hot restart following an emer-
or gency shutdown from high power set-
ting (T5.4 greater than 1150°F/621°C)
2 minutes on, 5 minutes off,
refer to Chapter 4.
2 minutes on, 21 minutes off for any
number of cycles (g) If air is used to drive the
Motoring— starter, it can be discharged directly from the
5 minutes on, 2 minutes off, starter with no additional piping. If natural gas
is used, the exhaust natural gas must be vented
5 minutes on, 18 minutes off for any
to a safe location. The back pressure on the
number of cycles.
starter must not exceed 2 psi (14 kPa).
or
10 minutes on, 20 minutes off for any (h) See Chapter 4 for definition
number of cycles. (For 10 minutes of at customer interface connections for the gas
motoring, maximum starter air inlet turbine model selected.
temperature is 200°F [93°]).

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(2) Continuous lube starter. (d) The maximum allowable

back pressure on the oil return from the starter
(a) The continuous lube starter is 275 psig (1896 kPa). Starter engagement
system consists of a pneumatic starter with oil may be made at gas generator speeds within
feed and scavenge ports and a magnetic carbon the starter manufacturer's recommendation.
seal, an oil feed tube connecting the starter
sump to the engine oil pump drive spline feed (e) For water washing or motor-
tube, a hose connecting the starter sump to the ing of the engine, the customer is to provide
A sump pressurization tube for starter scav- the means for limiting starter speeds.
enge, a tube which carries scavenged air and
oil from the starter into the accessory gearbox, (f) There are no duty cycle limi-
and associated clamps and brackets. tations on the starter so long as the oil tempera-
ture is maintained under 140°F (60°C).
(b) Regular maintenance of the
starter oil level is not required with this sys- NOTE
tem. An initial fill with 400 ± 50 cc of oil is The above starter duty cycle limits
required before first operation. shall apply during all normal operating
conditions. When performing an
(3) Hydraulic starter. See figure 2-45. engine hot restart following an emer-
gency shutdown from high power set-
(a) The hydraulic starter consists tings (T5.4 greater than 1150°F/621°C)
of a variable displacement type hydraulic refer to Chapter 4.
motor with piston stroke controlled by a wob-
ble plate. The starter weighs approximately (g) The maximum flow through
100 lbs (45.36 kg). the starter seal drain is 5 cc's/hr and maximum
allowable back pressure is one psig. Maxi-
(b) The starter is equipped with mum flow through the starter case drain is
an over running clutch to prevent the motor 1.5 gpm and maximum allowable back pres-
from being driven by the gas generator when sure is 25 psig.
the hydraulic supply pressure and flow are
reduced to zero. 2-10.23 Accessory Drive System.
(c) The hydraulic starter will a. The accessory drive system provides
start the engine within two minutes. A mini- drives and mounts for controls and accesso-
mum flow of 55 gpm (208 lpm) of hydraulic ries. It consists of an inlet gearbox, a radial
oil at a minimum pressure of 4875 psig drive shaft, a transfer gearbox and an acces-
(33637 kPa) is required. Maximum allowable sory gearbox. The inlet gearbox is driven by
pressure is 5300 psig (36570 kPa gage). Oil the compressor rotor front shaft, and drives the
temperature shall be maintained between radial drive shaft at a right angle to the com-
32-200°F (0-93°C) and the oil must be filtered pressor. The drive shaft powers the accessory
to 10 microns nominal. gearbox, which drives the controls and
accessories.

2-88
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Figure 2-45. Hydraulic Starter

2-89
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2-10.24 Variable Stator Control System. c. Oil to operate the variable vane system
See figures 2-46, 2-47, 2-48, 2-49, 2-50, 2-51 is supplied from the gas turbine tube oil supply
and 2-52. line to the speed sensor. From the speed sen-
sor the oil is pumped to the servo valve where
2-10.25 General. The variable stator con- it is routed to the VSV actuators. The oil is
trol system senses gas generator speed and then returned to the gas turbine tube oil supply
compressor inlet temperature (CIT), and posi- line from the servo valve. Bypass oil from the
tions the variable compressor stator vanes. For speed sensor is routed through an anti-static
any one temperature and any one speed, the check valve to the lube oil pump supply line
variable compressor stator vanes take one entering the supply element of the pump.
position and remain in that position until the
gas generator speed or CIT changes. Early d. The servo valve receives a mechanical
configurations consist of a speed sensor and demand signal from the speed sensor and a
servo valve as two separate components. The mechanical feedback signal from the variable
current configuration variable stator vane con- vane actuators. By means of a control valve it
trol combines the speed sensor and servo valve provides high pressure oil (supplied by the
into one unit. speed sensor) to the rod and head ends of the
VSV actuators.
2-10.26 Components.
e. The variable vane actuators (see
a. Early Configuration Components: figure 2-53) receive high pressure oil from the
servo valve and move the variable stator
• Speed sensor vanes. Movement of the two actuators is
transmitted through master levers and actua-
• Servo valve
tion rings to the individual vanes.
• Variable stator actuators
• Demand linkage f. The demand linkage transmits the
desired vane position signal from the speed
• Feedback cable sensor to the servo valve.
• Speed sensor oil bypass check valve
g. The feedback cable transmits the actual
b. The speed sensor senses gas generator vane position signal from the vane actuators to
speed and compressor inlet temperature (CIT). the servo valve pivot lever to null the servo
By means of a regulator, it provides high pres- valve when the vanes have reached the proper
sure oil to the servo valve and by means of the position.
demand linkage it provides a mechanical vane
position desired signal. The speed sensor con- h. The bypass check valve, located in the
tains a pilot valve which moves in response to bypass oil line from the speed sensor prevents
CIT signals and to speed signals, and a servo oil from draining out of the lube tank into the
piston which moves in response to the pilot gearboxes and sumps when the gas turbine is
valve. not operating.

2-90
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Figure 2-46. Variable Stator Control System (Early Configuration)

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Figure 2-47. Variable Stator Control Functional Schematic (Early Configuration)

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Figure 2-48. Variable Stator Control PN L34379 System (Current Configuration)

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Figure 2-52. Variable Stator Control PN L34379 Functional Schematic (Current Configuration)

2-97
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Figure 2-53. Variable Stator Vane Actuators
i. Current Configuration, PN L34379: accessory gearbox and the compressor front

frame. See figures 2-48, 2-49, 2-50, 2-51, and
• Variable stator vane control 2-52.
• Variable stator actuators
k. The variable stator actuators receive
• Feedback cable k high pressure oil from the variable stator vane
control and move the variable stator vanes.
j. The variable stator vane control, when See figure 2-53. Movement of the two actua-
operating in conjunction with a hydraulic filter tors is transmitted through master levers and
and position feedback cable, positions the gas actuation rings to the individual vanes.
turbine variable stator vanes. The control pro-
vides hydraulic flow to the head and rod ends l. The feedback cable transmits the actual
of the variable stator vane actuators as a func- vane position signal from the vane actuators to
tion of feedback position, gas generator speed the variable stator vane control lever to null the
and compressor inlet temperature. The control control when the vanes have reached proper
is supplied with lubricating oil for computation position. See figure 2-49.
and actuation purposes from the gas turbine oil
pump. All return flow is bypassed back to the
high pressure side of gas turbine lube oil
pump. The control is a single unit assembly
designed for mounting on the gas turbine

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2-10.27 Operation. piston. If the spool is centered (its control land

exactly covering the control port in the bush-
a. The speed sensor senses gas generator ing), no oil flows to or from the piston. High
speed and, through its CIT sensor, the tempera- pressure oil (Pc) from the gear pump, directed
ture of the air entering the gas generator, and to the smaller-area side of the differential pis-
positions an output lever arm. For any one ton, continually urges the piston up in the
temperature and any one speed, the output arm direction to close the gas generator stator
will take but one position and remain in that vanes. However, the piston cannot move
position until the gas generator speed or inlet unless the oil trapped between the control land
temperature change. of the pilot valve plunger and the larger area
side of the piston returns to the pump inlet
b. The lever arm in turn positions a servo (Po).
valve through mechanical linkage. The servo
valve ports oil to the head end or rod end of d. If the speed input increases or the CIT
two actuators that move, through mechanical decreases, the pilot valve is moved above its
lever arms, the variable stator vanes in the gas centered position, venting the top of the differ-
generator compressor. The servo valve system ential piston to Po. The differential piston
is the feedback type in which the movement of moves up, causing the output lever to move in
the stator actuators is used to provide a feed- the opening direction. If the pilot valve
back signal to the servo valve to null the valve. plunger is moved below its centered position
This is done by means of a floating link on the because of a decrease in speed or increase in
servo valve. One end of the link is connected CIT, high pressure oil (Pc) is directed to the
to the speed sensor output lever and the other larger-area side of the differential piston (as
end is connected to the feedback cable from well as to the smaller-area side). The resulting
the stator actuators. The center of the floating net force is in the direction to move the piston
link is attached through pivoted and rotary down, causing the output lever to move in the
levers to position the spool of the servo valve. closing direction.
As the linkage from the speed sensor moves,
the floating link pivots around the point where e. The greater of two opposing forces
the feedback cable attaches. This moves the moves the pilot valve plunger; the force from
servo valve spool and directs oil to the the speeder spring tends to push the plunger
actuators. down, the centrifugal force of the rotating fly-
weights is translated into an upward force
c. The movement of the actuators causes which tries to push the plunger up.
the feedback cable to move, repositioning the
floating arm (which now pivots about the point f. The speeder spring force is determined
where the push-pull cable attaches) and moves by the output of the CIT sensor and the posi-
the servo valve spool to the null position, tion of the feedback cam. The feedback cam is
restoring the system to a steady-state condi- positioned as a function of the angular output
tion. The oil pressure to operate the system is signal. For any setting of the speeder spring,
obtained from a 400 psig (2760 kPa) oil pump there is but one speed of the rotating fly-
in the speed sensor. See figure 2-52. The pilot weights at which the developed centrifugal
valve plunger controls the flow of oil to and force exactly opposes the spring force when
from the larger-area side of the differential the pilot valve plunger is centered.

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g. The output schedule is thus controlled 2-10.29 Compressor Inlet Temperature

by the contour of the feedback cam and the (T2) Sensor Kit (Optional).
output schedule of the compressor inlet tem-
perature sensor. Should speed decrease, the a. The optional T2 sensor kit consists of
flyweight force would become less than the five copper-constantan thermocouple probes
spring force. The pilot valve plunger would that mount in bosses provided at equally
move down. The differential piston would spaced locations on the compressor front
move down, causing the output shaft to be frame. These bosses are located at approxi-
rotated in the direction to move the output mately the 12:00, 2:30, 4:30, 7:30 and 1:30
lever toward closing. The output shaft would o'clock positions as viewed aft looking for-
rotate the feedback cam, decreasing the ward. The cover plates must be removed at
speeder spring force, until the pilot valve these five locations to gain access to the
plunger is again centered and the spring force bosses.
and flyweight force are again equal. Similar
movements - in the opposite directions - would b. The T2 probes are flange mounted and
occur when speed increased. the probe electrical connector mates with inter-
face connection E 19 (refer to installation
2-10.28 Flame Sensing System (Optional). drawings).
See figure 2-54.
2-10.30 Inlet Seal Kit (Optional). The
a. The optional flame sensing system is assembly, installation and interface inlet seal
part of an overall gas turbine flameout protec- kit is provided as an optional item. It provides
tion system that closes the fuel shutoff valves an effective and flexible environmental sealing
should combustor flameout occur. The flame barrier between the inlet duct and the enclo-
sensing system monitors combustion flame sure barrier wall.
using an ultra-violet sensor which views the
flame through a quartz window and is mounted 2-10.31 Hydraulic Supply System
in a combustor borescope boss. Should flame- (Optional). An optional hydraulic pump is
out occur, the ultra-violet sensor transmits a mounted on and driven from the accessory
signal to an amplifier. The amplifier, upon gearbox. It is used for operation of fuel con-
receiving this signal, provides a signal to a trol servo valves. Drawing 537L162 defines
control which, in turn, closes the fuel shutoff the equipment provided. See figure 2-55.
valves. An interlock arrangement provided in
the customers control system allows the fuel a. The hydraulic pump is a positive dis-
valves to open during normal gas generator placement gear type with an integral bypass
start cycle. type pressure regulating valve which is set for
425 psig (2230 kPa). The discharge from the
b. The optional flame sensing system pressure regulating valve discharges back to
consists of two ultra-violet sensors, two flame the inlet of the pump. To prevent overheating
sights and associated brackets and hardware. of the pump, a cooling flow circuit, which is
Mounting is accomplished on the compressor routed back to the customer's oil tank, is pro-
rear frame/combustor at the borescope port vided. This cooling flow circuit return line
positions located 36 and 276 degrees from the must be ported to the oil tank below oil level.
12 o'clock position as viewed aft looking
forward.
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Figure 2-54. Flame Sensing System - Optional (Kit 537L358)

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Figure 2-55. Hydraulic Pump - Optional (Kit 537L162G02)

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GEK 97310
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b. The pump is designed to operate with ports and mounting hardware for assembly are
servo control valve systems where low steady also provided with the kit.
state and high transient flows are required.
When operating in the low flow steady state 2-11.3 Alignment Coupling (Gas Turbine
condition, practically all the flow is bypassed Models). The power turbine is equipped with
back to the inlet of the pump and the outlet an adapter which will mate to a flexible cou-
pressure is 425 psig (2230 kPa). pling. The coupling shall be designed to allow
angular misalignment and offset between the
2-11 AUXILIARY SYSTEM gas turbine and the driven load.
REQUIREMENTS.
2-11.4 Anti-icing.
NOTE
a. The engine is not equipped with anti-
The following systems are required for icing provisions. Secondary cooling air, com-
installation and operation of the gas pressor bleed air or engine exhaust gases may
generators and gas turbines but are not be used to heat inlet air. If exhaust gas is used,
furnished as part of the engine. it should be introduced upstream of the inlet
2-11.1 Mounting Systems. filter to minimize fouling of the compressor
and to anti-ice the filter system. Introduction
a. The mounting system must provide as of exhaust gases for ant-icing may adversely
a minimum, provisions for: affect emissions.
• The dead weight of the gas turbine/
gas generator b. Under certain conditions, as a function
of temperature and humidity, ice can form at
• The torque reaction imposed by the engine inlet, be ingested into the flow path,
power extraction
and cause foreign object damage (FOD). The
• Engine self-induced vibratory and engine is not equipped with an integral anti-
two blade-out loads
icing protection system. GE does recommend,
• Exhaust gas loads however, that such a system be installed and
• Flexible coupling loads operational for any installation operating in an
environment where the ambient temperature
• Any other induced loading
can fall below 40°F (4°C) in combination with
b. The mounting connections to the a relevance humidity greater than 70%. The
engine must be made through pinned joints so anti-icing system, whether installed by the
that bending loads are not transmitted to the operator/user or the packager, shall ensure that
engine. Figure 2-56 and 2-57 show a typical the humidity and temperature measured at the
mounting system. engine inlet are within the limits shown in
figure 2-56A.
2-11.2 Optional Gas Turbine Assembly/
Installation Mounting Kit. The optional kit
provides for mounting of the gas turbine
assembly within the enclosure, and consists of
a forward clevis, rear frame support and aft
clevises. Associated nuts, bolts, spacers, sup-

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Figure 2-56. Mounting Arrangements - LM2500 Series Gas Turbine (Sheet 1 of 3)

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Figure 2-56A. Anti-Icing System Requirements

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Figure 2-57. Mounting Arrangements - LM2500 Gas Generator

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c. An acceptable alternative method, 2-11.6 Heat Rejection. The engine is

which eliminates the need for a humidity sen- designed to operate with inlet air temperature
sor, is to heat the inlet air 10°F (-12°C) when from -65 to +104°F (-55 to +40°C) and ambi-
ambient temperatures are less than 30°F (-1°C) ent temperature of -40 to +140°F (-40° to
and to heat the inlet air to 40°F (4°C) when +60°C). It is recommended that it be installed
ambient temperatures are between 30°-40°F inside an enclosure to protect it from the
(-1° to 4°C). No heating is required for ambi- weather and to isolate the operating personnel
ent temperatures above 40°F (4°C). Note that from the heat and noise radiated by the engine.
this alternate method requires both an ambient Heat is released from the engine by radiation
temperature sensor and a compressor inlet or and convection from the hot surfaces and by
inlet plenum temperature sensor. hot air leakage from flanges and struts. The
exact quantity of cooling air required is a func-
d. Recommended accuracy requirements tion of the air velocity over the engine and the
for anti-icing system instrumentation are radiation characteristics of the enclosure walls.
±1.5°F for temperature and ±3% for relative The cooling air must meet, as a minimum, the
humidity. same contaminant limits as the inlet air to the
engine.
e. Because of the potential for the forma-
tion of ice, evaporative coolers or inlets chill- 2-11.7 Engine Control. The fuel control
ers should not be operated when the system is operator furnished and is off-engine
temperature measured at the gas generator mounted. It is the operator's responsibility to
inlet or in the inlet plenum is 45°F or less. specify the system regulation requirements.
The system must be free of periodic or random
f. As described in Appendix A, antifreeze hunting which results in cycling of gas genera-
mixtures are required for both on-line and tor speed or temperature. The frequency of the
crank soak compressor cleaning when ambient fuel flow functions shall not be a harmonic of
temperatures are 50°F or less. the natural frequency of the springs in the liq-
uid/dual fuel nozzles. The natural frequency
2-11.5 Exhaust Gas System (Gas Turbine of these springs is 200 Hz. Cycling of these
Models). The gas turbine exhaust duct termi- parameters will reduce hot section life and the
nates in a rectangular flange. The operators life of the engine.
exhaust extension shall have the same expan-
sion characteristics as the exhaust duct flange
which is 321 stainless steel.

2-109
GEK 97310
VOLUME I
2-11.8 Electrical Services. The only elec- b. Power Turbine Inlet Gas Temperature.
trical devices supplied with the engine are the Power turbine inlet gas temperature (T5.4)
two ignition units. The characteristics of the shall have an interlock that prevents operation
power input to the ignition units shall be as of the engine if T5.4 exceeds 1575°F (857°C).
follows: A set of chromel-alumel thermocouples is pro-
Voltage 115 volts ± 5 volts vided on the gas turbine for measuring T5.4.
Frequency 50 to 60 Hz c. Failure to Light-Off. Power turbine

Phase Single phase inlet gas temperature (T5.4) shall have an inter-
lock that prevents operation of the engine if it
Current Draw 350 VA inrush per unit, does not light-off during starting. The inter-
120 VA operating per unit lock must shut off the fuel if the temperature
does not reach 400°F (204°C) within 20 sec-
a. Both leads of the ignition unit are to be onds after fuel and ignition are applied. The
grounded when they are not operating to pre- same thermocouples as in step b. are to be used
vent induced voltages and sporadic uncon- for this purpose.
trolled firing.
d. Gas Generator/Gas Turbine Flame-
2-11.9 Electrical Interlocks. The follow- Out. Power turbine inlet gas temperature
ing electrical interlocks are required to protect (T5.4) shall have an interlock to close the fuel
the engine during starting and operation and shutoff valve upon loss of flame. This system
are to be supplied by the operator except as must remain latched out if a flameout occurs
indicated. The interlocks should shut the until the engine stops and the system is reset.
engine down and not permit the reapplication This interlock must operate any time the power
of fuel until the gas generator has stopped turbine inlet gas temperature goes below
rotating. It is also desirable for most applica- 400°F (204°C) during operation. The same
tions to provide a warning level at some point thermocouples as in step b. are to be used for
below the shutdown point for all interlocks. this purpose.
a. Lubricating Oil Pressure. Lubricating

oil pressure shall have an interlock that pre-
vents operation of the engine when sufficient
oil pressure is not available. The engine oil
pressure must be 6 psig (41 kPa) or greater at
idle and 20 psig (138 kPa) or greater at
8000 rpm and above. This system must be
bypassed until the gas generator reaches
4500 rpm at which speed sufficient oil pres-
sure will be developed by the shaft driven
pump. A 3/8 inch (9.5 mm) pressure tap is
provided on the engine to sense oil pressure.

2-110
GEK 97310
VOLUME I
e. Excessive Vibration. An interlock 2-11.10 Electrical Systems.

shall be provided to monitor engine vibration
and prevent operation if the limits are a. Ignition System, The ignition system is
exceeded. Two vibration pickups are pro- normally energized only during the starting
vided, one on the front flange of the compres- sequence. However, the circuit should be
sor rear frame at the 6 o'clock position, and arranged so that the ignition system can be
one on the front flange of the turbine rear manually operated for reasons given in the fol-
frame at the 6 o'clock position to indicate lowing paragraph. Both sides of the supply
power turbine vibration. The shut-down limit line to the ignition units must be grounded
is 7 mils double amplitude with 75 Hz high when the units are not energized, this is to pre-
pass and 164 Hz low pass filters with 60 db/ vent sporadic uncontrolled sparking because of
octave roll-off. The system shall be bypassed induced voltage.
until the engine reaches idle speed (5000 rpm).
The gas turbine shall not be operated continu- b. Starting System. The starting system is
ously with vibration levels above 4 mils at used for starting the engine and for motoring
engine frequency, and it is recommended that a for water washing, maintenance checks, and
warning level be established at that point. The purging the gas engine. The electrical control
vibration pickups are of the velocity type. See system for the starter must be designed to meet
paragraph 2-10.13. these requirements:
f. High Scavenge Oil Temperatures. An (1) Be energized between 0 and

interlock shall be provided to monitor engine 4500 rpm during a normal start.
oil scavenge temperature for A (forward trans-
fer gearbox), B, C, and D sumps (Gas Turbine (2) Be energized between 0 and
Models) and the accessory gearbox and to pre- 1200 rpm for water washing the gas turbine.
vent operation if the oil scavenge temperature
exceeds 340°F (171°C). Five temperature sen- (3) Be energized between 0 to maxi-
sors are supplied as part of the gas turbine, mum motoring speed (approximately
four as part of the gas generator. 2300 rpm) during maintenance checks. Dur-
ing maintenance checks it should be possible
g. Starting Time. An interlock shall be to manually energize the ignition systems and
provided that will abort the start if the time to fuel shutoff valves independently.
reach 1200 rpm exceeds 20 seconds or the time
to reach 4500 rpm exceeds 90 seconds. (4) Be energized between speeds of
0 to 1200 rpm for purging the engine and inlet
h. Power Turbine Overspeed. An inter- and exhaust ducts.
lock shall be provided that will prevent the
power turbine rotor from reaching a speed in
excess of 3960 rpm under any condition. The
time constant of the power turbine speed pick-
ups is one millisecond maximum. It is recom-
mended that the system be redundant and
fail-safe.

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VOLUME I
c. Construction. The electrical devices g. Fuel Manifold Pressure. A pressure

on the engine are designed in accordance with tap is provided on the fuel manifold. Refer to
air-craft ignition proof requirements. All arc- Chapter 4 for the specific model instrumenta-
ing devices, such as limit switches, etc., are tion requirements and the recommended indi-
hermetically sealed. Connections are made by cator range.
pin and socket connectors and the circuits
should be arranged so that power is removed h. Compressor Total Inlet Pressure. The
before they are disconnected for maintenance engine can be equipped with an optional com-
purposes. Connections to these connectors are pressor inlet total pressure sensor. The recom-
to be made by means of flexible cables which mended indicator range is 10-15 psia
allow one inch of movement in all directions. (79-110 kPa).
2-11.11 Instrumentation. i. Power Turbine Inlet Gas Pressure. The

gas generator/gas turbine is equipped with a
a. Gas Generator Speed. Refer to power turbine inlet gas total pressure probe.
paragraph 2-10.12. The recommended indicator range is 0-75 psia
(0-517 kPa).
b. Oil Temperature. Refer to
paragraph 2-10.14. j. Compressor Discharge Pressure. The
engine is equipped with a 0.375 inch
c. Vibration. Refer to paragraph 2-10.13. (9.52 mm) pressure tap for measuring com-
pressor discharge pressure. The recommended
d. Power Turbine Speed (Gas Turbine indicator range is 0-300 psia (0-2070 kPa).
Models). Refer to paragraph 2-10.12.
k. Fuel Supply Pressure and Temperature.
e. Power Turbine Inlet Temperatures. A pressure tap and thermocouple well should
Refer to paragraph 2-10.11 be provided in each fuel supply line to the
engine. The recommended pressure indicator
f. Oil Supply Pressure. A 0.375 inch range is 0 to 1200 psig (0-8275 kPa). The tem-
(9.52 mm) oil supply pressure tap is provided perature indicator range for the thermocouple
on the engine. The recommended indicator well should be 0 to 250°F (-18 to 121°C).
range for normal operation is 0-100 psig
(0-690 kPa). l. Inlet Air Temperature. A temperature
sensor and indicator should be provided to
NOTE measure the inlet air temperature to the engine.
The following items are not mandatory The sensor should be located in the plenum in
for normal operation but are required front of the gas turbine. The recommended
for monitoring of engine operation dur- indicator range is 0-150°F (-18 to 66°C).
ing troubleshooting.
m. Scavenge Oil Pressure. A 0.375 inch
(9.52 mm) oil scavenge pressure tap is pro-
vided on the engine. The recommended indi-
cator range is 0-100 psig (0-690 kPa).

2-112
GEK 97310
VOLUME I
n. Remote Reading Compressor Variable b. The engine requires an oil supply of

Stator Vane Position Indicator. A remote read- 18 gpm (68 lpm) of MIL-L-23699 or
ing linear variable differential transducer MIL-L-7808 oil or oil conforming to
(LVDT) is available for indicating variable sta- MID-TD-0000-6 in Appendix A at a positive
tor vane position. The recommended indicator pressure to assure a flooded suction but not to
range is -5 degrees to +45 degrees rotation. exceed 2 psig (14 kPa) at the supply pump
inlet. The oil flow varies directly with gas gen-
o. Starter Air (Gas) Supply Pressure. A erator speed. The temperature of the supply oil
pressure tap should be provided in the supply to the lube pump must be above 20°F (-7°C)
line to the starter as close to the starter flange for MIL-L-23699 oil or above -20°F (-28°C)
as possible. The recommended indicator range for MIL-L-7808 oil during starting. During
is 0-50 psig (0-345 kPa). normal operation the oil temperature to the
bearings should be between 140° and 160°F
CAUTION (60-71°C). The oil supplied to the lubrication
pump must be filtered to 46 microns nominal
ALL INSTRUMENTATION CON- and the oil supplied to the bearings must be fil-
NECTIONS TO THE ENGINE MUST tered to 10 microns nominal.
BE FLEXIBLE TO PERMIT THER-
MAL EXPANSION WITHOUT c. The maximum oil supply temperature
PLACING UNDUE LOADS ON THE to the pump shall not exceed 240°F (116°C).
CONNECTIONS. The scavenge capacity of the pumps is approx-
imately two times that of the supply pump and
2-12 MECHANICAL SERVICES. therefore the system must be designed to han-
2-12.1 Fuel. dle the 3.6 scfm (0.1 m3/min) of air returned
with the oil. The maximum temperature of this
a. Refer to Chapter 4 for specific details air is 340°F (171°C). The oil supplied to the
of the fuel to be used for the engine model gas turbine shall not contain more than 10% by
selected. volume of entrapped air. The maximum
allowable back pressure on the scavenge pump
2-12.2 Lubrication Oil. is 180 psig (1242 kPa) at -20°F (-28°C) oil
temperature. The normal scavenge lube oil
a. The engine assembly includes the temperature is between 240° and 300°F
lubrication supply and scavenge pump and the (116-149°C) with a maximum oil temperature
engine mounted lube and vent system piping. of 340°F (171°C).
The remainder of the lubrication system
including the oil tank, oil cooler, oil filters, and 2-12.3 Starter. Refer to
precipitator are to be furnished by the paragraph 2-10.21.
packager.
2-12.4 Compressor Cleaning. Refer to
Chapter 5.

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GEK 97310
VOLUME I
2-12.5 Bleed Air. Bleed air is available 2-12.7 Liquid Drains.

from the 16th stage of the compressor. The
maximum total air flow available from the a. The windback seal drains from the B
16th stage is 15 pps (6:8 kg/s). The air is avail- and C sump bearings are connected together.
able at four connections on the compressor This drain must be vented to atmosphere and
rear frame. If the bleed air is used it must be the line must slope continuously downward
extracted uniformly from the four ports. away from the engine.
2-12.6 Air Vents. b. The drains for the shaft seals on the
lube pump and starter are connected together.
a. The air-oil separator will discharge The maximum flow from this drain is 7 cc/
0.25 pps (0.11 kg/s) of air-oil mixture at 350°F hour and the line must slope continuously
(177°C) maximum. The maximum allowable downward away from the engine.
back pressure in the discharge line is 15 inches
(381 mm) H20. Piping from the air-oil separa- c. The exhaust duct is equipped with two
tor must be arranged to allow for continuous drains, one at the forward end and one at the
drainage of any fluids which may collect in the aft end. Both fuel and water may flow from
line. the drains; fuel if the engine fails to start, and
water entering through the exhaust stack and
b. The compressor seal leakage will dis- from water washing. The maximum amount
charge 0.22 pps (0.1 kg/s) of air at 880°F of fuel is one gallon (3.81) per non-ignition on
(471°C) maximum. The air may be piped to start and the quantity of water is to be deter-
the exhaust system or overboard by removing mined by the operator. Hot exhaust gas will
the short pipes provided on the engine and flow from those drains during engines opera-
connecting to the flanges. The maximum tion. The maximum allowable back pressure is
allowable back pressure is 2 psi (14 kPa). 3 inches (76 mm) H20. If greater back pres-
sures occur, flooding of the engine can result.
c. The C sump vent will discharge 0.4 pps
(0.18 kg/s) air at 700°F (371°C) maximum 2-13 FUEL SYSTEM.
through three ports on the turbine mid frame.
This air may be dumped directly into the gas a. General. Many fuel systems have been
turbine enclosure or piped into the exhaust sys- developed for the 7LM2500 series engines to
tem by removing the screened covers on the meet the diverse application requirements of
ports and attaching suitable piping. If the air is the operators. The currently operational fuel
piped into the exhaust duct, the maximum systems are identified in Table 2-1. The fuel
allowable back pressure is 8 inches (203 mm) system schematics are illustrated in
H20. figures 2-58 through 2-69. Specific hardware
details can be found in GEK 50336, LM2600
Illustrated Parts Breakdown.

2-114
GEK 97310
VOLUME I
Table 2-1. LM2500 ENGINE FUEL SYSTEMS
No. Fuel Manifolds Fuel Nozzle Type NOx Power Current

System Supp Ehmt Engine Model
1 Gas Gas Gas only No No 7LM2500-PE-MG
2 Gas/Water Gas and water Gas/Water Yes No 7LM2500-PE-MGW
3 Gas/Steam Gas Steam Pre-mix nozzle Yes No 7LM2500-PE-MGS
Pre-Mix
4 Gas/Steam Gas Dual gas nozzle Yes No 7LM2500-PE-MGS
Direct injet NOx steam (gas and steam)
CDP steam
(purge)
5 Gas/Water/ Gas Gas/water nozzle Yes Yes 7LM2500-PE-MGB
Steam Water 7LM2500-PH-MGB
CDP steam
6 Gas/Steam Gas Dual gas nozzle Yes Yes 7LM2500-PE-MGA
(STIG) NOx steam (gas and steam) 7LM2500-PH-MGA
CDP steam (STIG models)
7 Gas/CDP Gas Gas only No Yes 7LM2500-PE-MGC
Steam CDP steam
8 Liquid Single liquid Liquid fuel only with No No 7LM2500-PE-ML
fuel integral flow divider
valves
9 Liquid/ Primary, sec- Liquid/water with off- Yes No 7LM2500-PE-MLW
Water ondary and engine flow divider
water mixing valve
tee
10 Liquid/ Same as liquid/ Liquid/water with Yes Yes 7LM2500-PE-MLB
Steam/ water, plus off-engine flow
Water CDP steam divider
(Mixed
Mode)
11 Liquid/ Single liquid Liquid fuel only with No Yes 7LM2500-PE-MLC
CDP fuel CDP integral flow divider
Steam steam valves
12 Dual Fuel Same as liquid/ Dual fuel with No No 7LM2500-PE-MD
water plus gas off-engine liquid fuel
flow divider valve

2-115
GEK 97310
VOLUME I
Table 2-1. LM2500 ENGINE FUEL SYSTEMS - Continued
No. Fuel Manifolds Fuel Nozzle Type NOx Power Current

System Supp Ehmt Engine Model
13 Dual Fuel/ Same as liquid/ Dual fuel with off- Yes No 7LM2500-PE-MDW
Water water plus gas engine liquid fuel flow
divider valve
14 Dual Fuel/ Same as liquid/ Dual fuel with off- Yes Yes 7LM2500-PE-MDB
Water/ water plus gas engine liquid fuel flow
Steam plus CDP divider valve
steam
15 Dual Fuel/ Same as dual Dual fuel with off- No Yes 7LM2500-PE-MDC
CDP fuel plus CDP engine liquid fuel flow
Steam steam divider valve
16 Dual Fuel/ Same as dual Dual fuel with off- Yes No 7LM2500-PE-MDS
Steam fuel plus Nox engine liquid fuel flow
steam divider valve and
steam injection port
17 Dual Fuel/ Same as dual Dual fuel with off- Yes Yes 7LM2500-PE-MDA
Steam fuel plus Nox engine liquid fuel flow
steam plus divider valve and
CDP steam steam injection port

2-116
GEK 97310
VOLUME I
Figure 2-58. Natural Gas Fuel System

2-117
GEK 97310
VOLUME I
Figure 2-59. Natural Gas Fuel System with Water Injection for NOx Suppression

2-118
GEK 97310
VOLUME I
Figure 2-60. Natural Gas Fuel System with Fuel Nozzle Premix Steam Injection
for NOx Suppression

2-119
GEK 97310
VOLUME I
Figure 2-61. Natural Gas Fuel System with Direct Fuel Nozzle Steam Injection
for NOx Suppression

2-120
GEK 97310
VOLUME I
Figure 2-62. Natural Gas Fuel System with Water Injection for NOx Suppression and Steam
Injection into CDP Ports for Power Enhancement

2-121
GEK 97310
VOLUME I
Figure 2-63. Natural Gas Fuel System with Steam Injection for NOx Suppression and
Power Augmentation (STIG)

2-122
GEK 97310
VOLUME I
Figure 2-64. Liquid Fuel System

2-123
GEK 97310
VOLUME I
Figure 2-65. Liquid Fuel System with Water Injection for NOx Suppression

2-124
GEK 97310
VOLUME I
Figure 2-66. Liquid Fuel System with Water Injection for NOx Suppression and Steam Injection
into CDP Ports for Power Enhancement

2-125
GEK 97310
VOLUME I
Figure 2-67. Dual Fuel System

2-126
GEK 97310
VOLUME I
Figure 2-68. Dual Fuel System with Water Injection for NOx Suppression

2-127
GEK 97310
VOLUME I
Figure 2-69. Dual Fuel System with Steam Injection for NOx Suppression

2-128
GEK 97310
VOLUME I
2-13.1 Fuel Pump And Filter Assembly d. High pressure fuel flows from the
(Optional). See figure 2-70. pump through the flange port and enters the
filter bowl. The fuel then flows from the out-
a. The fuel pump and filter assembly is side of the filter element to the center, up into
available as an optional on-engine mounted the head, out the flange return port and back
component for engines designed to operate on into the fuel pump where it is routed to the off-
liquid or dual fuel (liquid fuel and natural gas). engine fuel control.
It is mounted on the left rear pad and is driven
through the accessory gearbox. The pump 2-14 WINDMILLING.
contains two pumping elements: a centrifugal
boost element and a high pressure gear ele- 2-14.1 Gas Generator. If the inlet system
ment. It provides flange ports for the pump is such that air will be forced through the
mounted fuel filter, the fuel supply inlet hose engine when it is shut down, the gas generator
flange and the bypass fuel hose. This feature shaft may rotate. The duration of gas genera-
reduces the amount of external piping tor windmilling is limited by the lubrication of
required. its rotor bearings. The following defines these
limits:
b. Fuel enters the pump through the fuel
inlet port, is boosted in pressure by the centrif- a. The gas generator may windmill for
ugal boost element, and is discharged into a two weeks in duration at speeds below
circumferential scroll. The flow passes 100 rpm, provided each period is preceded by
through a screen which has an integral bypass, normal engine operation.
and then into the high pressure positive dis-
placement gear element. The combination of b. The gas generator may windmill for
the pumping elements is designed to provide periods up to five minutes at speeds between
improved fuel pump characteristics so that 100 rpm and 1000 rpm, provided each period
normal operation can be sustained without is preceded by normal engine operation.
external boost pumps. The pump also contains
a high pressure relief valve that protects the c. Unlimited windmilling of the gas gen-
pump and downstream components against erator is allowed at gas generator speed above
excessive system pressures. 1000 rpm provided the scavenge oil tempera-
ture is maintained below 340°F (171°C). At
c. The fuel filter is a high pressure filter these speeds the lube supply and scavenge sys-
mounted on the fuel pump and flange-ported to tems are in normal operation. Adequate cool-
eliminate external piping. The filter head ing of the oil must be provided at the higher
houses a bypass relief valve and the bowl free rotational speeds.
houses the filter element. The filter element
prevents contaminants from being carried to
downstream components.

2-129
GEK 97310
VOLUME I
Figure 2-70. Fuel Pump - Optional (Kit L24093G01)

2-130
GEK 97310
VOLUME I
2-14.2 Power Turbine. The following 2-16 SHIPPING AND HANDLING.

limits apply to windmilling of the power tur-
bine: (Gas Turbine Models) CAUTION
a. Free rotation of the power turbine for HIGHWAY SHIPMENT OF

speeds up to 400 rpm is allowed for periods of ENGINES COVERED IN THIS
twenty hours duration, providing each period MANUAL REQUIRES USE OF A
is preceded by normal gas turbine operation PNEUMATIC SUSPENSION
for a minimum of five minutes at idle or EQUIPPED TRACTOR AND
above. TRAILER. THE ENGINES SHALL
BE SECURED TO THE TRAILER IN
b. Free rotation of the power turbine for SUCH A MANNER THAT THE
speeds up to 1400 rpm is allowed for periods SHOCK ABSORBING CAPABILITY
of ten hours duration, providing each period is OF THE SHIPPING DEVICE IS NOT
preceded by normal gas turbine operation for a DISABLED. FAILURE TO COMPLY
minimum of five minutes at idle or above. WITH THESE REQUIREMENTS
MAY RESULT IN DAMAGE TO
c. It is recommended that a brake be pro- ENGINE BEARINGS.
vided to prevent free rotation of the power tur-
bine when the limits listed above are to be The engine is provided with four lifting eyes
exceeded. for handling. The maximum allowable loads
on each of the front lifting eyes is 12,000 lbs
2-15 ACCESSORY DRIVE PAD. (5443 kg) vertical, 12,000 lbs (5443 kg) hori-
zontal, and 2,000 lbs (907 kg) axial. The max-
An accessory drive pad is available for the imum allowable loads on each of the rear
operator's use. The accessory drive pad speed lifting eyes is 8,000 lbs (3629 kg) vertical,
ratio to main shaft speed is 5990/9827 and the 8,000 lbs (3629 kg) horizontal, and 1,000 lbs
horsepower rating is 60 HP at 5998 rpm. The (454 kg) axial. The gas generator can be sepa-
accessory drive pad is located on the left aft rated from the power turbine and exhaust duct
side of the accessory gearbox. Rotation is and the power turbine from the exhaust duct
clockwise looking into the gearbox from the for removal, lifting eyes are provided on each
aft side. of these subassemblies. Refer to Chapter 3.

2-131/(2-132 Blank)
GEK 97310
VOLUME I
CHAPTER 3
GENERAL INSTALLATION
3-1 INSTALLATION plete set of installation drawings is provided

with each engine. Items covered in these
NOTE drawings include outline and mounting dimen-
• The System Internationale (S.I.) sions diagrams, interface connection points,
units shown in this chapter are direct weights of major components, list points, and
mathematical conversions and may center of gravity. Refer to Chapter 5 for gen-
be rounded off in most cases at the eral maintenance practices. Refer to Chapter 1
user’s discretion. Examples of units for safety precautions.
that may be rounded off are those
utilized for temperatures, torque val- NOTE
ues, pressures, etc. Examples where For complete changeout of the gas tur-
S.I. units may not be rounded off are bine, gas generator, or power turbine,
those utilized for drop checks, rig- refer to Volume II of this manual enti-
ging adjustments, runouts, etc. tled “Corrective Maintenance”.
• Commensurate with the adoption of the 3-1.2 Site Information.

S.I. system has been the introduction of
torque wrenches calibrated in newton 3-1.2.1 General. Refer to the packager’s
meters. These will eventually replace manuals and drawings for installation design
the conventional metric torque wrench details. The mounting base on which the
calibrated in kilogram meters (kgm) and engine will be mounted shall meet the require-
will be given in specifications of N·m or ments of the specific engine model installation
Nm. To convert kilogram meters (kgm) drawings delivered with the engine.
to newton meters (N·m) simply discard
the decimal point. For example, 3-1.3 Tools. The following tools are nor-
3.5 kgm would become 35 N·m. To mally required for initial engine installation:
convert kilogram centimeters (kg cm) to
newton meters, round off to one decimal Table 3-1. INSTALLATION TOOLS*
place. For example, 50 kg cm would
become 5.0 N·m. Although the above Sling, Horizontal Lift - Gas Generator
values are not mathematically precise Stand, Horizontal
(3.5 kgm actually equals 34.3 N·m) they
are considered adequate for general Fixture, Lift-Inner Exhaust Deflector
purposes.
Wrench, Coupling Nut Forward Adapter
3-1.1 General. This chapter contains gen- Hand Tool Set - Mechanics
eral information relative to the initial installa- (Recommended)
tion of the gas generator/gas turbine, the
installation checkout, and the verification test. Spline Wrenches, Set
Refer to the packager’s manual for detailed Torque Multipliers
installation and alignment procedures. A com-

3-1
GEK 97310
VOLUME I
c. Connect ignition leads to ignition

Table 3-1. INSTALLATION TOOLS*
exciters. Tighten couplings to 130-150 lb in.
Support, High Speed Coupling Shaft, (14.7-17.0 N·m) of torque. Attach input leads
Forward to ignition exciters. Hand-tighten connectors.
Deflector Support Stabilizers d. Make the supply connections listed in
* Refer to Volume II of this manual, Work Chapter 4 for the particular engine model
Package 001 00 for the current installa- being installed.
tion tool part numbers.
e. Make the instrumentation connections
3-1.4 Installation Procedure. listed in Chapter 4 for the particular engine
model being installed.
NOTE
3-1.5 Customer Furnished Power Shaft
Refer to Chapter 4 for the particular Installation Requirements. The engine is
engine model selected for mounting equipped with a flanged output shaft for con-
points, interface locations and compo- nection to the buyer’s flexible coupling. The
nent weights. mating surface of the output shaft flange has a
cold station location of 214.720 ± 0.083 inches
a. Install and align engine per packager’s (5453 ± 2 mm) with the ball thrust bearing in
instructions. the power turbine in its mid position. The
thrust bearing play is 0.021 inch (0.533 mm).
b. Install starter on accessory gearbox and
configure the engine as required by the pack- a. Provision must be made to protect the
ager’s instructions. engine from excessive vibration induced by
the buyer-supplied flexible coupling assembly
WARNING as follows:
OUTPUT VOLTAGE OF THE IGNI-
NOTE
TION EXCITER IS DANGEROUS
AND COULD BE LETHAL. BE The coupling shaft must have been bal-
SURE NEITHER IGNITION SYS- anced dynamically in a minimum of
TEM IS ENERGIZED. BEFORE two planes to an equivalent of 60 gram-
WORKING ON THE IGNITION inches prior to installation.
SYSTEM, DISCONNECT IGNITION
EXCITER INPUT LEAD. DO NOT (1) The coupling shaft assembly
CONTACT CENTER ELECTRODE alignment, as established by the axis of the GE
OF SPARK IGNITER OR CENTER supplied forward shaft adapter and the axis of
CONTACT OF THE EXCITER OUT- the buyer-supplied aft adapter, must be within
PUT TERMINAL. 0.002 inch (0.051 mm) FIR.
NOTE (2) The coupling shaft assembly must

be removed/replaced as a unit.
Use new O–rings, seals or gaskets at all
connections where they are required.

3-2
GEK 97310
VOLUME I
(3) Monitor vibration by the vibration (1) Check engine and supply systems
pickups provided on the engine. for leaks (lube, fuel and air).
3-2 INSTALLATION CHECKOUT (2) Observe and record results of idle

operational parameters as defined in Chapter 4
3-2.1 Inspection and Pre-Energizing. for the particular engine model being operated.
Perform engine and associated equipment
check per Chapter 4 for the particular engine h. Shut down the engine.
model selected.
3-2.3 Verification Test. Perform the fol-
3-2.2 Turn-On and Preliminary Tests. lowing verification test on the installed engine.
Perform the following actions to start and Record any abnormal condition and perform
operate the installed engine. Record any any needed corrective action.
abnormal conditions and perform any needed
corrective action. NOTE
This verification test is to be used only
a. Verify that required equipment checks when packager does not specify a veri-
have been completed. fication test.
b. Check for leaks in fuel and lube oil a. Verify that all service systems (electri-
lines. cal, air, fuel, lube oil, fire control, water, indi-
cators and controls) are checked out and ready
c. Perform pre-start checks per Chapter 4 to operate the equipment.
for the particular engine model to be operated.
b. Start the engine per the operational
d. Perform ignition check per Chapter 4 instructions contained in Chapter 4 for the par-
for the particular engine model to be operated. ticular engine model being operated and stabi-
lize at idle power setting.
e. Motor gas generator for two minutes.
During motoring check for the following: c. Perform power turbine overspeed shut-
down test, with the power turbine unloaded, by
(1) Oil pressure indication. slowly increasing power turbine speed until
automatic shutdown occurs. Shutdown should
(2) Lube oil leaks. occur at 3960 ± 40 RPM power turbine speed.
If automatic shutdown does not occur, shut-
(3) Unusual noise during coastdown. down manually and check speed indication
and automatic shutdown systems.
f. Perform false start, governor check,
and wet prestart per Chapter 4 for the particu- d. Restart the engine and increase load to
lar engine being operated. full power setting.
g. Start engine and set idle power. When e. Stabilize at full power for three min-
stabilized at idle power, check the following: utes minimum and then observe and record the
following:

3-3
GEK 97310
VOLUME I
(1) Compressor inlet temperature. (10) Lube supply pressure.
(2) Power turbine inlet temperature. (11) Lube supply temperature.
(3) Gas generator speed. (12) CDP (if used).
(4) Power turbine speed (GT models). f. Reduce power to idle.
(5) Fuel manifold pressure. g. Shut down engine.
(6) Scavenge oil pressure. h. Perform a visual check of engine and

service systems for any leaks. Record any
(7) Scavenge oil temperature. leakage condition and perform any needed cor-
rective action.
(8) Gas generator vibration.
i. Check lube and scavenge pump screens
(9) Power turbine vibration (GT for evidence of contamination.
models).

3-4
GEK 97310
VOLUME I
CHAPTER 4
GENERAL OPERATION AND TROUBLESHOOTING
4-1 OPERATION IMMEDIATE OR SUBSEQUENT

DESTRUCTIVE FAILURE OF THE
4-1.1 General. The following are general ENGINE AND INJURY TO
instructions relating to the operating proce- PERSONNEL.
dures and limits recommended by the General
Electric Company for the 7LM2500 Series 4-2 PERFORMANCE RATINGS AND
engines. For complete detailed instructions OPERATING LIMITS
covering engine operation, performance rat-
ings and operating limits, refer to the specific 4-2.1 General. Refer to the appropriate
addendum for the engine model to be operated. addendum for the specific engine model
selected.
a. These general instructions are intended
to provide operating personnel with the infor- 4-3 PREPARATION
mation required to operate the engine. They 4-3.1 General. The engine and associated
pertain to routine and emergency conditions systems must be inspected and checked out for
and procedures. When a fault exists, refer to proper installation and operation before nor-
the troubleshooting portion of this chapter. mal operation can commence. Use the check
b. It is possible that these instructions list provided in the appropriate addendum for
may not provide for every possible variation in the engine model to be operated.
equipment or contingency to be met in connec- 4-4 GAS FUEL REQUIREMENTS
tion with the operation of the engine. Refer
requests for additional information to: 4-4.1 General. The requirements for gas
fuel are provided in document MID-TD-0000-
GE Aircraft Engines 1, included in Appendix A.
Marine & Industrial Engines Customer Service
Mail Drop S-155 4-5 LIQUID FUEL REQUIREMENTS
4-5.1 General. The requirements for liq-
uid fuel are provided in document MID-TD-
WARNING
0000-2, included in Appendix A. The fuel
IF A QUESTIONABLE CONDITION shall be filtered to 20 microns absolute.
EXISTS, DO NOT OPERATE THE
ENGINE UNTIL A THOROUGH 4-5A LUBRICATING OIL
INVESTIGATION HAS BEEN REQUIREMENTS
MADE. DO NOT REPEAT HOT Lubricating oil is used to lubricate shaft bear-
STARTS, COMPRESSOR STALLS, ings, sumps, and gearboxes. Additionally, lube
OR OTHER RECOGNIZED PROB- oil actuates the variable geometry control sys-
LEMS WITHOUT PRIOR THOR- tem and control valves. Lube oil flows at a rate
OUGH INVESTIGATION. FAILURE of 10-18 gpm (0.63-1.14 l/s). The oil shall be
TO DO SO CAN RESULT IN UNDUE temperature-controlled and kept clean per the
STRESS BEING IMPOSED ON following requirements in order to adequately
ENGINE COMPONENTS, WITH perform its function.

4-1
GEK 97310
VOLUME I
a. The requirements for gas turbine/gas This procedure should be followed whether the
generator lubricating oil are provided in engine is removed and replaced or repaired on
document MID-TD-0000-6, included in site.
Appendix A.
g. Engine oil is filtered to 10 microme-
b. Minimum temperature at start is 20ºF ters, nominal.
(-6.7°C) for lubricating oil, MIL-L-23699
(type II), and -20°F (-28.9°C) for MIL-L-7808 4-6 NOX SUPPRESSION WATER
(type I). REQUIREMENT
c. Steady-state operations and transients 4-6.1 General. The requirements for
above idle should be restricted until oil supply water injected for NOx suppression are pro-
temperature is at least 90°F (32.2°C). vided in document MID-TD-0000-3, included
d. Mixing different (type I vs. II) oil is not in Appendix A.
allowed. Changing of oil viscosity type
requires draining and flushing. Topping off 4-7 INITIAL OPERATION
when changing oil brands of the same type is
preferred method, but indiscriminate changing 4-7.1 General. Initial operational period
is not recommended. is that period of operation immediately follow-
ing engine replacement or major maintenance
CAUTION on the system.
FAILURE TO PROPERLY MAIN-
4-8 NORMAL OPERATION
TAIN A CLEAN LUBE SYSTEM
COULD RESULT IN PREMATURE
4-8.1 General. Normal operation is the
FAILURE OF THE GAS TURBINE
routine operation of an installed engine. For
OR COMPONENTS.
directions in the use of either manual or auto-
e. Before the initial motoring and start of matic operation, for normal engine operation,
an LM2500 in new installation or following refer to the packager’s manual.
work on the lube system, the lube oil condition
and storage system, and any circuits that sup- 4-9 SPECIAL INSTRUMENTATION
ply the control valves should be circulated,
4-9.1 General. Refer to the appropriate
flushed, etc. to ensure cleanliness prior to the
addendum for the specific engine model to be
engine being connected.
operated.
NOTE
4-10 EMERGENCY OPERATIONS
Following this flushing, the system fil-
ter elements should be removed and 4-10.1 Emergency Shutdown.
replaced to avoid engine a. In an emergency, the engine may be
contamination. shut down from any power setting by closing
f. In the event of a failure during site the fuel valves. However, this should only be
operation that involves the engine lube system, done in an emergency since rapid shutdown
the system shall be disconnected, drained, and will decrease the life of the engine.
cleaned as described in the preceding step.

4-2
GEK 97310
VOLUME I
NOTE (2) If a hot restart is to be performed

If an emergency shutdown must be ini- between one minute and two hours following
tiated while operating an engine the emergency shutdown, motor the gas gener-
equipped with optional NOx suppres- ator/turbine at 2000-2500 rpm Ngg for five
sion on-line, the water and fuel valve minutes. At the end of the five minute motor-
can be shut off simultaneously. Action ing/purge cycle, perform normal restart and
must be taken to purge the water from accelerate to idle. Acceleration to the desired
the fuel manifold at the earliest oppor- power setting can then be accomplished.
tunity and prior to the next startup. (3) After two hours following coast-
b. Emergency shutdown procedures for down of the HPC rotor, restart can be made
engines with steam injection for NOx shall be using the normal starting procedure.
made per the instructions contained in the 4-12 ENGINE TROUBLESHOOTING
addendum for the specific engine model being
operated. 4-12.1 Introduction.
4-10.2 Post Shutdown Fire. During a nor- a. Troubleshooting is a systematic analy-

mal shutdown, exhaust gas temperature should sis of symptoms that indicate equipment mal-
decrease. If during the time the engine is function. These symptoms usually appear as
coasting to a stop, temperature increases deviations from normal values of observed
instead of decreasing, it indicates that combus- equipment parameters.
tion is still taking place because of a leaking
b. Effective troubleshooting requires an
fuel valve. A slight temperature increase after
intimate knowledge of the engine, its systems,
rotation stops is normal. Make certain fuel is
and their interrelated effects. As a guide to
shut off, and motor the engine. This will blow
intelligent troubleshooting, the most probable
out the fire. As soon as the temperature
troubles and their possible symptoms are pre-
decreases to normal discontinue motoring.
sented in this section. To assist in trouble-
4-11 RESTART PROCEDURE FOLLOW- shooting, the operation of the packager’s
ING EMERGENCY SHUTDOWN controls should be understood. For this infor-
mation, refer to the packager’s instructions.
a. If an emergency shutdown from a high
power setting (T5.4) greater than 1150°F c. Remember that troubleshooting begins
(621°C) has occurred, and a hot restart is at the control panel. Before concluding that an
required, proceed as follows: engine fault does exist, the troubleshooter
must assure that his knowledge of the sus-
(1) If the fault detection and sequenc- pected trouble area is adequate, that the instru-
ing system can be cleared and the gas genera- ments used are calibrated and working
tor/turbine can be restarted within one minute properly, and that they have been accurately
following coastdown of the HPC rotor, accept- read and interpreted.
able restarts can be made using the normal
starting procedure. d. Refer to Table 4-1 for listing of faults
and applicable troubleshooting procedures.

4-3
GEK 97310
VOLUME I
NOTE ING OR CLOSING THE

If troubleshooting procedures do not ENCLOSURE DOOR.
isolate and eliminate the fault, secure • THE ENCLOSURE DOOR
assistance from the General Electric SHALL BE KEPT OPEN. IF THE
Company service representative GAS TURBINE IS OPERATING,
through your Customer Service AN OBSERVER SHALL BE STA-
Manager. TIONED AT THE ENCLOSURE
4-12.2 Gas Generator Fails to Motor. DOOR AND CONFINED SPACE
ENTRY PROCEDURES SHALL
a. If engine is hot, allow it to cool for BE FOLLOWED.
30 minutes, and then attempt motoring.
• ALLOW THE GAS TURBINE TO
WARNING COOL DOWN. AVOID CON-
TACT WITH HOT PARTS, AND
WHEN ENTERING THE GAS TUR- WEAR THERMALLY INSU-
BINE ENCLOSURE, THE FOLLOW- LATED GLOVES AS
ING REQUIREMENTS SHALL BE NECESSARY.
MET:
• EAR PROTECTION SHALL BE
• THE GAS TURBINE SHALL BE WORN IF GAS TURBINE IS
SHUT DOWN. OPERATING.
• ENCLOSURE ENTRY DURING • DO NOT REMAIN IN THE
ENGINE OPERATION IS PRO- ENCLOSURE OR IN THE
HIBITED IN GENERAL. IF PLANE OF ROTATION OF THE
ENTRY SHOULD BE STARTER WHEN STARTING OR
REQUIRED DURING ENGINE MOTORING THE GAS
OPERATION, CONTACT GE TURBINE.
FIELD SERVICE FOR A REPRE-
SENTATIVE WHO IS TRAINED b. Determine audibly if gas generator
TO ENTER THE ENCLOSURE and/or starter is rotating.
UNDER SUCH CONDITIONS.
c. If gas generator rotates, check instru-
• THE FIRE EXTINGUISHING mentation per paragraph 4-12.22.
INACTIVE ACCORDING TO d. Check supply pressure to starter. Refer
THE CUSTOMER’S to packager’s manual. If necessary, adjust sup-
PROCEDURES. ply pressure to starter.
• SECONDARY AIR TO THE
ENCLOSURE SHALL BE SHUT e. If pressure to starter is correct and the
OFF. HIGH SECONDARY AIR- engine is equipped with a pneumatic starter,
FLOW MAY PREVENT OPEN- check exhaust pressure from starter. If it
exceeds operating limits, check starter exhaust
line for obstructions.

4-4
GEK 97310
VOLUME I
Table 4-1. ENGINE TROUBLESHOOTING INDEX
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

4-5
GEK 97310
VOLUME I
f. If supply and exhaust pressures are cor- h. If rotor does not come free during man-
rect, attempt manual rotation through gearbox. ual rotation, continue rotation until it rotates
If rotor turns, problem is in starter. If compres- freely. Then start engine, operate it at idle for
sor will not rotate by hand, wait three hours 5 minutes, turn off the fuel, and let the engine
and try again to see if seals have seized coast to a stop. Listen for any unusual noise
because of unequal thermal contraction during during coastdown. If everything is normal,
shutdown. In a three hour period, contraction place engine back into operation.
should equalize and rotor should move. If
rotor still cannot be moved by hand after the i. If gas generator rotates through manual
3 hour waiting period, try motoring the gas drive but starter will not rotate it, troubleshoot
generator, using the starter at reduced power. starter per packager’s manual.
Do not exceed the starter output normally
required to motor the engine at low speed dur- j. If starter and gear train operate prop-
ing water wash. erly, but gas generator will not rotate, perform
borescope inspection of compressor rotor and
g. If gas generator will not turn after wait- high pressure turbine rotor. Check sump scav-
ing three hours, and starter will not turn it, enge screens in lube and scavenge pump for
troubleshoot gearbox per paragraph 4.12-24. evidence of bearing or seal problems.

4-6
GEK 97310
VOLUME I
4-12.3 Gas Generator Fails to Reach CAUTION

Maximum Motoring Speed.
ALWAYS PURGE FUEL FROM GAS
a. If engine is hot, allow it to cool for GENERATOR BY MOTORING THE
30 minutes and then attempt motoring. GAS GENERATOR AFTER ANY
FALSE START.
b. Check starter supply pressure. If pres-
sure is below minimum limit (refer to pack- b. Check supply pressure to fuel control
ager’s manual) check pressure source. and fuel manifold.
c. Check instrumentation. Replace indi- WARNING

cator if defective. NO FUEL AIR MIXTURE MAY BE
PRESENT DURING THIS TEST.
d. Replace starter. If rotation is still low, HIGH VOLTAGE EXISTS AT THE
perform borescope inspection of compressor IGNITERS, THEY MUST NOT BE
and high pressure turbine. Check scavenge oil TOUCHED WHILE ENERGIZED.
screens for sump problems.
c. If fuel supply pressures are within
4-12.4 Fuel Manifold Pressure Too High limits, troubleshoot ignition system per
or Too Low. paragraph 4-12.25.
NOTE 4-12.6 Hot Starts.
During motoring, the gas generator
will develop a few pounds of compres- NOTE
sor discharge pressure (CDP). This
Hot starts normally result from insuffi-
pressure will be reflected on the fuel
cient starting power, too high starting
manifold pressure gage. Assure that fuel flow, too high acceleration fuel
the fuel manifold pressure specified in
flow rate, or open variable stator vanes.
the addendum for the engine being
Starts in excess of 1200°F (649°C) are
operated is indicated on gage. considered hot; normal starts are 900°F
(482°C). Do not repeat hot starts with-
(1) If fuel manifold pressure is too out prior thorough investigation. See
high or too low, mixture may be too rich or too appropriate addendum for transient
lean for light-off. Refer to the appropriate temperature limits.
addendum for starting fuel flow limits. Adjust
fuel control. Refer to packager’s manual. a. For normal starts, the starter must be
capable of driving gas generator rotor to
4-12.5 Gas Generator Fails to Light Off. 2300 rpm without fuel or ignition being sup-
plied to gas generator.
a. Check to make sure gas generator will
motor to 2000-2600 rpm on starter. b. Variable stator vanes should be nearly
closed (40.3 ± 1 degree) during starting. If not
refer to paragraph 4-12.17.

4-7
GEK 97310
VOLUME I
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.
4-12.7 Gas Generator Starts, But Fails to 4-12.10 Slow Acceleration.

Accelerate to Idle.
a. Check fuel control per packager’s man-
a. Check to make sure inlet fuel pressure ual and adjust as required.
is within operating limits.
b. Check variable stator vane scheduling
b. Make sure bleed air (if used) is closed. to make sure vanes open during acceleration
per WP 118 00 or SWP 118 01.
c. Make sure maximum motoring speed
has been reached. 4-12.11 Compressor Stall or High T5.4
During Acceleration or Deceleration.
d. Check fuel flow during motoring.
a. Check for ice on inlet screen.
e. Check fuel control.
b. Check fuel control per packager’s
f. Perform start-stall troubleshooting pro- manual.
cedure per paragraph 4-12.26.
c. Check for foreign object damage to
4-12.8 Idle RPM Not Within Limits. compressor blades or vanes per Chapter 5.
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.
c. Check for gas generator stall per

paragraph 4-12.26.

4-8
GEK 97310
VOLUME I
f. Check to make sure variable stator d. If performance loss is due to normal

vanes move during acceleration or decelera- operation (deterioration), continue to operate
tion. Troubleshoot per paragraph 4-12.22. within limits of the addendum for the specific
engine model.
4-12.12 High Gas Generator Speed, Low
Power, Low T5.4. High gas generator speed, 4-12.15 High Vibration in Gas Generator.
low output power, and low gas generator
exhaust gas temperature is a symptom of gas a. Check that vibration instrument and its
generator variable stator vanes remaining com- wiring are operating properly.
pletely or partially closed. Check position of
variable stator vanes to see that they are on b. Check that vibration pickup is securely
schedule per WP 118 00 or SWP 118 01. If mounted.
not on schedule, adjust per WP 118 00 or
SWP 118 01. Borescope inspect for damage to c. Check engine mounting system for
compressor blades or vanes. security.
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.
c. Check engine mounting system for

security.

4-9
GEK 97310
VOLUME I
d. Using vibration measuring instrument d. If scavenge oil pressure is zero, shut

with frequency-scanning type filter, determine down gas generator, since it indicates a failed
predominant frequency. If it is same as power lube/scavenge oil pump, and it could cause
turbine speed, problem probably lies in power flooding of gas generator with oil. Replace or
turbine. Shut down engine, and listen for repair pump as necessary.
unusual noises during coastdown. Inspect
power turbine rotor. 4-12.19 High Scavenge Oil Temperature.
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 oil supply line to, and vent line from, that bear-
lube/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).

4-10
GEK 97310
VOLUME I
4-12.20 High Lube Oil Consumption. 4-12.21 Incorrect or Fluctuating T5.4. If

all other parameters are correct and steady and
NOTE T5.4 is incorrect or fluctuating, troubleshoot
Excessive oil leakage from the acces- T5.4 system per paragraph 4-12.27.
sory gearbox pad drain may be due to
the omission of the fuel pump gear 4-12.22 Variable Stator Control System
plugs. Two plugs (forward plug Troubleshooting Procedure.
L21431G01 and aft plug L21431G02)
are sometimes required. The aft plug is a. System is inoperative and vanes remain
not required on a gas generator with a in one fixed position.
gearbox-mounted fuel pump. The for-
ward plug is not used with single piece (1) Check for binding as follows:
VG control.
(a) With engine not operating,
a. Check gas generator and its lube sys- disconnect lines from servo valve to actuators,
tem for external leaks; repair as necessary. and connect a regulated dry nitrogen pressure
source to actuator manifold. See figure 4-1.
b. Check air discharge line from air-oil Clean shop air may be used in place of dry
separator mounted on gas generator transfer nitrogen. Apply pressure first to rod end, then
gearbox. If excessive oil is being discharged to head end. Pressure source shall not exceed
from separator, replace separator or separator 200 psig (1380 kPa). Line not being pressur-
cover. Normal leakage rate would be 15 cc/hr. ized should be connected to oil tank or suitable
container. If actuators and mechanism move
c. Check vent line from oil tank for oil freely, problem is not in actuators or
discharge. Refer to packager’s manual. mechanism.
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 and should not exceed 200 psig (1380 kPa) to
5 cc/hr. If leakage is excessive, disconnect close them. If pressure required exceeds lim-
drain line at each area and isolate source and its, inspect mechanism for bent and damaged
correct cause of leakage. Check condition of parts, and repair as necessary.
O-ring seals on starter and VG control splines
if AGB pad leakage is excessive.

4-11
GEK 97310
VOLUME I
Figure 4-1. Hookup for Variable Stator Vane System Actuation (Early Configuration)

4-12
GEK 97310
VOLUME I
(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 tance between pins A and B on the speed
in place of dry nitrogen. Connect oil return pickup. Resistance limits are 200 ± 20 ohms.
line to oil tank or suitable container. Apply If not within limits, replace pickup. If resis-
pressure not to exceed 200 psig (138 kPa). tance is within limits, proceed to step c.
Loosen rig plate on speed sensor output arm to
permit engagement of arm against manual c. Connect an ac voltmeter between pins
stop. Move output lever arm of speed sensor A and B on the speed pickup connector.
from stop to stop, and observe action of servo
valve. Actuators should move linkage to full d. Motor gas generator. At maximum
extend position when speed sensor lever arm is motoring speed, voltage should be 30-40 volts
moved to maximum stop. Check demand link- peak-to-peak.
age and feedback cable to assure they are not
disconnected or broken, and that they move e. If speed pickup voltage is within limits,
freely. If they operate correctly, replace servo check continuity and insulation resistance of
valve. speed pickup cables and connectors.
f. If cables and connectors are good,

check gas generator speed instrumentation.

4-13
GEK 97310
VOLUME I
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.
a. Remove accessory gearbox manual (d) If accessory gearbox will

drive pad cover plate and O-ring (located on turn after removal of an accessory, replace that
aft side between lube pump and starter) by accessory. If accessory gearbox will not turn
removing four nuts and washers. Discard after removal of all driven accessories, replace
O-ring. gearbox.
NOTE (3) If accessory gearbox turned in

Gears should turn with the application step (b) but gas generator did not turn, proceed
of 40 lb ft (54.24 N·m) of torque as follows:
maximum.
(a) Remove radial drive shaft
b. Using a torque wrench with 3/4 x 3 in cover plate (located on bottom of forward sec-
(19 x 76 mm) drive extension attempt to turn tion of transfer gearbox) by removing 4 nuts
the gas generator (turn drive clockwise). and washers. Remove and discard cover plate
O-ring.
c. Depending upon results obtained in
step b., perform the following: (b) Look into accessory gearbox
opening where radial drive shaft cover plate
(1) If gas generator rotates, trouble- was removed. While observing radial drive
shoot starter per packager’s manual. shaft bevel gear, rotate accessory gearbox.
(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.

4-14
GEK 97310
VOLUME I
4-12.25 Ignition System Troubleshooting (2) If input voltage is correct, con-

Procedure. tinue with the following isolation procedure.
b. Measure spark igniter immersion depth

WARNING
per WP 106 00 and determine if proper num-
• INPUT AND OUTPUT VOLT- ber of gaskets were used; if not, install spark
AGES OF THE IGNITION igniters with proper number of gaskets and
EXCITER MAY BE LETHAL. attempt to start engine. If start is successful,
ASSURE INPUT POWER IS OFF system is functioning properly. If start is
BEFORE DISCONNECTING unsuccessful, proceed to step c.
INPUT LEAD. BEFORE WORK-
ING ON IGNITION SYSTEM, c. Remove spark igniters and tape in
DISCONNECT EXCITER INPUT place on leads.
AND OUTPUT LEADS AND
USING A WELL INSULATED d. Ground plugs to metal braid on leads
JUMPER WIRE, TEMPO- with insulated jumper cables.
RARILY GROUND IGNITER
OUTPUT TERMINAL TO
REMOVE ANY CHARGE. DO WARNING
NOT TOUCH IGNITERS VOLTAGE AT SPARK IGNITER
WHERE TESTING. ASSURE MAY BE LETHAL. DO NOT TOUCH
GROUNDING WIRE (ELECTRI- IGNITERS WHEN TESTING.
CAL JUMPER) FROM EXCIT-
ERS IS SECURE. e. Connect input and output leads to
• ASSURE THAT FUEL AND ignition exciter.
FUEL VAPORS ARE NOT
PRESENT DURING THE FOL- f. Energize ignition system and observe
LOWING TEST. MOTOR GAS igniter firing. Both igniters should fire at a
GENERATOR IF NECESSARY rate of approximately two sparks per second.
TO PURGE FUEL AND FUEL- Sparks should have bright blue color and make
VAPORS. a loud, sharp cracking sound.
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 h. If igniters still do not fire correctly,
results of this test, proceed as indicated in the check continuity and insulation resistance of
following: 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. Trou-
bleshoot cables (step h).

4-15
GEK 97310
VOLUME I
4-12.26 Start Stall Troubleshooting b. If step a. shows fuel manifold pressure

Procedure. to be normal, the trouble could be in the vari-
able vane system. Incorrect variable vane
CAUTION position can cause stall. Inspect the variable
vane system for obvious damage or malfunc-
BEFORE STARTING AN ENGINE tion. Check variable vane feedback cable for
THAT HAS EXPERIENCED A HOT proper rigging per WP 118 00 or SWP 118 01.
START, A PRESTART MOTORING The variable vanes should be closed or nearly
CHECK MUST BE PERFORMED TO closed during engine startup. Inspect all vari-
DETERMINE IF FUEL MANIFOLD able vane linkage for proper rigging per
PRESSURE IS WITHIN LIMITS. WP 118 00 or SWP 118 01 and for damage.
REFER TO THE ADDENDUM FOR Inspect variable vane actuators for correct
THE PARTICULAR ENGINE adjustment of rod length. Inspect compressor
MODEL BEING OPERATED. inlet temperature sensor for damage or leaks.
Inspect inlet guide vanes and first stages of
NOTE compressor for damage. Correct all
A start stall is characterized by a hung discrepancies.
start, slow acceleration to idle, lower
than normal fuel manifold pressure (or c. If step b does not reveal any discrepan-
fuel flow) and higher than normal cies, perform water wash per Chapter 5.
power turbine inlet temperature (T5.4).
Occasionally, the stall will continue at d. If step c does not correct problem, per-
idle power. A stall at idle can be recog- form borescope inspection of gas generator.
nized by one or a combination of any Refer to Chapter 5. Inspect for damage in
of the following symptoms: low NPT, compressor, combustor and turbine sections.
higher than normal T5.4, higher than Inspect turbine mid frame for collapsed liner.
normal fuel manifold pressure, or NGG
does not increase or is sluggish when e. If step d does not correct problem,
throttle is advanced from idle position. replace control components per packager’s
control manual or replace variable stator vane
a. Perform prestart motoring check of speed sensor.
engine. Fuel manifold pressure should be
within operating limits. If fuel pressure is f. If none of the above steps correct prob-
high, troubleshoot fuel control per packager’s lem, gas generator must be replaced.
manual.

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GEK 97310
VOLUME I
4-12.27 Power Turbine Inlet T5.4 Thermo- within the starter duty cycle. Refer to pack-
couple System Troubleshooting Procedure. ager’s manual.
a. Perform T5.4 thermocouple test as c. Disconnect electrical interface connec-

follows: tor from thermocouple harness. Measure
resistance at pins A to B at connector J5. Con-
CAUTION ductor resistance is 1.7 to 2.15 ohms. If out of
limits, proceed to step d.
DO NOT EXCEED STARTER DUTY
CYCLE. d. Disconnect thermocouple leads and
harnesses and measure continuity and insula-
b. Check temperature indicator, if temper- tion resistance of each part per Table 4-2 and
ature is above 200°F (93°C), allow thermocou- figure 4-2. Replace each component that is out
ple to cool, or cool by motoring. To motor, set of limits. Upon completion of individual com-
starter inlet air pressure at 20-22 psig ponent tests, repeat step c to verify thermocou-
(138-151 kPa) and motor as necessary, staying ple system resistance is within limits.
Table 4-2. ELECTRICAL TEST - T5.4 SYSTEM COMPONENTS
Conductor 500 vdc Minimum

Ohmmeter Resistance Megger Insulation
Nomenclature Connections Limits (1) Connections (3) Resistance
Forward T/C (2) A-to-B 1.89 to 2.31 A-to-(4) 1 K Ohms

Lead Ohms B-to-(4) 1 K Ohms
(Original
Configuration)
NOTE
The above checks apply only to engines originally configured with forward
thermocouple lead, L21574P03.
T/C Harness:
Top Right - A-to-B 1.65 to 2.00 A-to-(4) 1 K Ohms
9055M89 A-to-C Ohms B-to-(4)
A-to-D C-to-(4)
D-to-(4)
Bottom Right - A-to-B 1.65 to 2.00 A-to-(4) 1 K Ohms
A-to-D C-to-(4)
D-to-(4)

4-17
GEK 97310
VOLUME I
Table 4-2. ELECTRICAL TEST - T5.4 SYSTEM COMPONENTS - Continued

Top Left - A-to-B 1.65 to 2.00 A-to-(4) 1 K Ohms
A-to-D C-to-(4)
D-to-(4)
Bottom Left - A-to-B 1.80 to 2.20 A-to-(4) 1 K Ohms
C-to-(4)
T/C Aft Lead:
9051M71P01 See Note (5)
L24054P02
L24867P0l See Note (6)
L24867P02
L24867P03
L28030P01 See Note (6)
L28030P02
L28030P03
L28030P04
L28030P05
L28030P06
T/C Harness:
(after SB
LM2500-IND-
117)
L44721P01 See Notes (7 and 8)
L44722P01 See Notes (7 and 8)
Probes (See figure 4-2)
Thermocouple (See figure 4-2
Probe: (after SB and figure 4-2A)
LM2500-IND-
117)

4-18
GEK 97310
VOLUME I
Table 4-2. ELECTRICAL TEST - T5.4 SYSTEM COMPONENTS - Continued

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 chromel circuit shall be between .81 to .90 ohm at
65 to 75°F (18.33 to 23.89°C).
(b) The resistance of each alumel 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 alumel contact
(contact A) and any chromel 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.

4-19
GEK 97310
VOLUME I
Figure 4-2. T5.4 Thermocouple System Schematic - P and G Series (Except GA101)

4-20
GEK 97310
VOLUME I
Figure 4-2A. Thermocouple Probe (Sheet 1 of 3)

4-21
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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).
a. If T5.4 spread (T5.4 max - T5.4 min) is NOTE

greater than 200°F (93°C), troubleshoot as Maintenance of engine high pressure
follows: recoup cavity pressure within defined
limits is required to ensure adequate
(1) At first opportunity, complete No. 4B bearing life. During initial
T5.4 probe and harness troubleshooting proce- build and testing of an engine, HP
dures per paragraph 4-12.27. recoup cavity pressure is adjusted to
within acceptable limits using selected
(2) Inspect connectors to ensure there metering spacers. Periodic monitoring,
is no water, oil, or corrosion on pins or sockets. and if necessary, an adjustment of
orfice spacers is required in service to
(3) If no anomalies are found, iden- maintain HP recoup cavity pressures
tify highest and lowest reading T5.4 probes. within limits. Seal clearance leakage
flow can change in service, particularly
(4) Identify fuel nozzles affecting on new or recently overhauled engines,
temperature of highest and lowest reading which has the effect of raising HP
T5.4 probes. See figure 4-2A, sheet 3. recoup pressure at a given set of
conditions.
(5) Mark locations of these fuel noz-
zles and remove to inspect for clogging or a. Use at least one of the two HP recoup
burning per WP 104 00, SWP 104 01, pressure taps (5, figure 4-3) located on
SWP 104 02, SWP 104 03, SWP 104 04, upstream side (toward compressor rear frame)
SWP 104 05, or SWP 104 09. of left and right metering spacers, for measur-
ing HP recoup pressure.
(6) If no clogging or burning is noted,
swap positions of these nozzles, i.e., install b. Use average of the left -and right-side
nozzles from lowest reading probe upstream of HP recoup pressure readings if both measure-
highest reading probe and vice versa per WP ments are recorded.
104 00, SWP 104 01, SWP 104 02, SWP 104
03, SWP 104 04, SWP 104 05, or SWP 104 09. c. Check and record the part number of
left- and right-side metering spacers
(7) Operate engine and check effect (4, figure 4-3). Determine the corresponding
of this change. Repeat steps 4 through 6 as spacer size (diameter) from the chart in
necessary. figure 4-3. Left- and right-side metering plates
must have the same diameter. If in doubt,
remove orifice plates and establish the actual
orifice diameter(s).

4-23
GEK 97310
VOLUME I
Figure 4-3. High Pressure Recoup Air Metering Spacer Configuration - Left Side
Pneumatic System (Sheet 1 of 3)

4-24
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VOLUME I

4-25
GEK 97310
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4-26
GEK 97310
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4-12.28.1 Adjustment Procedure for All c. Using HP Recoup Orifice Selection

GE, PE, and PL Models (With and Without Worksheet, figure 4-4 or figure 4-5, calculate
Emissions Suppression, With and Without whether orifice change is required.
CDP Steam Injection).
d. If orifice change is required, always
a. During engine operation, between 9000 install identical orifice size metering spacers at
and 9400 RPM gas generator speed and at P5.4 both right and left side locations. Install with
of 40 psia (275.8 kPa) or above, record the fol- orifice part number visible from outside.
lowing engine parameters at steady-state These metering spacers are symmetrical and,
conditions: therefore, nondirectional.
(1) P5.4 e. Reidentify part number of orifice plate

if reworked to a different orifice diameter.
(2) PS3 Refer to figure 4-3 for applicable part number.
(3) NGG f. HP recoup spacers of less than 0.3 inch

(7.62 mm) diameter should not be required or
(4) P2 (or barometer - inlet loss) used without prior consultation with
manufacturer.
(5) T2
(6) HP recoup pressure
b. Ensure that all pressure measurements

are in absolute. Convert all pressure data to
psia and convert all temperature measurements
to Fahrenheit.

4-27
GEK 97310
VOLUME I
Figure 4-4. High Pressure Recoup Orifice Selection Worksheet

4-28
GEK 97310
VOLUME I
Figure 4-5. Typical Excel Spreadsheet Based on Figure 4-5 Worksheet

4-29
GEK 97310
VOLUME I
g. Recheck orifice calculation at same a. During engine operation at P5.4 of 40

power setting with new orifice plates installed psia (275.8 kPa) or greater, monitor HP recoup
in order to see if further adjustment is required. pressure as a function of P5.4 on figure 4-6.
Three points at different P5.4 levels above 40
h. If orifice selection cannot satisfy both psia should be evaluated.
requirements (18) and (19) of worksheet, use
larger orifice to satisfy requirement (18), (1) If data is not within limits of
figure 4-4 or figure 4-5. figure 4-6 for dry operation, replace metering
spacers with next size larger spacers in order to
NOTE reduce HP recoup cavity pressure, or next size
Off schedule variable stator vane smaller metering spacers in order to increase
(VSV) tracking, with resultant NGG HP recoup cavity pressure. Repeat until data
effects, may make HP recoup orifice is within applicable limits.
size calculation invalid. Check to
ensure that VSV schedule is in limits in (2) If data is not within limits of
operating region. figure 4-6 and is above upper line for applica-
ble base load steam conditions, replace steam
4-12.28.2 Adjustment Procedure for PH tees with next size smaller orifices. Repeat
Model Engines. until data is within applicable limits.
NOTE (3) If data is not within limits of

figure 4-6 and is below lower line for applica-
PH engines with steam augmentation ble base load steam conditions, replace steam
to HP recoup system have orifices in tees with next size larger orifices. Repeat until
piping tee adjacent to HP recoup mani- data is within applicable upper and lower
fold on each side. These orifices are limits.
used to adjust HP recoup pressure for
operation with steam injection while (4) Always use same size metering
maintaining optimum HP recoup pres- spacers and steam tees on both right and left
sures when operating in dry mode side locations with identification numbers visi-
without injection using standard HP ble. Metering spacers are symmetrical and,
recoup metering spacers. Increasing therefore, nondirectional.
HP recoup steam tee orifices will raise
HP recoup cavity pressure. Increasing
size of metering spacers lowers HP
recoup cavity pressure.

4-30
GEK 97310
VOLUME I
Figure 4-6. Preferred Operating Range for High Pressure Recoup (GE, PE, and PL Models)
(Sheet 1 of 2)
4-31
GEK 97310
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Figure 4-6. Preferred Operating Range for High Pressure Recoup (GE, PE, and PL Models)
(Sheet 2 of 2)

4-32
GEK 97310
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Figure 4-6. Preferred Operating Range for High Pressure Recoup (PH Models)
(Sheet 3 of 3)

4-33
GEK 97310
VOLUME I
4-12.29 Power Turbine Transducer c. Transducers with coil resistance values

Motional Pickup Troubleshooting above or below Table 4-3 specifications are
unserviceable.
a. Disconnect electrical interfaces con-
nector from transducer motional pickup. d. Transducers with coil resistance values
within Table 4-3 specifications are serviceable.
b. Measure pickup coil resistance per
Table 4-3.
Table 4-3. ELECTRICAL TEST - POWER TURBINE TRANSDUCER MOTIONAL

PICKUP
Ohmmeter Conductor
Nomenclature Connections Resistance Limits (1)
Transducer Motional Pickup

L21656P01 A-to-B 130-170 Ohms
L21656P02
L21656P03 A-to-B 65-95 Ohms
L21656P04
NOTES:
(1) Average of 2 measurements. Reverse ohmmeter leads for second measurement.

4-34
GEK 97310
VOLUME I
CHAPTER 5
PERIODIC INSPECTION, SERVICING AND PREVENTATIVE MAINTENANCE
5-1 GENERAL INSPECTION 5-1.2 Evaluation of Engine Part Service-

INSTRUCTIONS ability Using The Borescope.
NOTE a. When the inspection and repair table

The S.I. units shown in this chapter are specifies the use of a borescope, limits in the
direct mathematical conversions and table are expressed in a manner to simplify the
may be rounded off in most instances judgement of the serviceability of viewed
at the users discretion. Examples of parts. In some instances the borescope limits
units that may be rounded off are those are expressed as if the part was in hand and
utilized for temperatures, torque val- could be easily inspected by conventional
ues, pressures, etc. Examples where means. For example, the tables may specify a
S.I. units may not be rounded off are borescope inspection wherein the length or
those utilized for drop checks, rigging depth of a defect must be evaluated by com-
adjustments, runouts, etc. parison to a given dimension of an adjacent
part or part feature. Where no comparative
5-1.1 Shop Practices. Parts or assemblies dimensions are given, evaluation must be
designated as matched sets elsewhere in this accomplished using good judgement and
technical manual or by the Parts List will be acquired knowledge/experience with the
maintained as a matched set. Set numbers, equipment. Borescope views of some parts are
part numbers, and serial numbers must be pro- limited due to the physical configuration of the
tected during cleaning or repair to prevent hardware. In these instances the condition of
removal. When identification is removed or is the remaining part/areas shall be judged on the
no longer legible, the item will be re-marked condition of the visible parts.
per applicable blueprint.
b. Information on the operation and use of
the borescope as applied to the gas generator/
power turbine and information regarding when
and what to inspect with the borescope is cov-
ered in paragraph 5-3.5. Inspection limits of
compressor blades and vanes, and high pres-
sure turbine blades are covered in table 5-3
through 5-8.

5-1
GEK 97310
VOLUME I
5-1.3 Special Inspections. (3) Any equipment failure where

parts are not contained within the gas genera-
a. The maintenance of the gas generator tor or power turbine, or where a major rotating
or power turbine requires that inspection component separates.
checks be made periodically. The inspection
requirements and limits throughout this man- (4) Sudden seizure or stoppage of the
ual are based on operation within specified gas generator or power turbine rotor or driven
limits. In addition to the regular inspections, equipment rotors.
there are special inspections necessary when
the gas generator or power turbine has been (5) Excess G-loading during opera-
operated outside of the specified limits, for tion in excess of packager manual limits.
example, off-schedule variable geometry oper-
ation, overspeed or overtemperature. There (6) Significant inlet ingestion events
also may be special inspections necessary if (e.g., foreign objects causing significant flow-
the gas generator or power turbine has been path damage, ice ingestion, inlet system
exposed to abnormal conditions. These events failure).
include failures with significant damage and
other abnormal exposure such as an installa- (7) Exposure to external fire, involv-
tion fire or mishap during transportation, han- ing inlet system, exhaust system, base, enclo-
dling, or storage. Some of the abnormal sure, and equivalent.
conditions to which an engine may be exposed
are: (8) Exposure to external fire in stor-
age or transport.
(1) Shock loading, collision impact,
exposure to explosion, handling, or transporta- (9) Internal fire.
tion mishap.
(10) Thermal quench by water or other
(2) Structural overstress, mounting agent, local overheating by fuel or steam sys-
system overload to gas generator or power tur- tem failure.
bine interface (e.g., earthquake, installation
error). (11) Exposure to corrosive chemicals,
fire-fighting agents, salt water, or sewage.

5-2
GEK 97310
VOLUME I
These events are highly variable and the expo- the service histories of these parts are known
sure and associated damage which a gas gener- and that, when applicable, the required special
ator or power turbine experiences is inspections and part disposition following
unpredictable. This prevents establishing a exposure to abnormal conditions have been
single, all-inclusive inspection and repair pro- completed and the part is serviceable.
cedure. Depending upon the circumstances of
the event, instances of localized, limited dam- b. Similarly, many components or assem-
age can often be dispositioned by normal chan- blies from aircraft engines which have experi-
nels. For abnormal events, such as the events enced previous flight service are not usable in
listed above, execution of a special inspection LM engines. In addition, gas turbine compo-
workscope is necessary for proper restoration nents which have experienced an extremely
of serviceability. In some extreme cases, high number of start/stop cycles may not be
repair may not be possible or economical, and usable. Specifically, use of used-serviceable
therefore, further repair effort may not be flight or high-cycle engine parts in the follow-
advisable. Before proceeding with inspection ing categories is prohibited:
and repair action to restore serviceability after
a mishap, the depot must obtain service history (1) Rotating components.
of the affected equipment and then contact the
following for guidance: (2) Stator cases and stator vanes.
GE Aircraft Engines (3) Frame assemblies, including

Marine & Industrial Customer Service sump components.
Depot Support
Mail Drop S-155 (4) Main shaft bearings.
1 Neumann Way
Cincinnati, Ohio 45215-1988 USA Prior to use of other components, contact
Marine & Industrial Engines Customer Service
Assurance of a part’s serviceability is derived about usability.
from control of material processing and manu-
facturing, operation within defined limits, and
maintenance within defined limits and pro-
cesses, as well as by inspection. Parts exposed
to abnormal conditions may appear to be ser-
viceable when in fact the actual state of the
material cannot be ascertained even by the
most advanced nondestructive testing and
inspection methods. Parts which have been
involved in an abnormal event must be for-
mally reviewed for severity of operation
beyond the normal working environment and
dispositioned as to the necessity for a special
inspection workscope. Since used replacement
parts may be available which have operated in
abnormal events, the depot should verify that

5-3
GEK 97310
VOLUME I
5-2 USE OF INSPECTION TABLES NOTE

AND INSTRUCTIONS The terms On-Site Maximum Service-
able Limit, On-Site Maximum Repair
5-2.1 Extent and Methods of Inspection. Limit and On-Site Corrective Action
Damage can be evaluated only by thorough apply only at the level of maintenance
inspection. Inspection for defects shall be at which the inspection is being con-
visual, without the aid of magnification or the ducted. For example, corresponding
use of special processes such as fluorescent entries of Not repairable and Replace
penetrant or magnetic-particle, unless other- part respectively in the On-Site Maxi-
wise specified at the beginning of each inspec- mum Repairable Limit and On-Site
tion table. Corrective Action columns in the
maintenance inspection/repair tables
5-2.2 Form of Inspection Tables. shall be interpreted as not repairable at
Inspection tables in this technical manual gen- this level of maintenance. The
erally treat each component as a separate item replaced part may be repairable at the
in order to provide a maximum amount of next higher level of maintenance.
information. The inspection and repair infor- Refer to local supply personnel, or con-
mation contained in the tables is often revised tact GE for the disposition of replaced
as experience is gained through increased ser- parts.
vice time of the equipment. An explanation of
the table headings follow:
Observed Condition/ Defines given areas of a
Discrepancy part with associated con-
Column ditions/discrepancies
which may be observed.
On-Site Maximum Defines the maximum
Serviceable Limit departure from the manu-
Column facturer’s established
new equipment standards
that will not materially
reduce the usability of
the part, or that will have
no significant bearing on
the effective use or oper-
ation of the equipment
between scheduled main-
tenance intervals.

5-4
GEK 97310
VOLUME I
On-Site Maximum Defines the extent of On-Site Corrective Defines if the part
Repairable Limit repair that can be per- Action Column should be replaced,
Column formed on a part to or denotes the para-
return it to a service- graph in which the
able condition. If there corrective action is
is no entry in this col- described. If the
umn it does not mean repair materials are
that the part cannot be not available, or if
repaired, but that to the part to be
date, no repair proce- replaced is not
dure has been estab- available, it is per-
lished. When a repair missible to replace
procedure has not been the next higher
established, or when an assembly.
existing procedure is
considered inadequate, 5-2.3 Definition of Terms. Definition of
analyze the difficulty, terms used in this section are listed in
determine the cause figure 5-1. The first column lists terms gener-
and frequency and ally used to describe deviations from normal
notify the engine con- conditions in equipment parts. The second
tractor. If a repair pro- column lists associated terms which, although
cedure should be not technically identical, are related since the
developed to the satis- damage they describe is similar in origin or in
faction of the local appearance.
cognizant authority,
notify the Engine con-
tractor immediately so
that it may be reviewed
and evaluated. If the
phrase “Not repair-
able” is entered in this
column, it means that
no repair is feasible
and that no attempt
should be made to
repair it under any cir-
cumstances, at the level
of maintenance for
which the inspection/
repair table is applica-
ble. See the preceding
Note.

5-5
GEK 97310
VOLUME I
Figure 5-1. Definition of Terms (Sheet 1 of 3)

5-6
GEK 97310
VOLUME I

5-7
GEK 97310
VOLUME I

5-8
GEK 97310
VOLUME I
5-3 PERIODIC INSPECTIONS 5-3.2 Lube Scavenge Filter Check. Per-

Refer to table 5-1. form lube scavenge filter check per packager’s
manual.
5-3.1 Tools and Parts. Refer to
Volume II, WP 001 00. 5-3.3 Lube Supply Filter Check. Per-
form lube supply filter check per packager’s
manual.
.
Table 5-1. MAINTENANCE CHECKS
Frequency
Maintenance Item Weekly Semi-Annual Paragraph

(Note 1) (Note 2)
Gas Generator/Gas Turbine

Exterior Inspection and
Cleaning x 5-3.22
Compressor Inlet
Inspection x 5-3.4
Compressor Cleaning (On Condition) 5-4.4
Borescope Inspection x 5-3.5
Inspect Stage 1 Mid Span
Damper (See Note 4) x 5-3.6
Enclosure Inspection x x 5-3.14
Exhaust Inspection x 5-3.15
Variable Stator
System Inspection x x 5-3.16
Lube and Scavenge Pump
Inlet Screens Inspection
and Cleaning x 5-3.18
Lube Oil Test x 5-3.19
Fuel Nozzle
Inspection x 5-3.20
External Inspection x x 5-3.21
Thermocouple Inspection x 4-12.27

5-9
GEK 97310
VOLUME I
Table 5-1. MAINTENANCE CHECKS - Continued
Frequency
Maintenance Item Weekly Semi-Annual Paragraph

(Note 1) (Note 2)
Spark Igniter
Inspection x 5-3.23
Pneumatic Starter Servicing (Every 1000 hours of
operation or first
opportunity there-
after) (Note 3) 5-4.5
High Pressure Recoup- Pre-
ferred Operating Range
(GE, PE and PH series) 5-3.30
Velocity Type
Vibration Transducer
Inspection/Verification x x 5-3.24
NOTES
1. The engine manufacturer recommends certain preventive maintenance checks on a weekly
basis; however, the user, for product efficiency purposes, may elect to interpret this as a
weekly or first opportunity thereafter frequency.
2. In no case should the semi-annual inspection interval be exceeded on any items. Semi-
annual inspections shall be made with engine shut down.
3. Starters modified with oil sump level indicators and top off capabilities can have weekly
inspections modified accordingly and contamination inspections performed semi-annually.
See paragraph 5-4.5 (8) and (9). Periodic servicing is not required when the Continuous
Lube Starter is installed. An initial fill with 400 ± 50 cc of oil is required before first opera-
tion. Refer to Volume II, SWP’s 122 02 and 122 03 for specific instructions.
4. The engine manufacturer recommends that stage 1 compressor blade mid span damper wear
pad (figure 5-12) be inspected per the following:
NOTE
Corrected NGG = physical NGG*SQRT (518.67/(459.67+T2)).
(1) If corrected GG speed is less than 8,500 RPM for sustained periods, perform first
inspection after 4000 hours. Inspect pads per step (4).
(2) If corrected GG speed is greater than 8,500 RPM but less than 9,000 RPM, perform
first inspection after 8000 hours. Inspect pads per step (4).

5-10
GEK 97310
VOLUME I
Table 5-1. MAINTENANCE CHECKS - Continued
(3) If corrected GT speed is greater than 9,000 RPM, perform first inspection after
4,000 hours using borescope. Perform subsequent inspections every 4,000 hours
using borescope.
(4) Inspect wear pads as follows:
(a) Thoroughly water-wash high pressure compressor.
(b) Remove inlet FOD screen. Using a soft cloth, clean wear pads.
(c) Using feeler gages, assess pad wear depth as follows:
0.020 in. (0.51 mm) pad thickness 0 percent wear

(d) Base subsequent inspections on the following values:
Observed Condition of Wear Pad Re-inspection Timetable

Less than 25% wear of pad, on any single pad on Reinspect between 3000-5000 hours
one or more blades
More than 25% but less than 50% wear of pad on Reinspect between 750-1250 hours
any single pad on one or more blades
More than 75% wear of pad on any single pad on Replace all blades within 50 hours*
one or more blades
* Worn blades can be repaired with installation of new wear pads.

5-11
GEK 97310
VOLUME I
5-3.4 Engine Inlet Inspection. CAUTION
a. Inspect the IGV, Stage 1, and Stage 2 • STRAIGHTEN PROBE BEFORE

VSV inner shrouds and bushings (compressor RETRACTING PROBE FROM
stator case closed) as follows: GUIDE TUBE.
(1) Remove the inlet duct per • RETRACT PROBE FROM GUIDE
WP 212 00. TUBE BEFORE REMOVING
GUIDE TUBE FROM COMPRES-
(2) Actuate the variable vanes to the SOR INLET
full open position as follows. See figure 5-2.
• IF HANG-UP OCCURS, FREE
NOTE PROBE BY GENTLE MOVE-
MENTS, AS EXCESSIVE FORCE
The vane actuator may be operated COULD DAMAGE THE
with either clean, dry shop air or regu- BORESCOPE.
lated, dry nitrogen.
(4) Remove probe and repeat
(a) Disconnect the oil supply substep (3) at eight equally spaced locations
line at the servo valve (Point A). Disconnect around shroud. Record conditions observed.
the oil return line, from the servo valve to the
lube tube, at the tube end (Point B). Catch oil (5) Remove probe and repeat above
drainage in a container. procedure for stage 1 and IGV shrouds, includ-
ing front side of IGV shrouds. Close VSV’s
(b) Connect pressure source to when inspecting the front side of IGV shrouds.
the servo valve and supply a maximum of After close visual inspection with borescope,
200 psig (1380 kPa). manually move vanes (IGVs and stage 1, if
possible) and check for any excessive play
(c) Actuate the variable vanes by between vane platform and shroud.
moving the speed sensor output lever arm.
NOTE
(3) Using a suitable borescope and
guide tube, as required, locate the gap at aft Wear on the IGV shroud will not likely
side of stage 2 inner shroud. Deflect the probe occur without wear on stage 1 or stage
tip downward toward engine centerline and 2 shrouds.
position probe tip in gap to view aft side of
shroud. Using probe tip articulation, rotate (6) Following inspection, refer to
probe body to change viewing direction along table 5-2 and compare recorded conditions to
back surface of shroud. Inspect and record determine category of wear and action
conditions per substeps b(1) through (4) below. required.

5-12
GEK 97310
VOLUME I
Figure 5-2. Hookup for Variable Stator Vane System Actuation

5-13
GEK 97310
VOLUME I
Table 5-2. CATEGORIES OF WEAR CONDITIONS. (SEE FIGURE 5-3.)
No. Wear (1) Slight Wear (2) Excessive Wear (3)
a. Shrouds slightly dirty a. Shrouds very dirty a. Evidence of vane trail-

ing edge rub on aft OD
of shroud
b. No protrusion of b. Slight protrusion of b. Cracks or holes worn
bushing material bushing material through shroud side
c. No evidence of vane c. No evidence of vane c. Bushing material pro-
trailing edge rub on trailing edge rub on aft truding from shroud
aft OD of shroud OD of shroud
d. No cracks or bulges d. No cracks or bulges on d. Aft movement of vane
on shroud sides shroud sides platform to extend
beyond the recess in
the upper surface
e. No aft movement of e. A small amount of aft
vane platform in movement of vane
shroud platform
(1) If inspection reveals no wear, comply with table 5-1 Maintenance Checks.
(2) If inspection reveals slight wear, reinspect every 2500 hours of operation or first
opportunity thereafter.
(3) If inspection reveals excessive wear, shroud replacement is required. Following
replacement, begin inspection period per table 5-1 Maintenance checks.

5-14
GEK 97310
VOLUME I
Figure 5-3. Inspection of VSV Shrouds and Bushings

5-15
GEK 97310
VOLUME I
b. When the upper forward compressor (6) After completion of inspection,

stator case is opened for any reason, visually refer to table 5-2 and compare recorded condi-
and manually inspect the VSV liner shrouds tions to determine category of wear and action
and bushings for wear as follows. See required, i.e., reinspection or shroud replace-
figure 5-3: ment per SWP 207 04.
(1) Inspect stage 1 and stage 2 inner c. Inspect the stage 1 compressor rotor
shrouds for wear holes on the back (down- blade mid-span shroud wear pads. Use a high
stream) side of the shroud. Inspect the IGV intensity spotlight and inspection mirror,
shrouds for wear holes on the forward side of through the inlet, to inspect for wear steps or
the shroud. Look for cracks, or bulges; look wear into parent metal.
closely at shroud bolthole locations. Any evi-
dence of wear, cracks, or bulges requires d. Log discrepancies as they are found.
replacement of shroud.
e. Using a bright light, inspect the
(2) Inspect the shrouds for visible following:
wear on the upper surface (airflow surface).
Look for indication of vane inner platform aft (1) Compressor blades and vanes for
movement with respect to the shroud surface. corrosion, cleanliness, and foreign object dam-
The first sign of this movement is seen as an age (FOD).
elongation (oval shaped) of the recess in the
shroud surface into which the vane platform is (2) Compressor front frame for corro-
positioned. The vane platform is no longer sion, cleanliness, and damage.
centered in the recess. With continued wear,
the platform moves aft out of this recess and (3) Inlet total pressure probe (located
wears into the aft sloped surface of the shroud. at 12 o’clock inside compressor front frame)
Additional indication of wear is seen when the for corrosion, cleanliness, security, obstruc-
trailing edge of the vane airfoil cuts a fan tions, and damage.
shaped groove into the shroud aft upper
surface. (4) Compressor inlet temperature sen-
sors for corrosion, cleanliness, security, and
(3) Inspect for protrusion of shroud damage.
bushing material out of the shroud toward the
engine centerline, as this is often an early sign f. Correct discrepancies that are out of
of bushing wear. Record this condition. limits.
(4) Inspect the shrouds for dirt, soot g. Perform borescope inspection per
or grime as shroud wear is accelerated by dirty paragraph 5-3.5. Borescope inspection is per-
conditions. Record degree of dirty condition. formed as a part of the gas generator inlet
inspection.
(5) Any shroud areas which cannot be
seen with the compressor case open should be h. Disconnect the pressure source and
inspected using a borescope per step a. connect the oil supply and return lines.
Tighten to appropriate torque and safety-wire.

5-16
GEK 97310
VOLUME I
5-3.5 Borescope Inspection of the (2) Insert a ratchet with a 3-inch

Engine. See figure 5-4. (76 mm) extension and a 3/4 inch (19 mm)
drive.
WARNING b. Installation and Operation of Gas Gen-
• ENGINE MUST NOT BE erator Borescope Inspection Motor Drive,
OPERATING. 1C8067G01. See figure 5-5.
• ENSURE THAT ALL PERSON- WARNING

NEL ARE CLEAR OF GAS GEN-
TO PREVENT POSSIBLE INJURY
ERATOR INLET BEFORE
TO MAINTENANCE PERSONNEL,
ROTATING COMPRESSOR
INSURE THAT OPERATING SER-
ROTOR.
VICES ARE SECURED BEFORE
• ON REMOVAL OR REINSTAL- CONDUCTING AN INSPECTION.
LATION OF THE BORESCOPE NOTE
PLUGS, USE EXTREME CAU-
TION IN MONITORING THE • The gas generator inspection motor
SAFE AND COMPLETE drive permits one operator to control the
rotation of the gas generator rotor for
REMOVAL OF ALL EXCESS
purpose of inspection. No other person-
SAFETY-WIRE. CARE MUST BE nel are required. The inspection motor
TAKEN WHEN CUTTING OFF drive will allow the gas generator rotor
ENDS OF INSTALLED WIRE TO to be rotated in either direction at a very
ENSURE COMPLETE slow, variable speed.
RETRIEVAL, PREVENTING
INJURY TO PERSONNEL AND • The air control valve has a belt clip for
SUBSEQUENT GAS TURBINE attachment to the operator’s belt.
DAMAGE. (1) Secure operating services to the
engine as follows:
CAUTION
(a) Shut off electrical power,
TO PREVENT FOREIGN OBJECTS
except for lighting and heating.
FROM ENTERING THE GAS TUR-
BINE, KEEP BORESCOPE PORTS (b) Shut off fuel supply.
COVERED WHEN THEY ARE NOT
BEING USED. OPEN ONE PORT AT (c) Shut off lube oil supply.
A TIME.
(d) Shut off air starter air supply.
a. Install drive adapter 1C8033:
(e) Comply with any additional
NOTE maintenance safety requirements.
For engines with optional hydraulic
(f) Tag operating console with a
pump installed, use motoring adapter,
1C8067, in lieu of 1C8033. DO NOT OPERATE tag.
(1) Remove transfer gearbox drive

pad cover plate and install drive adapter,
1C8033.
5-17
GEK 97310
VOLUME I
Figure 5-4. Borescope Inspection

5-18
GEK 97310
VOLUME I
Figure 5-5. Motor Drive, 1C8067G01, For Gas Generator Borescope Inspection

5-19
GEK 97310
VOLUME I
NOTE (4) Install adapter plate, 1C8067P02,

Transfer gearbox main fuel pump on transfer gearbox main fuel pump adapter.
adapter is located on aft side of transfer Adapter plate has two 1/2 inch holes that fit
gearbox, left hand pad, aft, looking over two corresponding locating pins in the
forward. transfer gearbox. Secure adapter plate with
eight 3/8 x 3/4 inch long hex head bolts
(2) Remove cover from transfer gear- (-24 thread). Tighten bolts to 150-200 lb in.
box main fuel pump adapter by removing (17-23 N·m) of torque.
safety wire and eight bolts. Two of the bolts
also secure a bracket which supports the VSV (5) Remove Gas Generator Inspection
cable. Leave bracket attached to VSV cable, Motor Drive, 1C8067G01, from carrying case.
and position so as not to interfere with work If the two hoses between air control valve and
area. Discard the cover plate gasket; retain motor are not connected, proceed as follows:
remaining hardware for reinstallation after (If hoses are connected, inspect to insure that
completion of inspection. connections are not reversed.)
(3) Remove transfer gearbox gear- CAUTION

shaft seal assembly, L21431G02, from ID of THE REVERSE HOSE IS MARKED
gearshaft as follows. See figure 5-6: AT BOTH ENDS WITH AN R. THE
FORWARD HOSE IS MARKED AT
(a) Hold end of tie rod with a BOTH ENDS WITH AN F. THE AIR
1/4 inch open end wrench on the flats pro- CONTROL VALVE AND MOTOR
vided, and remove nut. FORWARD AND REVERSE PORTS
ARE ALSO CLEARLY MARKED.
(b) Jiggle gearshaft seal assem- BE CERTAIN THAT THE TWO
bly until clevis (swivel foot) disengages from HOSES ARE ATTACHED TO THE
behind splines in gearshaft. Pull seal assembly CORRESPONDING PORTS ON THE
from ID of gear shaft. AIR CONTROL VALVE AND
MOTOR AND ARE NOT
(c) Remove preformed packing, REVERSED.
J221P216, from adapter of seal assembly.
Remove preformed packing, J221P214, from (a) Attach the 12 foot (3.6 m)
the rod of seal assembly. Discard removed hose marked with an R at both ends of reverse
packing. ports on air control valve and motor. Tighten
both ends to 120-150 lb in. (14-17 N·m) of
(d) Retain gearshaft seal assem- torque.
bly for reinstallation after borescope
inspection. (b) Attach the 12 foot (3.6 m)
hose marked with an “F” at both ends to for-
ward ports on air control valve and motor.
Tighten both ends to 120-150 lb in.
(14-17 N·m) of torque.

5-20
GEK 97310
VOLUME I
Figure 5-6. Removal/Installation of Transfer Gearbox Gearshaft Seal Assembly, L21431G02
(6) Position splined end of motor NOTE

through hole in center of adapter plate, The air control valve utilizes a 6 foot
1C8067P02, installed on fuel pump adapter of (18.3 m) section of hose which is
transfer gearbox in step (4). Ensure that attached to the air throttle metering
splined end on motor meshes with female valve. The other end of this hose con-
spline in transfer gearbox gearshaft. Secure tains a pipe thread connector. Use an
motor to adapter plate, 1C8067P02, with four appropriate adapter fitting between the
5/16 x 3/4 inch long hex head bolts shop or facility air supply and the pipe
(-18 thread). Tighten bolts to 70-110 lb in. thread connector.
(a) Close air throttle metering
(7) Attach shop or facility air supply valve located on air control valve.
to the air control valve as follows:
(b) Attach shop or facility air
CAUTION supply line to pipe thread connector in end of
THE SHOP OR FACILITY AIR SUP- the 6 foot (1.8 m) section of air control valve
PLY MUST PROVIDE CLEAN, DRY, hose. Tighten connecting hoses.
FILTERED, LUBRICATED AIR AT
90 PSI (621 KPA) WITH A 3 CFM (8) Attach air control valve on opera-
(0.9 M3/M) MINIMUM CAPACITY. tor’s belt with the clip provided on the valve.

5-21
GEK 97310
VOLUME I
(9) Operate the air control valve to (10) After the inspection is complete,
turn the rotor as follows: remove gas generator inspection motor drive
assembly from the transfer gearbox adapter
(a) Ensure that air control valve plate, 1C8067P02, by removing the four hex
throttle metering valve is closed. head bolts.
(b) Select the rotor direction of (11) Remove adapter plate,

rotation desired for the particular inspection. 1C8067P02, from transfer gearbox main fuel
Position the directional selector on the air con- pump adapter by removing eight hex head
trol valve either in or out as required. Push in bolts.
for CCW rotation or pull out for CW rotation
(aft, looking forward). (12) Reinstall transfer gearbox gear-
shaft seal assembly, L21431G02, as follows
(c) Slowly open the air throttle (see figure 5-6):
metering valve until sufficient air flow passes
to start the air motor. (a) Install a new preformed
packing, J221P216, on adapter of seal
(d) After the air motor starts, assembly.
adjust the air throttle metering valve to obtain
the air flow required to give the desired rotor (b) Install new preformed pack-
speed. Operator may perform borescope ing, J221P14, on tie rod of seal assembly.
inspection as planned, and may vary speed and
direction of rotation as required to accomplish (c) Install gearshaft seal assem-
the task. bly into ID of transfer gearbox gearshaft and
position as shown in figure 5-6. Ensure that
CAUTION clevis (swivel foot) of seal assembly catches
behind splines of gearshaft.
BEFORE REVERSING DIRECTION
OF ROTATION, BRING ROTOR TO (d) Install nut, holding end of tie
A COMPLETE STOP. FAILURE TO rod with a 1/4 inch open end wrench on the
STOP THE ROTOR BEFORE flats provided. Tighten nut to 160 lb in.
REVERSING ROTATION MAY (18 N·m) of torque.
RESULT IN SEVERE DAMAGE TO
THE DRIVE MOTOR MECHANISM. (13) Reinstall cover plate on transfer
gearbox main fuel pump adapter using a new
(e) To reverse the direction of gasket and the eight bolts removed previously.
rotation, move the directional selector to the Reinstall the VSV support bracket on the aft
neutral position which allows the gas generator face of cover plate, using the two longer bolts
to free wheel. Wait until the rotor completely in holes 6 and 7, counting CW from bolt 1 at
stops; then, and only then, move the direc- 12 o’clock position. Tighten the eight bolts to
tional selector to the opposite direction. 225 lb in. (25 N·m) of torque and safety-wire.

5-22
GEK 97310
VOLUME I
(14) Reinstate operating services to CAUTION

engine as follows:
USE OF THE BORESCOPE IN A
(a) Turn on electrical power. GAS GENERATOR WITH TEMPER-
ATURES ABOVE 200°F (93°C) CAN
(b) Turn on fuel supply. DAMAGE THE GLASS FIBER
ADHESIVES, PREVENTING ACCU-
(c) Turn on lube oil supply. RATE LIGHT TRANSMISSION.
(d) Turn on air starter air supply. (3) Rotate rotor counterclockwise,
CCW, (aft looking fwd) until the first rotor
(e) Reinstate any additional ser- blade slot locking lug is visible. See
vices that were rendered inactive. figure 5-7.
(f) Remove DO NOT OPER- (4) Continue to rotate CCW until the
ATE tag from operating console. second locking lug appears (this is normally
two blades past the first locking lug).
NOTE
(5) Position the next rotor blade
Zero indexing of gas generator rotor is (CCW from second locking lug) so that its
required so that it can be determined leading edge is in line with the leading edge of
when the rotor has completed one revo- the stage 11 compressor stator vane.
lution, during inspection of compressor See figure 5-7.
and turbine blades.
(6) Count blades in rotation from zero
c. Zero-index gas generator rotor. Fol- and record blade numbers with defects in
lowing is the typical procedure for stage 3 amount and size in order to determine if they
through 16. See figure 5-7: comply with the On-Site Max Serviceable
Limits in table 5-4.
(1) Remove plug from 10th stage
borescope port 19. d. Remove short elbow section of the
3-inch sump vent line to air-oil separator
(2) Insert borescope, 1C6811, or (at 90-degree location), to facilitate inserting
equivalent, look aft, and observe the stage 11 borescope at stages 3, 10 and 15.
rotor blade platforms.
e. Remove PT5.4 probe and four port
plugs.
f. Perform borescope inspection per

table 5-3. Rotate gas generator CCW one revo-
lution during inspection of each stage of com-
pressor or gas generator turbine blades. Start at
zero index, and refer to step c. for zero index-
ing procedure.

5-23
GEK 97310
VOLUME I
Figure 5-7. Zero Indexing Gas Generator Rotor

5-24
GEK 97310
VOLUME I
Table 5-3. BORESCOPE INSPECTION REQUIREMENTS
Sequence Port Location

No. (See figure 5-5) Parts Viewed Plug Torque
1 Compressor Stator, Stages 3 and 4 compressor *40-60 lb in.
Stage 3 (26) rotor blades, 2 stage 3 stator (4.5-6.8 N·m)
vane airfoils
Stage 9 (20) rotor blades; 2 stage 9 stator (4.5-6.8 N·m)
vane airfoils
Stage 15 (14) rotor blades; 2 stage 15 stator (9-13 N·m)
vane airfoils (metal O-ring under
plug)
NOTE
On the compressor rear frame, ports 13A and 13E may each have an ultraviolet flame
sensor installed. If so, loosen brackets as necessary to move the sensor out of the way.
Remove and install the sight glass using the same procedure as for the plugs in the
remaining ports. Following sight glass installation, reposition the flame sensor and
secure the brackets.
4 Compressor Rear Combustor, fuel nozzles and ∆*140-160 lb in.

Frame, 6 ports stage 1 gas generator turbine (15.8-18 N·m)
(13A through 13F) nozzle (washer under plug)
5 Compressor Rear Stage 1 gas generator turbine ∆*300-325 lb in.
Frame (12) rotor blades; 2 gas generator (34-36.7 N·m)
turbine stage 1 nozzle vane air- (washer under plug)
foils
6 Compressor Rear Stage 1 and 2 gas generator ∆*200-224 lb in.
Frame (11) turbine rotor blades, 2 gas gen- (22.6-25.3 N·m)
erator turbine stage 2 nozzle (washer under plug)
vane airfoils
7 Turbine Mid Frame, Stage 2 gas generator turbine ∆*70-80 lb in.
PT5.4 probe ports blades, stage 1 power turbine (7.9-9 N·m) (probe nut)
(10B, F, J, M, and Q) blades and vanes, turbine mid
frame liner, and T5.4 thermo-
couple probes

5-25
GEK 97310
VOLUME I
Table 5-3. BORESCOPE INSPECTION REQUIREMENTS - Continued

NOTE
The following optional borescope ports can be used as required to assess total extent of
damage. It may be necessary to remove piping or components to gain access to some
ports. Inspection of IGV’s and stage one blades may also be made through inlet.
Optional Compressor Stator Stage one compressor rotor **40-60 lb in.
Stage 0 (IGV) (29) blades and 2 each IGV vane (4.5-6.8 N·m)
airfoils
Optional Compressor Stator Compressor rotor stages 1 and *40-60 lb in.
Stage 1 (28) 2. Stage 1 vane airfoils 2 each (4.5-6.8 N·m)
Optional Compressor Stator Stages 2 and 3 compressor *40-60 lb in.

Stage 2 (IGV) (27) rotor blades; 2 each stage 2 (4.5-6.8 N·m)
stator vane airfoils
Stage 4 (25) rotor blades; 2 each stage 4 (4.5-6.8 N·m)
Stage 8 (21) rotor blades and stage 8 vane (4.5-6.8 N·m)
airfoil

5-26
GEK 97310
VOLUME I
Table 5-3. BORESCOPE INSPECTION REQUIREMENTS - Continued

compressor vane airfoils
compressor vane airfoils (metal O-ring under
plug)
Optional Compressor Stator Stages 13 and 14 compressor 43-48 lb in.
Stage 13 (16) (13th rotor blades; 2 each stage 13 (4.9-5.4 N·m) manifold
stage manifold compressor vane airfoils clamp
connection) *80-100 lb in.
(92-115 kg cm)
compressor vane airfoils (metal O-ring under
plug)
Optional Turbine Mid Frame Stage 2 gas generator turbine ∆*18-20 lb in.
Thermocouple Har- blades, stage 1 power turbine (2-3 N·m)
ness Probes (10A, C, blades and vanes and turbine
D, E, G, H, K, L, P, mid frame liner and PT5.4
and R probes
* Safety Wire
** Apply Loctite, Type A to threads. (Loctite Corp., 705 North Mountain Road,
Newington, CT 06111)
∆ Apply lubrication A50TF21 (or equivalent graphite grease) to threads.

5-27
GEK 97310
VOLUME I
Table 5-4. COMPRESSOR BLADES AND VANES
On-Site On-Site
Max Serviceable Max Repairable On-Site
Inspect Limits Limits Corrective Action
COMPRESSOR BLADES - ALL STAGES:

See paragraph 5-3.6 and figures 5-8, 5-9, and 5-10.
1. Blades for:
a. Cracks Not serviceable Replace blades
within the scope of
Volume II
WP 222 00*
b. General damage on Any amount provided damage Replace blades
airfoil, concave/ does not form a line transverse within the scope of
convex surfaces to airfoil that may crack in sub- Volume II
sequent operation; damage is WP 222 00*
0.50 inch (12.7 mm) from
leading or trailing edge; dam-
age does not break through
(protrusion acceptable); dam-
age is less than 0.095 inch
(2.41 mm) in diameter
c. Leading and trail- Judge acceptability by the Replace blades
ing edge damage sharpness of the damage. within the scope of
Sharp or torn edges are not Volume II
serviceable WP 222 00*
d. Blade tips for:
(1) Tip curl 25 percent of chord provided it Replace blades
does not engage stationary within the scope of
parts during operation, there is Volume II
no blade distortion caused by WP 222 00*
the damage, and there are no
tears in the airfoil

5-28
GEK 97310
VOLUME I
Table 5-4. COMPRESSOR BLADES AND VANES - Continued
On-Site On-Site
(2) Tip trailing edge for missing pieces. See figure 5-11.
a Stages 1-9 Maximum of six per stage pro- Replace blades
vided any downstream damage within the scope of
is serviceable and gas genera- Volume II
tor vibrations are within limits. WP 222 00*
Maximum size of any missing
piece is 1/3 chord X 1/3 span
b Stages 10-16 Maximum of 10 per stage pro- Replace blade
vided any downstream damage within the scope of
is serviceable and gas genera- Volume II
tor vibrations are within limits. WP 222 00*
Maximum size of any missing
piece is 1/3 chord X 1/3 span
e. Aluminum or abra- Any amount unless compres- See Corrective Troubleshoot for
sive deposits on sor stall occurs Action Column Stalls/High Vibra-
blades (leading tions as required
edge especially)
f. Stage 1 mid span See figure 5-12 Replace blade per
shroud wear Volume II
WP 222 00*
g. Tip clanging Not serviceable Replace gas
contact. generator*
Stages 3 thru 6
(see figure 5-10.)
NOTE
Tip clanging contact occurs when blade vibration causes contact between the leading edge
tip of one blade and the convex side of the adjacent blade. It often indicates that the com-
pressor underwent a severe compressor stall.

5-29
GEK 97310
VOLUME I
On-Site On-Site
2. Rotor and Stator Airflow Path Surfaces for:

a. Corrosion and dirt Any amount See Corrective Water wash com-
on air flow path Action Column pressor as
surfaces required, or when
specified as a
scheduled mainte-
nance action
b. Abrasive coating Any amount unless perfor- See Corrective Troubleshoot for
missing from rotor mance (T5.4 margin, power Action Column Stalls/High Vibra-
hub or stator case output or compressor stall) is tions as required
adversely affected
COMPRESSOR STATOR VANES - IGV, STAGES 1-15, AND OGV.
See figures 5-13 and 5-14.
1. Vanes for:
a. Cracked or torn
material
(1) All vanes Not serviceable Replace vanes per
Volume II
SWP 207 02 or
SWP 207 05*
b. General damage Any amount up to Replace vanes per
(peppering) - IGV 0.015 inch (0.38 mm) deep Volume II
through OGV provided vane is not cracked, SWP 207 02 or
damage does not break SWP 207 05*
through, and vane is not dis-
torted. None allowed in fillets
c. Nicks and Any number 0.015 inch Replace vanes per
scratches - All (0.38 mm) deep, 0.50 inch Volume II
vanes (12.7 mm) long, with a min SWP 207 02 or
separation of 0.063 inch SWP 207 05*
(1.60 mm). None allowed in
transverse direction

5-30
GEK 97310
VOLUME I
On-Site On-Site
d. Dents - IGV 0.047 inch (1.17 mm) deep Replace vanes per
through stage 11 provided damage is of smooth Volume II
contour and does not form a SWP 207 02 or
crease SWP 207 05*
e. Tip curl - All vanes 24 percent of chord length pro- Replace vanes per
vided it does not engage rotat- Volume II
ing parts during operation and SWP 207 02 or
there is no other distortion. SWP 207 05*
2. Variable Vanes, Stages 1-6 for:
a. Looseness (visu- 0.015 inch (0.38 mm) in the
ally inspect com- circumferential or axial direc-
pressor case OD) tion, 0.010 inch
(0.25 mm) in the radial
direction
3. IGVs, Stage 1 and 2 Variable Vanes (for reference Area E, figures 5-13 and 5-14):
NOTE
If IGV, stage 1 and 2 vane inner shroud replacement is required, inspect the IGVs, stage 1
and 2 vane trunnions, and inner platforms for the following:
a. Scoring or wear on Any amount up to Replace vanes per
inner trunnion 0.020 inch (0.51 mm) deep for Volume II,
diameter 50 percent of circumference SWP 207 02*
b. Wear on edge of Not serviceable Replace vanes per
inner trunnion Volume II,
groove SWP 207 02*
c. Wear on inner 0.010 inch (0.25 mm) deep Replace vanes per
platform face Volume II,
SWP 207 02*
d. Wear on inner 0.030 inch (0.76 mm) deep Replace vanes per
platform edge Volume II,
SWP 207 02*
* May be repairable, consult GE for disposition of replaced parts.

5-31
GEK 97310
VOLUME I
Figure 5-8. Compressor Blade and Vane Damage Examples

5-32
GEK 97310
VOLUME I
Figure 5-9. Compressor Rotor Blades
Figure 5-10. Tip Clanging Contact (Rotor Stages 3 through 6)

5-33
GEK 97310
VOLUME I
Figure 5-11. Inspection of Tip Trailing Edge
Figure 5-12. Stage 1 Mid Span Damper Inspection Limits

5-34
GEK 97310
VOLUME I
Figure 5-13. Variable Stator Vane Inner Trunnions and Platforms - Dimensions

5-35
GEK 97310
VOLUME I
Figure 5-14. Fixed and Variable Compressor Vanes

5-36
GEK 97310
VOLUME I
g. After the borescope inspection is com- 5-3.6 Compressor Blades and Vanes.
plete, perform the following: Remove plugs from borescope ports in the
compressor casing and use a borescope to
NOTE inspect the compressor blades and vanes. Two
If motoring adapter, 1C8067, was used vanes in each stage may be inspected. All
in lieu of 1C8033 adapter, remove blades may be inspected by rotating the com-
motoring adapter, 1C8067 and rein- pressor rotor per paragraph 5-3.5. Refer to
stall rear shaft seal assembly, figures 5-8 through 5-14 for blade and vane
L21431G02. Replace preformed pack- description. Refer to table 5-4 for inspection
ing, J221P14, and J221P216, on rear items and limits, and to the following descrip-
shaft seal assembly prior to installation tion of acceptable and unacceptable blade and
in gearshaft. Tighten nut on rear shaft vane damage examples.
seal assembly to 160 lb in. (18 N·m) of
torque. Install new gasket and cover a. Cracks or Torn Metal - Cracks and torn
plate and tighten bolts to 225 lb in. metal are not serviceable at any depth of any
(25 N·m) of torque. Angle bracket, blade or vane. Cracks and torn metal have a
L21804P01, is assembled at holes 3 sharp edge, with less than a 0.010 inch
and 4 counterclockwise from the (0.26 mm) radius, at the crack front which is
12 o’clock position as viewed aft look- the advancing edge of crack or tear.
ing forward.
b. Dents - The two critical parameters of a
(1) Remove the ratchet, extension and dent are depth, D, measured from the original
1C8033 adapter from transfer gearbox drive location of the metal, and the radius, R. The
pad. Install the cover plate, gasket and four depth, D, shall not measure more than
nuts. Tighten the four nuts to 55-70 lb in. 0.040 inch (1.02 mm) and the radius, R, shall
(6.2-7.9 N·m) of torque. not be less than 0.010 inch (0.26 mm).
figure 5-8 also shows another view of a dent,
(2) Install short elbow section of without dimensions. There are no critical
3-inch sump vent line. parameters to measure in this type of dent.
(3) Install P5.4 pressure probe and c. Crush - Crush type deformation is a
plugs. chordwise depression on the blade or vane
edge with metal protruding above the airfoil
(4) Make sure that all borescope surface on both the concave and convex side.
plugs have been installed per table 5-3. No metal may be torn or missing. For a blade
or vane to be serviceable with crush type dam-
age, depth D, measured from the original loca-
tion, shall not exceed 0.040 inch (1.02 mm)
and radius R, shall not be less than 0.010 inch
(0.26 mm).

5-37
GEK 97310
VOLUME I
d. Chip - A chip in a blade or vane is e. Tip Curl - An example of a blade with

caused by shearing metal out of the edge. The tip curl is shown in figure 5-8. The critical
two critical parameters of a chip are depth, D, parameter of the tip curl is the curled length, L,
measured from the edge, and radius R, mea- of the tip chord. A maximum of 25 percent of
sured at the bottom (root) of the chip. the tip chord is allowed to be curled, provided
it does not engage stationary parts during oper-
(1) A blade or vane containing a chip ation, provided there is no other blade distor-
with a root radius less than 0.010 inch tion caused by the damage, and provided there
(0.26 mm) is not serviceable. In figure 5-8, the is no torn metal.
lower chip has a root radius less than
0.010 inch (0.26 mm), rendering the blade 5-3.7 Combustor and Fuel Nozzles.
unserviceable. The middle and upper chips Inspect with a borescope per paragraph 5-3.5.
have root radii of 0.010 inch (0.26 mm) and Refer to figures 5-15 through 5-18 for hard-
0.020 inch (0.51 mm) respectively, both of ware description. Refer to table 5-5 for
which are serviceable. A 0.025 inch inspection limits.
(0.64 mm) diameter wire is shown in
figure 5-8 for comparison. 5-3.8 High Pressure Turbine Nozzles.
Inspect per paragraph 5-3.5. Refer to
(2) The maximum allowable depth figures 5-19, 5-20, and 5-21 for hardware
for a chip in a stage 1 rotor blade or vane is description. Refer to table 5-6 for inspection
0.005 inch (0.13 mm), provided that it is sepa- limits.
rated by at least 3/8 inch (9 mm) of unaffected
material. The allowable depth for all other
compressor blades and vanes is 0.040 inch
(1.02 mm), provided root radius of chip is
0.010 inch (0.26 mm) minimum, and separated
by at least 0.38 inch (9.7 mm) of unaffected
material.

5-38
GEK 97310
VOLUME I
Figure 5-15. Combustor (Sheet 1 of 3)

5-39
GEK 97310
VOLUME I

5-40
GEK 97310
VOLUME I

5-41
GEK 97310
VOLUME I
Figure 5-16. Fuel Nozzle (Liquid Fuel)

5-42
GEK 97310
VOLUME I
Figure 5-17. Fuel Nozzle (Natural Gas Fuel)
Figure 5-18. Fuel Nozzle (Dual Fuel)

5-43
GEK 97310
VOLUME I
Table 5-5. COMBUSTION LINER ASSEMBLY AND FUEL NOZZLES
On-Site On-Site On-Site

Max Serviceable Max Repairable Corrective
Inspect Limits Limits Action
COMBUSTION LINER. See figure 5-15.

1. All surfaces for:
a. Discoloration Serviceable
b. Carbon Any amount
accumulation
2. Riveted joints for:
a. Loose, cracked Six nonadjacent rivets in each Replace
or missing rivet circle may be loose, combustion liner
rivets cracked or missing per WP 204 00*
b. Cracked or torn One crack 0.030 inch Replace
rivet holes in (0.76 mm) long per hole; combustion liner
cowl and skirts 20 holes max per rivet circle per WP 204 00*
3. Dome band and dome plate excluding overhung surfaces (see paragraph 5b.) for:
a. Axial cracks Any number less than Replace
1.25 inch (31.8 mm) long; one combustion liner
crack greater than 1.25 inch per WP 204 00*
(31.8 mm) in each swirl cup
location, max length of
2.25 inch (57.2 mm) not to
exceed eight per dome
b. Circumferential Any number less than Replace
cracks 0.75 inch (19.1 mm) long, five combustion liner
cracks 2.25 inches (57.2 mm) per WP 204 00*
long separated by 1.00 inch
(25.4 mm) from any other
crack greater than 0.75 inch
(19.1 mm) long

5-44
GEK 97310
VOLUME I
Table 5-5. COMBUSTION LINER ASSEMBLY AND FUEL NOZZLES - Continued

4. Trumpet and swirl cup excluding overhung surfaces (see paragraph 5b.) for:
a. Cracks Four cracks, 1.25 inch Replace
(31.8 mm) long per item; any combustion liner
number less than 0.50 inch per WP 204 00*
(12.7 mm) long
b. Distortion of Any amount
trumpet
5. Dome assembly (dome band, dome-plate, trumpet, and swirl cup) for:
a. Burn through or Any amount less than Replace
missing metal of 90 degrees maximum burn combustion liner
non-overhung through of domeplate around per WP 204 00*
surfaces any one swirl cup. Burn
through limited to eight areas
per dome, maximum size
1.0 inch (25.4 mm) by 1.0 inch
(25.4 mm). Any amount of
trumpet distress is allowed
b. Burn through or Any amount
missing metal of
overhung
surfaces. See
View A,
figure 5-15,
sheet 1
NOTE
Burn through in combustor dome will reduce the cooling flow to the HPT vanes. Inspect
the HPT vanes to the limits of table 5-6.
6. Igniter ferrule for:
a. Cracks Any number 0.25 inch Replace
(6.4 mm) long combustion liner
per WP 204 00*

5-45
GEK 97310
VOLUME I

b. Burns 0.13 inch (3.3 mm) burn Replace

permissible on bottom of combustion liner
ferrule (flame side) per WP 204 00*
c. Wear 0.75 inch (19.1 mm) ID max Replace
combustion liner
per WP 204 00*
7. Inner and Outer Liners for:
a. Circumferential Any number non-interconnect- Replace
cracks ing cracks per band, each combustion liner
1.00 inch (25.4 mm) long sep- per WP 204 00*
arated by 2.00 inches
(50.8 mm) from any other
crack. Total length of all cir-
cumferential cracks in any
band shall not exceed
7.00 inches (177.8 mm)
b. Axial cracks Six cracks per liner, max Replace
length not to exceed 2 adjoin- combustion liner
ing bands (3 rows of cooling per WP 204 00*
holes), any number of cracks
1.25 inch (31.8 mm) per band.
Axial and circumferential
cracks, 1.00 inch
(25.4 mm) or longer must have
a minimum separation of
2.00 inches (50.8 mm)
c. Burns Six burned through areas of Replace
0.75 inch (19.5 mm) by combustion liner
1.00 inch (25.4 mm) per liner per WP 204 00*
separated by 2.50 inches
(63.5 mm)
d. Distortion Any amount within Replace
0.50 inch (12.7 mm) from combustion liner
original contour per WP 204 00*

5-46
GEK 97310
VOLUME I

8. Cowl for:
a. Burns at fuel Accept three burn through Replace
nozzle eyelet areas of 0.25 inch (6.4 mm) by combustion liner
(fuel nozzle 1.00 inch (25.4 mm) per WP 204 00*
removed)
b. Cracks Any number 0.25 inch Replace
(6.4 mm) long combustion liner
per WP 204 00*
FUEL NOZZLE [See figure 5-16 (Liquid Fuel), 5-17 (Natural Gas Fuel), or 5-18 (Dual Fuel)]
1. Fuel Nozzles for:
a. Cracks Not serviceable Replace
fuel nozzle*
b. Chafing Not serviceable Replace part*
2. Dual Fuel Nozzles for:
a. Nicks, scratches, Not serviceable 0.015 inch Stone raised
dents, or wear on (0.38 mm) metal. Replace
shroud OD maximum depth metering set if
in cylindrical limits are
surface exceeded
3. Fuel Nozzle Spray Orifices for:
a. Carbon Deposit Not serviceable Any amount Remove carbon
deposit, inspect
for carbon cause
4. Face for:
a. Spalling Not serviceable Replace part *
5. Tip for:
a. Wear Maximum of 0.020 inch Replace part *
(0.51 mm) deep
* May be repairable, consult GE for disposition or replace parts.

5-47
GEK 97310
VOLUME I
Figure 5-19. High Pressure Turbine Nozzles (Twin Shank Configuration)

5-48
GEK 97310
VOLUME I
Figure 5-20. First-Stage High Pressure Turbine Nozzle (Single Shank Configuration)

5-49
GEK 97310
VOLUME I
Figure 5-21. Second-Stage High Pressure Turbine Nozzle (Single Shank Configuration)

5-50
GEK 97310
VOLUME I
Table 5-6. HIGH PRESSURE TURBINE NOZZLES

On-Site On-Site
FIRST STAGE HIGH PRESSURE TURBINE NOZZLE
See figure 5-19 for Twin Shank, 5-20 for Single Shank.
1. Vane Airfoil for:
a. Axial cracks One per slot Replace nozzle or seg-
in trailing 0.31 inch (7.9 mm) long, ment per NOTE* **
edge or two per vane 0.75 inch
(concave (19.1 mm) long, provided
side) they are 0.31 inch
(7.9 mm) apart. The
1.50 inch (38.1 mm) long
crack cannot extend axi-
ally beyond the first row
of gill holes
NOTE
Replace nozzle or segment per WP 203 00 or WP 210 00 for Twin Shank, SWP 203 01
or SWP 210 01 for Single Shank.
NOTE
To assist in visually gaging observed defects by comparison, the center-to-center dimen-
sion between nose or gill holes in any given row (radial direction) is approximately
0.06 inch (1.5 mm).
b. Axial cracks Any number 0.50 inch Replace nozzle or seg-
in leading (12.7 mm) long separated ment per NOTE* **
edge by 0.25 inch (1.5 mm), or
any number of cracks
interconnecting the cool-
ing holes provided total
length of inter-connect-
ing cracks does not
exceed six gill holes.
Cracks extending aft of
gill holes on convex side
are not allowed.

5-51
GEK 97310
VOLUME I
Table 5-6. HIGH PRESSURE TURBINE NOZZLES - Continued

On-Site On-Site
c. Radial cracks Any number 0.50 inch Replace nozzle or seg-
in concave (12.7 mm) long, or two ment per NOTE* **
surface per vane, 0.75 inch
between inner (19.1 mm) long, provided
and outer they are 0.31 inch
platforms (8.00 mm) apart
d. Radial cracks One crack allowed Replace nozzle or seg-
in convex 0.75 inch (19.1 mm) long ment per NOTE* **
surfaces
between inner
and outer
platforms
e. Buckling or Any number 0.31 inch Replace nozzle or seg-
bowing of (8.0 mm) from original ment per NOTE* **
trailing edge contour
f. Axial cracks Two cracks per vane Replace nozzle or seg-
in concave extending aft from aft row ment per NOTE* **
surface of gill holes to (not
through) slot in trailing
edge
g. Corrosion, Not to exceed an area of Replace nozzle or seg-
burns and 1.20 inch (30.4 mm) long ment per NOTE* **
cracks on and 1.00 inch (25.0 mm)
concave and wide per vane, max of
convex side four vanes per 90 degrees
including arc. Missing metal in
trailing edge inserts (inner liner) not
allowed
h. Burns or 0.50 inch (12.7 mm) Replace nozzle or seg-
spalling on diameter per vane, max of ment per NOTE* **
vane leading four vanes affected per
edge 90 degree arc. No miss-
ing metal in inserts
allowed

5-52
GEK 97310
VOLUME I

On-Site On-Site
i. Craze Any amount
cracking
NOTE
Craze cracking is defined as numerous superficial surface cracks which have no visual
width or depth.
j. Nicks, scores, Any number, any length Replace nozzle or seg-
scratches 0.031 inch (0.79 mm) ment per NOTE* **
deep
k. Bulging, 0.125 inch (3.18 mm) out Replace nozzle or seg-
bowing or of original contour. Maxi- ment per NOTE* **
dents mum of three vanes
affected per 90 degree arc
2. Inner and Outer Platform for:
a. Cracks in 2/3 length of weld at outer Replace nozzle or seg-
welds platform provided weld at ment per NOTE* **
between inner platform has no
vanes cracks, or 1/3 length of
original weld if inner plat-
form has crack of any
length
b. Cracks in par- Any number, Replace nozzle or seg-
ent metal 0.875 inch (22.2 mm) ment per NOTE* **
max length.
c. Nicks, scores, Any number, 0.063 inch Replace nozzle or seg-
scratches and (1.60 mm) deep ment per NOTE* **
dents on plat-
form surface
d. Corrosion, 0.50 inch (12.7 mm) Replace nozzle or seg-
erosion and wide, any length, max. of ment per NOTE* **
burns on vane six vanes per 90 degrees.
platform Burn through allowed,
0.125 inch (3.28 mm)
wide by 0.50 inch
(12.7 mm) length, two per
90 degrees, not in same
nozzle segment

5-53
GEK 97310
VOLUME I

On-Site On-Site
e. Corrosion, Six vanes per 90 degrees Replace nozzle or seg-
erosion and arc, 0.25 inch (6.0 mm) ment per NOTE* **
burns on two per vane
inner plat-
form trailing
edge (loss of
metal)
f. Displace- Replace nozzle or seg-
ment of inter- ment per NOTE* **
segment seals
from groove
SECOND STAGE HIGH PRESSURE TURBINE NOZZLE
See figure 5-19 for Twin Shank, 5-21 for Single Shank.
NOTE*
Replace nozzle, segment or shroud per WP 202 00 or WP 209 00 for Twin Shank,
SWP 202 01 or SWP 209 01 for Single Shank.
a. Axial cracks Any number, 0.09 inch Replace nozzle or seg-
in trailing (2.4 mm) long, two per ment per NOTE* **
edge vane, 0.50 inch (12.7 mm)
long, provided they are
0.25 inch (6.4 mm) apart
b. Axial cracks Not serviceable Replace nozzle or seg-
in leading ment per NOTE* **
edge
c. Cracks in Two cracks, 1.50 inch Replace nozzle or seg-
concave (38.1 mm) max length ment per NOTE* **
surfaces
d. Craze Any amount
cracking

5-54
GEK 97310
VOLUME I

On-Site On-Site
NOTE
Craze cracking is defined as numerous superficial cracks which have no visual width or
depth.
e. Displace- Replace nozzle or seg-
ment of inter- ment per NOTE ***
segment seals
from groove
f. Buckling of Any number, 0.06 inch Replace nozzle or seg-
trailing edge (1.6 mm) from original ment per NOTE* **
contour
g. Burns on air- One inch square Replace nozzle or seg-
foil surfaces (6 cm²) area with no ment per NOTE* **
through holes
h. Corrosion Any amount provided Replace nozzle or seg-
corrosion is not com- ment per NOTE* **
pletely through metal
thickness
i. Nicks, scores, Any number, Replace nozzle or seg-
scratches or 0.25 inch (6.3 mm) long, ment per NOTE* **
dents 0.03 inch (1.8 mm) deep
after removal of high
metal
j. Buckling of 0.06 inch (1.6 mm) from Replace nozzle or seg-
trailing edge original contour ment per NOTE* **
k. Eroded areas Any amount, 0.02 inch Replace nozzle or seg-
(0.4 mm) deep ment per NOTE* **
a. Cracks Any number 0.63 inch Replace nozzle or seg-
between (15.9 mm) long separated ment per NOTE* **
vanes by 0.25 inch (6.4 mm)
b. Craze Any amount
cracking

5-55
GEK 97310
VOLUME I

On-Site On-Site
NOTE
Craze cracking is defined as numerous superficial cracks which have no visual width or
depth.
c. Cracks in Two cracks, 0.38 inch Replace nozzle or seg-
outer band (9.5 mm) long, any num- ment per NOTE* **
trailing edge ber 0.13 inch (3.2 mm)
long
STAGE 1 AND STAGE 2 SHROUD
1. Shroud for:
a. Wear Any amount as long as Replace shroud per
backing strip is not NOTE*
damaged
b. Erosion Total eroded area missing Replace shroud per
not to exceed 10% pro- NOTE*
vided missing area is not
completely across axial
width of shroud; no single
area to exceed 1 square
inch (6 cm²)
c. Axial cracks Two per shroud segment Replace shroud per
0.25 inch (6.4 mm) long; NOTE*
one per shroud segment
1.00 inch (25.4 mm) long
d. Distortion Free state distortion Replace shroud per
allowable, provided NOTE*
proper assembly and
blade clearance can be
maintained.
** May be repairable, consult GE for disposition of replaced parts.
5-3.9 High Pressure Turbine Twin

Shank Rotor Blades. Inspect per
paragraph 5-3.5. Refer to figure 5-22 for blade
description. Refer to table 5-7 for inspection
limits.

5-56
GEK 97310
VOLUME I
Figure 5-22. High Pressure Turbine (Twin Shank) Rotor Blades

5-57
GEK 97310
VOLUME I
Table 5-7. HIGH PRESSURE TURBINE TWIN SHANK ROTOR BLADES
On-Site On-Site
STAGE 1 BLADES ONLY. See figure 5-22.

1. Leading Edge for:
a. Cracks Any number, Replace blades
0.16 inch (4.1 mm) within the scope of
long provided they do WP 202 00 or
not intersect adjacent WP 209 00 *
holes. None allowed
in Area B
b. Clogged air (TBD) Replace blades
passages within the scope of
WP 202 00 or
WP 209 00 *
c. Erosion on Any amount in Replace blades
leading edge Area A, provided within the scope of
(from blade wall is not pene- WP 202 00 or
tip down lead- trated. Any amount in WP 209 00 *
ing edge to Area B, provided it is
the sixth gill not through coating.
hole from tip) If coating in Area B
is penetrated, gas
generator must be
replaced within
1800 hours and bore-
scope inspected at
600 hour intervals
prior to replacement
2. Trailing Edge for:
within the scope of
WP 202 00 or
WP 209 00 *

5-58
GEK 97310
VOLUME I
Table 5-7. HIGH PRESSURE TURBINE TWIN SHANK ROTOR BLADES - Continued
On-Site On-Site
b. Clogged air Two holes plus three Replace blades

passages additional holes in within the scope of
any area above the WP 202 00 or
bottom eight holes WP 209 00 *
provided no two are
adjacent. None
allowed in bottom
eight holes
c. Erosion and Any amount in Replace blades
corrosion in Area A, provided within the scope of
area of hot cooling holes are not WP 202 00 or
spots penetrated from WP 209 00 *
either concave or
convex walls. If coat-
ing in Area B is pene-
trated, gas generator
must be replaced
within 1800 hours
and borescope
inspected at 600 hour
intervals prior to
replacement
3. Concave and Convex Surfaces for:
a. Cracks at gill Not serviceable Replace blades
holes or air- within the scope of
foil surface WP 202 00 or
WP 209 00 *
b. Blocked gill Top gill hole plus one Replace blades
holes additional hole per within the scope of
row, not within WP 202 00 or
0.25 inch (6.4 mm) of WP 209 00 *
root
c. Distortion or Not serviceable Replace blades
evidence of within the scope of
burning or WP 202 00 or
melting WP 209 00 *

5-59
GEK 97310
VOLUME I
On-Site On-Site
STAGE 2 BLADES ONLY. See figure 5-22.

1. All Areas for:
within the scope of
WP 202 00 or
WP 209 00 *
STAGE 1 AND 2 BLADES
1. Leading and Trailing Edges in Area A for:
a. Nicks and Any amount provided Replace blades
dents there is not torn metal within the scope of
or cracks WP 202 00 or
WP 209 00 *
b. Tears Not serviceable Replace blades
within the scope of
WP 202 00 or
WP 209 00 *
2. Concave and Convex Surfaces in Area A for:
a. Nicks and Any amount provided Replace blades
dents there is not torn metal within the scope of
or cracks WP 202 00 or
WP 209 00 *
3. All Area B Including Root Radius for:
a. Nicks and Not serviceable Replace blades
dents within the scope of
WP 202 00 or
WP 209 00 *

5-60
GEK 97310
VOLUME I
On-Site On-Site
4. Blade Tip for:

NOTE
Blade tip is the area from blade tip down to the third gill hole from tip for stages 1
and 2.
a. Cracks in One axial crack Replace blades
stages 1 and 2 0.50 inch (12.7 mm) within the scope of
blade tips long, provided it does WP 202 00 or
not extend below tip WP 209 00 *
metering cap
b. Bent or curled Two areas 0.25 inch Replace blades
blade tips (6.4 mm) long within the scope of
WP 202 00 or
WP 209 00 *
c. Dents in lead- Any depth if metal is Replace blades
ing edge of not torn within the scope of
blade tip of WP 202 00 or
stage 1 WP 209 00 *
d. Missing A maximum area of Replace blades
pieces 0.188 inch within the scope of
(4.78 mm) long WP 202 00 or
above blade tip WP 209 00 *
metering cap
e. Tip wear Acceptable to
0.070 inch (1.8 mm)
above tip cap
5-3.10 High Pressure Turbine Single

Shank Rotor Blades. Inspect per
paragraph 5-3.5. Refer to table 5-8 for inspec-
tion limits. See figure 5-23.

5-61
GEK 97310
VOLUME I
Figure 5-23. High Pressure Turbine (Single Shank) Rotor Blades

5-62
GEK 97310
VOLUME I
Table 5-8. HIGH PRESSURE TURBINE SINGLE SHANK ROTOR BLADES

On-Site On-Site
STAGE 1 SINGLE SHANK TURBINE BLADES ONLY. See figure 5-23.
NOTE
During inspection of blades, visual evidence of plugged cooling holes is not positive.
Evidence of plugged cooling holes is acceptable providing the crack, erosion and burning
limits are serviceable.
1. Leading Edge in Area A for:
a. Cracks propa- Any number provided Not repairable Replace blade within the
gating from they do not extend into the scope of SWP 202 01 or
nose holes gill holes SWP 209 01 or replace
rotor per SWP 202 01 or
SWP 209 01
b. Cracks propa- Any number on convex Not repairable Replace blade within the
gating from side provided they do not scope of SWP 202 01 or
gill holes extend into the nose holes SWP 209 01 or replace
SWP 209 01
c. Erosion and Any amount to the gill Not repairable Replace blade within the
burning holes provided the radial scope of SWP 202 01 or
cooling passage is not SWP 209 01 or replace
exposed rotor per SWP 202 01 or
SWP 209 01
d. Nicks and Any amount provided Not repairable Replace blade within the
dents damage does not extend scope of SWP 202 01 or
past the gill holes and SWP 209 01 or replace
there is no torn metal rotor per SWP 202 01 or
SWP 209 01
e. Tears Not serviceable Not repairable Replace blade within the
scope of SWP 202 01 or
SWP 209 01 or replace
SWP 209 01

5-63
GEK 97310
VOLUME I
Table 5-8. HIGH PRESSURE TURBINE SINGLE SHANK ROTOR BLADES - Continued
On-Site On-Site
2. Leading Edge in Area B for:
a. Cracks propa- No cracks allowed Not repairable Replace blade within the
gating from scope of SWP 202 01 or
nose holes SWP 209 01 or replace
SWP209 01
b. Radial cracks Any number provided Not repairable Replace blade within the
out of leading they do not connect two scope of SWP 202 01 or
edge holes holes and do not turn into SWP 209 01 or replace
the axial direction rotor per SWP 202 01 or
SWP 209 01
c. Erosion and Any amount provided it is Not repairable Replace blade within the
burning not through coating. If scope of SWP 202 01 or
coating is penetrated, gas SWP 209 01 or replace
generator must be rotor per SWP 202 01 or
replaced within SWP 209 01
1800 hours and borescope
intervals prior to
replacement
d. Axial cracks Not serviceable Not repairable Replace blade within the
out of leading scope of SWP 202 01 or
edge holes SWP 209 01 or replace
SWP 209 01
e. Nicks and Any number provided Not repairable Replace blade within the
dents there is no torn metal or scope of SWP 202 01 or
surface distortion outside SWP 209 01 or replace
the dent itself rotor per SWP 202 01 or
SWP 209 01
f. Tears Not serviceable Not repairable Replace blade within the
SWP 209 01

5-64
GEK 97310
VOLUME I
On-Site On-Site
3. Blade Tip for:
a. Coating Any number of radial Not repairable Replace blade within the
cracks cracks 0.65 inches scope of SWP 202 01 or
(16.5 mm) long SWP 209 01 or replace
SWP 209 01
b. Bent or curled Any amount above tip cap Not repairable Replace blade within the
blade tips retention lug scope of SWP 202 01 or
SWP 209 01
c. Dents in lead- Any depth if metal is not Not repairable Replace blade within the
ing edge of torn below tip cap scope of SWP 202 01 or
blade tip SWP 209 01 or replace
SWP 209 01
d. Missing Any amount above tip cap Not repairable Replace blade within the
pieces retention lug scope of SWP 202 01 or
SWP 209 01
e. Tip wear Any amount above tip cap Not repairable Replace blade within the
retention lug scope of SWP 202 01 or
SWP 209 01
f. Tip burning Any amount provided the Not repairable Replace blade within the
blade internal cooling pas- scope of SWP 202 01 or
sages are not exposed SWP 209 01 or replace
SWP 209 01

5-65
GEK 97310
VOLUME I
On-Site On-Site
4. Trailing Edge in Area A for:
a. Cracks Not serviceable Not repairable Replace blade within the
SWP 209 01
b. Clogged air Top hole plus three addi- Not repairable Replace blade within the
passages tional holes in any area scope of SWP 202 01 or
above the bottom eight SWP 209 01 or replace
holes provided no two are rotor per SWP 202 01 or
adjacent SWP 209 01
c. Erosion and Any amount provided Not repairable Replace blade within the
corrosion in cooling holes are not pen- scope of SWP 202 01 or
area of hot etrated from either con- SWP 209 01 or replace
spots cave or convex walls rotor per SWP 202 01 or
SWP 209 01
d. Nicks and Any amount provided Not repairable Replace blade within the
cracks SWP 209 01 or replace
SWP 209 01
e. Tears Not serviceable Not repairable Replace blade within the
SWP 209 01
5. Trailing Edge in Area B for:
a. Cracks Not serviceable Not repairable Replace blade within the
SWP 209 01

5-66
GEK 97310
VOLUME I
On-Site On-Site
b. Clogged air Not serviceable Not repairable Replace blade within the
passages scope of SWP 202 01 or
SWP 209 01
c. Erosion and If coating is penetrated, Not repairable Replace blade within the
corrosion in blade must be replaced scope of SWP 202 01 or
area of hot within 1800 hours and SWP 209 01 or replace
spots borescope inspected at rotor per SWP 202 01 or
600 hour intervals prior to SWP 209 01
replacement
d. Nicks and Any number provided Not repairable Replace blade within the
surface distortion outside SWP 209 01 or replace
the dent itself rotor per SWP 202 01 or
SWP 209 01
6. Concave Surface in Area A for:
a. Axial cracks Not serviceable Not repairable Replace blade within the
SWP 209 01
b. Coating craz- Craze cracks are tight, Not repairable Replace blade within the
ing cracks multiple, multi-direc- scope of SWP 202 01 or
tional coating cracks. Any SWP 209 01 or replace
number of crazing cracks rotor per SWP 202 01 or
at any location on airfoil SWP 209 01
or platform
c. Blocked gill Top gill hole plus one Not repairable Replace blade within the
holes additional hole per row, scope of SWP 202 01 or
not within 0.25 inch SWP 209 01 or replace
(6.4 mm) of root rotor per SWP 202 01 or
SWP 209 01

5-67
GEK 97310
VOLUME I
On-Site On-Site
d. Distortion or Not serviceable - wrin- Not repairable Replace blade within the
evidence of kling of coating is scope of SWP 202 01 or
burning or acceptable SWP 209 01 or replace
melting rotor per SWP 202 01 or
SWP 209 01
e. Nicks and Any amount provided Not repairable Replace blade within the
SWP 209 01
7. Concave Surface in Area B for:
a. Axial cracks No cracks allowed Not repairable Replace blade within the
SWP 209 01
b. Blocked gill Top gill hole plus one Not repairable Replace blade within the
SWP 209 01
c. Distortion or Not serviceable Not repairable Replace blade within the
evidence of scope of SWP 202 01 or
burning or SWP 209 01 or replace
SWP 209 01
d. Nicks and Not serviceable Not repairable Replace blade within the
dents scope of SWP 202 01 or
SWP 209 01
8. Convex Surface in Area A and B for:
a. Blocked gill Top gill hole plus one Not repairable Replace blade within the
SWP 209 01

5-68
GEK 97310
VOLUME I
On-Site On-Site
b. Distortion or Not serviceable Not repairable Replace blade within the
evidence of scope of SWP 202 01 or
burning or SWP 209 01 or replace
SWP 209 01
c. Nicks and Any amount provided Not repairable Replace blade within the
cracks in Area A. No SWP 209 01 or replace
nicks or dents allowed in rotor per SWP 202 01 or
Area B including root SWP 209 01
radius
STAGE 2 SINGLE SHANK TURBINE BLADES ONLY. See figure 5-23.
1. All Areas for:
a. Axial cracks Not serviceable Not repairable Replace blade within the
and radial scope of SWP 202 01 or
cracks except SWP 209 01 or replace
tip cracks rotor per SWP 202 01 or
SWP 209 01
b. Erosion and Any amount in Area A Not repairable Replace blade within the
corrosion in provided internal cooling scope of SWP 202 01 or
area of hot passages are not pene- SWP 209 01 or replace
spots trated from either con- rotor per SWP 202 01 or
cave or convex walls. If SWP 209 01
coating is penetrated in
Area B, blade must be
replaced within
1800 hours and borescope
intervals prior to
replacement
a. Nicks and Any amount provided Not repairable Replace blade within the
SWP 209 01

5-69
GEK 97310
VOLUME I
On-Site On-Site
b. Tears Not serviceable Not repairable Replace blade within the
SWP 209 01
a. Nicks and Any amount provided Not repairable Replace blade within the
SWP 209 01
a. Nicks and Not serviceable Not repairable Replace blade within the
dents scope of SWP 202 01 or
SWP 209 01
5. Blade Tip for:
a. Tip cracks Any number of radial Not repairable Replace blade within the
cracks 0.300 inches scope of SWP 202 01 or
(7.62 mm) long. One axial SWP 209 01 or replace
crack 0.50 inch (12.7 mm) rotor per SWP 202 01 or
long, provided it does not SWP 209 01
extend below tip metering
cap
b. Bent or curled Any amount provided dis- Not repairable Replace blade within the
blade tips tortion is above tip cap lip scope of SWP 202 01 or
SWP 209 01
c. Missing Any amount above blade Not repairable Replace blade within the
pieces tip metering cap lip scope of SWP 202 01 or
SWP 209 01

5-70
GEK 97310
VOLUME I
On-Site On-Site
d. Tip wear Acceptable to 0.070 inch Not repairable Replace blade within the
(1.8 mm) above tip cap scope of SWP 202 01 or
SWP 209 01
e. Missing Any amount Not repairable Replace blade within the
coating scope of SWP 202 01 or
SWP 209 01

5-71
GEK 97310
VOLUME I
5-3.11 Turbine Mid Frame. Inspect per

paragraph 5-3.5. Refer to table 5-9 for inspec-
tion limits.
Table 5-9. TURBINE MID FRAME
On-Site On-Site
1. Liner for:
a. Cracks in skin Any number not exceed- Replace turbine mid
(no separation ing 2.00 inches frame per WP 201 00/
through aft (50.8 mm) length and not SWP 201 01 or
ring) joining with adjacent WP 208 00/
cracks. Monitor for prop- SWP 208 01*
agation by borescope
inspection at each oppor-
tunity but not later than
500 hours of operation
b. Missing Not serviceable Replace turbine mid
material frame per WP 201 00/
SWP 201 01 or
WP 208 00/
SWP 208 01*
c. Buckling or Any amount 0.25 inch Replace turbine mid
distortion (6.4 mm) from original frame per WP 201 00/
contour SWP 201 01 or
WP 208 00/
SWP 208 01*

5-72
GEK 97310
VOLUME I
5-3.12 Power Turbine Nozzles. Inspect per

paragraph 5-3.5. See figure 5-24. Refer to
table 5-10.
Table 5-10. POWER TURBINE NOZZLES
On-Site On-Site
NOTE
First stage nozzle assemblies are attached to turbine mid frame. These can be replaced
on-site.
1. Outer and Inner Platforms for:
a. Cracks not Any number 0.19 inch Not repairable Replace power turbine
in fillets (4.8 mm) long per WP 302 00 *
b. Nicks, dents Any number 0.06 inch Not repairable Replace power turbine
and (1.6 mm) long per WP 302 00 *
scratches
2. Airfoil Leading Edge for:
a. Cracks Not serviceable Not repairable Replace power turbine
per WP 302 00 *
b. Nicks, dents 0.06 inch (1.60 mm) Not repairable Replace power turbine
and deep provided no torn per WP 302 00 *
scratches metal
c. Corrosion, Any amount provided cor- Not repairable Replace power turbine
erosion rosion is not through vane per WP 302 00 *
3. Airfoil Concave and Convex Surfaces Other than Edges for:
a. Cracks Any number 0.125 inch Not repairable Replace power turbine
(3.18 mm) long per WP 302 00 *
b. Nicks, dents Any number, 0.031 inch Not repairable Replace power turbine
and (0.79 mm) deep provided per WP 302 00 *
scratches no torn metal
c. Corrosion, Any amount provided cor- Not repairable Replace power turbine
erosion rosion is not through vane per WP 302 00 *

5-73
GEK 97310
VOLUME I
Figure 5-24. Power Turbine Nozzles

5-74
GEK 97310
VOLUME I
5-3.13 Power Turbine Rotor Blades.

Inspect per paragraph 5-3.5. See figure 5-25.
Refer to table 5-11 for inspection limits.
Table 5-11. POWER TURBINE ROTOR BLADES

On-Site On-Site
NOTE
Stages 2 through 5 are not accessible.
STAGE 1.
1. All areas for:
blades per WP 225 00
2. Leading and trailing edges for:
a. Nicks None within 0.50 inch Not repairable Replace power turbine
(12.7 mm) of inner plat- blades per WP 225 00
form or within 0.25 inch
(6.4 mm) of shroud. Bal-
ance of blade any number
0.04 inch (1.0 mm) deep
with minimum separation
of 0.50 inch (12.7 mm)
b. Dents Any number with no pro- Not repairable Replace power turbine
trusions on opposite side blades per WP 225 00
and five per blade with
protrusion not to exceed
0.04 inch (1.0 mm) on
opposite side
c. Corrosion, Any amount Not repairable Replace power turbine
erosion blades per WP 225 00
3. Concave and convex surfaces for:
a. Nicks Any number 0.04 inch Not repairable Replace power turbine
(1.0 mm) deep; min separa- blades per WP 225 00
tion 0.25 inch (6.4 mm)
trusion on opposite side blades per WP 225 00
erosion blades per WP 225 00

5-75
GEK 97310
VOLUME I
Table 5-11. POWER TURBINE ROTOR BLADES - Continued

On-Site On-Site
STAGE 6.
1. All areas for:
per WP 302 00 *
2. Leading and trailing edges for:
a. Nicks None within 0.50 inch Not repairable Replace power turbine
(12.7 mm) of inner plat- per WP 302 00 *
form or within 0.25 inch
(6.4 mm) of shroud. Bal-
ance of blade any number
0.04 inch (1.0 mm) deep
with minimum separation
of 0.50 inch (12.7 mm)
trusions on opposite side per WP 302 00 *
and five per blade with
protrusion not to exceed
0.04 inch (1.0 mm) on
opposite side
erosion per WP 302 00 *
3. Concave and convex surfaces for:
a. Nicks Any number 0.04 inch Not repairable Replace power turbine
(1.0 mm) deep; min separa- per WP 302 00 *
tion 0.25 inch (6.4 mm)
trusions on opposite side per WP 302 00 *
erosion per WP 302 00 *
*May be repairable, consult GE for disposition of replaced parts.

5-76
GEK 97310
VOLUME I
Figure 5-25. Power Turbine Blades

5-77
GEK 97310
VOLUME I
5-3.14 Engine Enclosure Inspection. 5-3.16 Variable Stator System

Inspect per packager’s manual. Inspection. See figures 5-26 through 5-33.
5-3.15 Gas Turbine Exhaust Inspection.

WARNING
WARNING OBSERVE SAFETY PRECAU-
TIONS OF CHAPTER 1.
BEFORE ENTERING THE GAS
TURBINE EXHAUST DUCT, THE
CAUTION
GAS TURBINE MUST BE SHUT
DOWN AND THE EXHAUST DUCT OBSERVE MAINTENANCE PRAC-
TEMPERATURE MUST BE AT AN TICES OF PARAGRAPH 5-5.4.
ACCEPTABLE WORKING LEVEL
(BELOW 120°F) (49°C). IF NOTE
EXHAUST PARTS ARE HOT,
Inspect per table 5-12. If discrepant,
ALLOW THEM TO COOL BEFORE
replace part. Excessive wear of vari-
INSPECTION. STATION A SAFETY
able stator system hardware can lead to
OBSERVER ADJACENT TO THE
breakage and/or subsequent engine
EXHAUST DUCT ACCESS. MAKE
stall. Many of the replaced parts can
SURE THAT GAS TURBINE CAN-
be repaired for reuse. Consult GE for
NOT BE STARTED DURING
disposition of replaced parts.
INSPECTION.
CAUTION a. Inspect the variable stator system com-

ponents for evidence of oil leakage, security,
TO ENSURE THAT NO LOOSE damage, or wear. Refer to table 5-12.
OBJECTS ARE LEFT IN THE
EXHAUST, EMPTY POCKETS b. Inspect feedback cable brackets for
BEFORE ENTERING. cracks or other damage.
a. If possible, enter the exhaust duct with
c. For semi-annual maintenance inspec-
a portable light and inspect the duct area for
tion, check variable vane schedule using
loose parts. If any are found, immediately
1C6977 vane position indicator per
investigate to determine the source and take
Volume II, WP 118 00.
corrective action.
b. Inspect the turbine rear frame, power d. Correct discrepancies as necessary.

turbine blades and vanes, exhaust duct, outer
cone, and inner deflector for cracks, security,
metal deposits, and damage. Log all
discrepancies.
c. Correct discrepancies as necessary.

5-78
GEK 97310
VOLUME I
Figure 5-26. Variable Stator System

5-79
GEK 97310
VOLUME I
Figure 5-27. Compressor Variable Stator Vanes

5-80
GEK 97310
VOLUME I
1. Self Locking Nut (1 ea) 29. Glass Bushing, Stg-5 (58 ea)
3. Vane Arm, Stg-IGV (4 ea) 31. Flanged Bushing, Stg-IGV (34 ea)
14. Vane Arm, Stg-6 (56 ea) 42. Connecting Link, Stg-IGV (2 ea)
15. Vane Arm, Stg-6 (8 ea) 43. Connecting Link, Stg-1 (2 ea)
16. Alignment Sleeve, Stg-IGV thru 2 44. Connecting Link, Stg-2 (2 ea)
21. Spacer, Stg-IGV (34 ea) 49. Act. Arm Sleeve, Stg-IGV (30 ea)
22. Spacer, Stg-1 (36 ea) 50. Act. Arm Sleeve, Stg-1 (32 ea)
23. Spacer, Stg-2 (40 ea) 51. Act. Arm Sleeve, Stg-2 (36 ea)
24. Washer, Stg- IGV (34 ea) 52. Act. Arm Sleeve, Stg-3 (42 ea)
25. Washer, Stg-1 (36 ea) 53. Act. Arm Sleeve, Stg 4 (46 ea)
26. Washer, Stg-2 (40 ea) 54. Act. Arm Sleeve, Stg-5 (50 ea)
27. Glass Bushing, Stg-3 (46 ea) 55. Act. Arm Sleeve, Stg-6 (56 ea)
28. Glass Bushing, Stg-4 (50 ea) 56. Ring Segment, Stg-IGV (2 ea)
Legend for Figure 5-28 (Sheet 1 of 2)

5-81
GEK 97310
VOLUME I
57. Ring Segment, Stg-1 (2 ea) 80. Bushing, Stg-1 (36 ea)
58. Ring Segment, Stg-2 (2 ea) 81. Bushing, Stg-2 (40 ea)
63. Vane, Stg-IGV (34 ea) 86. Alignment Sleeve, Stg-5 (8 ea)
64. Vane, Stg-1 (36 ea) 87. Alignment Sleeve, Stg-6 (8 ea)
70. Vane Shroud, Stg-IGV (2 ea) 93. Vane Dovetail Liner (4 ea Stage)
71. Vane Shroud, Stg-1 (2 ea) 94. Vane Dovetail Liner (4 ea Stage)
72. Vane Shroud, Stg-2 (2 ea) 95. Act. Arm Sleeve (36 ea)
73. Shear Bolt, Stg-IGV (12 ea) 96. Machine Bolt (56 ea)
74. Shear Bolt, Stg-1 (14 ea) 97. Flat Washer (56 ea)
75. Shear Bolt, Stg-2 (14 ea) 98. Straight Pin (28 ea)
76. Self Locking Nut, Stg-IGV (12 ea) 99. Safety Wire (AR)
77. Self Locking Nut, Stg-1 (14 ea) 100. Act. Ring Spacer (56 ea)
78. Self Locking Nut, Stg-2 (14 ea) 101. Self Locking Nut (56 ea)
79. Bushing, Stg-IGV (34 ea) 102. Flat Washer (56 ea)
Legend for Figure 5-28 (Sheet 2 of 2)

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GEK 97310
VOLUME I

(Sheet 1 of 5)
5-83
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VOLUME I

(Sheet 2 of 5)

5-84
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VOLUME I

(Sheet 3 of 5)
5-85
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VOLUME I

(Sheet 4 of 5)

5-86
GEK 97310
VOLUME I

(Sheet 5 of 5)
5-87
GEK 97310
VOLUME I
Figure 5-29. Variable Stator Vane Actuating Mechanism (Sheet 1 of 2)

5-88
GEK 97310
VOLUME I
Figure 5-29. Variable Stator Vane Actuating Mechanism (Sheet 2 of 2)

5-89
GEK 97310
VOLUME I
Figure 5-30. Vane Actuation Ring Segment Inspection Areas

5-90
GEK 97310
VOLUME I
Figure 5-31. Variable Stator Vane Lever Arm Inspection

5-91
GEK 97310
VOLUME I
Figure 5-32. Actuation Ring Spacer Nut Stabilized with RTV
Figure 5-33. Actuation Ring Spacer Clearance

5-92
GEK 97310
VOLUME I
e. Inspect and, if necessary, adjust actua- (2) Using feeler stock, measure
tor ring spacers (8 per stage) for IGV’s and Dimension M (detail A, figure 5-27). Use an
stages 1 through 6 for correct clearance as fol- Allen wrench to adjust the clearance.
lows (refer to table 5-12):
(3) When the proper clearance has
NOTE been obtained, hold the spacer with the Allen
When adjusting for dimension M wrench and torque the jamnut to 70-90 lb in.
(detail A, figure 5-54), vane angle may (7.9-10.2 N·m).
be at any setting other than full open or
full closed. (4) Repeat steps (1) through (3), as
required, for the remaining spacers in all
(1) Loosen jamnut securing actuation stages to ensure correct clearance.
ring spacer to actuation ring segment.
Table 5-12. COMPRESSOR STATOR CASE AND VARIABLE VANE

COMPONENTS
On-Site On-Site
COMPRESSOR FRONT CASE
NOTE
Hot spots and bulges indicate internal damage in that area. Assess condition by borescope
inspection.
1. Casing for:
a. Cracks (except in Not serviceable Replace casing per
flange bolt holes) WP 207 00/SWP 207 01 *
b. Cracks emanating Not serviceable Replace casing per
from horizontal WP 207 00/SWP 207 01 *
and vertical flange
boltholes
c. Grooves worn by Any number Replace casing per
actuation ring 0.015 inch WP 207 00/SWP 207 01 *
spacers (0.38 mm) deep after
removal of high metal
d. Hot spots Serviceable if metal is Replace casing per
(discoloration) not granular and cracks WP 207 00/SWP 207 01 *
are not present

5-93
GEK 97310
VOLUME I

COMPONENTS - Continued
On-Site On-Site
e. Bulges Not serviceable when Replace casing per
associated with heat WP 207 00/SWP 207 01 *
discoloration
f. Nicks, gouges and scratches in:
(1) Casing skin One per each 4 square Replace casing per
and inch (26 cm²) area WP 207 00/SWP 207 01 *
manifolds 0.015 inch (0.38 mm)
deep, 1.00 inch
(25.4 mm) long after
removal of high metal,
provided no sharp areas
appear
(2) Flanges and Any number Replace casing per
ribs 0.063 inch (1.60 mm) WP 207 00/SWP 207 01 *
deep, 0.50 inch
(12.7 mm) long with a
min separation of
2.00 inches (51 mm)
metal
COMPRESSOR REAR CASE
NOTE
Hot spots and bulges indicate internal damage in that area. Assess condition by borescope
inspection.
1. Casing for:
a. Cracks
(1) Casing skin Not serviceable. Replace casing per
and WP 207 00/SWP 207 01 *
manifolds

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GEK 97310
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On-Site On-Site
(2) Casings ribs One crack 0.25 inch Replace casing per
(6.4 mm) long, and two WP 207 00/SWP 207 01 *
weld cracks 0.065 inch
(1.60 mm) long per rib
in weld or heat affected
zone that will not allow
air leakage and does not
extend into casing skin
(3) Cracks ema- Not serviceable Replace casing per
nating from WP 207 00/SWP 207 01 *
horizontal
and vertical
flange
boltholes
b. Hot spots Serviceable if metal is Replace casing per
(discoloration) not granular and cracks WP 207 00/SWP 207 01 *
are not present
c. Bulges Not serviceable when Replace casing per
associated with heat WP 207 00/SWP 207 01 *
discoloration
d. Grooves worn by Any number 0.015 inch Replace casing per
actuation ring (0.38 mm) deep after WP 207 00/SWP 207 01 *
spacers removal of high metal
e. Nicks, dents, scratches, and gouges in:
(1) Casing skin Any number Replace casing per
0.015 inch (0.40 mm) WP 207 00/SWP 207 01 *
deep, 0.50 inch
(12.7 mm) long after

5-95
GEK 97310
VOLUME I

On-Site On-Site
VARIABLE VANE SYSTEM (see figures 5-26 through 5-33)
NOTE
All inspections are visual unless specified otherwise.
1. Vane Locknut (1, figure 5-28) for:
a. Thread damage Not serviceable Not repairable Replace nut
b. Loss of self- 5-40 lb in. Not repairable Replace nut
locking feature (0.56-4.5 N·m) free
running torque
c. Looseness Nut must be tight with Any amount Replace nut if run-on
at least three vane stud torque is less than 5 lb in.
threads showing as (0.6 N·m). If more than
determined visually 5 lb in. (0.6 N·m), retorque
nut to 70-80 lb in.
(7.9-9 N·m), except on
stages 5 and 6 straight lever
arms which are retorqued
to 90-100 lb in.
(10.2-11.3 N·m). If lock
nut is missing, see
Off-Schedule Variable
Vane Inspection per
paragraph 5-3.17
d. Missing dry film Not serviceable Any amount Replace lubricant
lubricant
2. Sleeve (see figure 5-28) for:
a. Cracks Not serviceable Not repairable Replace sleeve per
SWP 207 02

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On-Site On-Site
3. Vane Lever Arm (see figures 5-27 through 5-33):
a. Security Lever arm must be in Any amount if Replace nut and tighten per
place and secure the nut is in SWP 207 02. If nut was
place and lever not in place, see Off-Sched-
arm is engaged ule Variable Vane Inspec-
in vane trunnion tion per paragraph 5-3.17
b. Distortion, bend- Any amount less than Not repairable See Off-Schedule Variable
ing or pin hole 2 degrees. Measure per Vane Inspection per
elongation paragraph 5-3.17 Off- paragraph 5-3.17
Schedule Vane Opera-
tion. Use 2C6962 gauge
on lever arms at hori-
zontal flange, and
2C6966 gauge on all
other lever arms.
c. Cracks Not serviceable Not repairable Replace lever arm per
SWP 207 02
d. Bent, distorted or Not serviceable if more Not repairable Replace lever arm per
misaligned (use than ± 2 degrees SWP 207 02
2C6962 gage set
on lever arms at
horizontal flange.
Use 2C6966 gage
set on all other
arms.)
4. Spacer (21, 22 or 23, figure 5-28) for:
a. Cracks Not serviceable Not repairable Replace spacer per
SWP 207 02
5. Flanged Bushing (31, 32 or 33, figure 5-28) for:
a. Wear Shake the vane while Not repairable Replace bushing per
holding the nut and lis- SWP 207 02
ten for metal to metal
contact

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On-Site On-Site
6. Actuation Ring Segment (56 through 62, figure 5-28) for:
a. Nut loose in actu- Not serviceable One spacer per actuation
ation ring ring segment may be
backed off until the spacer
head is against the ring -
and locked in that position
to prevent further wear of
actuation ring. RTV 106
(Red) (General Electric
Co.) may be applied
around the loose nut to sta-
bilize it in the ring.
See figure 5-33.
b. Cracks in side Any number 0.40 inch
walls, adjacent to (10.2 mm) max. in
nuts either direction circum-
ferentially from nut
centerline
c. Cracks in both ID Two per end, from first
and OD wall, nut to end of ring pro-
between nut and vided nut is tight and
end of ring will not rotate
d. All other cracks Not serviceable Not repairable Replace segment
e. Broken Not serviceable Not repairable See Off-Schedule Variable
Vane Inspection per
paragraph 5-3.17
f. Pin hole Any amount of lever Not repairable See Off-Schedule Variable
elongation arm movement less Vane Inspection per
than two degrees. paragraph 5-3.17
Measure per
paragraph 5-3.17,
Off Schedule Vane
Operation.

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On-Site On-Site
g. Wear of hole at Relative movement Not repairable Replace ring segment per
actuation ring between the insert and SWP 207 02*
spacer threaded the ring segment should
insert (see detail not exceed 0.005 inch
B, figure 5-30) (0.13 mm). Use wire
gage.
h. Wear of hole at Relative movement Not repairable Replace ring segment per
metal bushing between the insert and SWP 207 02*
insert the segment should not
exceed 0.005 inch
(0.13 mm). Use wire
gage.
i. Distortion (bent or Not serviceable Not repairable Replace ring segment per
twisted) SWP 207 02
j. Nicks and dents Any amount 0.015 inch Not repairable Replace ring segment per
(0.38 mm) deep, six per SWP 207 02
segment or 0.030 inch
(0.76 mm) deep with a
minimum separation of
2.00 inches (50.8 mm)

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GEK 97310
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On-Site On-Site
7. Actuation Ring Spacers (92, figure 5-28) for:
a. Loose or out of Not serviceable Any amount See figure 5-28. Adjust to
adjustment (Dim. obtain case to spacer clear-
M, figure 5-34). ance.
Visually inspect IGV 0.002-0.004 in.
on compressor (0.05-0.10 mm)
case OD Stg 1 0.002-0.004 in.
(0.05-0.10 mm)
Stg 2 0.002-0.004 in.
(0.05-0.10 mm)
Stg 3 0.002-0.004 in.
(0.05-0.10 mm)
Stg 4 0.005-0.007 inch
(0.13-0.18 mm)
Stg 5 0.010-0.012 inch
(0.25-0.30 mm)
Stg 6 0.014-0.016 inch
(0.36-0.40 mm)
Torque 70-90 lb in.
(7.9-9.0 N·m))
8. Connecting Link (42 through 48, figure 5-28) for:
a. Cracks Not serviceable Not repairable Replace link per
SWP 207 02*
b. Pin hole wear Any amount of lever Not repairable Replace link per
arm movement less SWP 207 02*
than two degrees.
Measure per
paragraph 5-3.17,
Off Schedule Vane
Operation.
c. Wear at rod bear- The fit between the Not repairable Replace link per
ing mounting hole hole and bolt (28) SWP 207 02*
should not exceed
0.004 inch (0.10 mm)
on diameter

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On-Site On-Site
d. Wear at the locat- A 0.010 inch Not repairable Replace link per
ing pin (0.25 mm) diameter SWP 207 02*
wire gage should not
pass through the hole
when the pin is in place
e. Loose bolts Not serviceable Not repairable Tighten or replace bolt or
replace actuation ring per
SWP 207 01 if female
thread is stripped
f. Broken Not serviceable Not repairable See Off-Schedule Variable
Vane Inspection per
paragraph 5-3.17
g. Nicks, dents, Any number 0.005 inch Not repairable Replace link per
scratches in ribs (0.13 mm) deep SWP 207 02*
and rod end bear-
ing mounting ears
NOTE
The position of the pushrod clevis assembly may preclude visually inspecting certain con-
necting link lever arm pin journals for wear. Using a bright light and a small inspection
mirror (such as a dental mirror), visually inspect the connecting links where the vane arm
pin engages the connecting link pin bushing for evidence of wear. Attempt to move each
vane arm by hand to verify any indications of excessive wear. Using the above inspection
method, check pin bushings (table 5-12, item 10) for serviceability.

5-101
GEK 97310
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On-Site On-Site
9. Vane Assembly for:
a. Looseness Radial looseness: Any Remove case and replace
amount of radial move- bushings if metal-to-metal
ment provided bushings contact is noted
or washer are not miss-
ing. No metal-to metal
contact allowed See Off-Schedule Variable
Side looseness: Any Vane Inspection per
amount of side loose- paragraph 5-3.17
ness 2 degrees or less.
Measure per
paragraph 5-3.17,
Off-Schedule Vane
Operation
b. Bent lever arms Any number, bent two See Off-Schedule Variable
degrees or less. Mea- Vane Inspection per
sure per paragraph 5-3.17
paragraph 5-3.17,
Off Schedule Vane
Operation
c. Misassembled Not serviceable See Off-Schedule Variable
lever arms Vane Inspection per
paragraph 5-3.17
10. Pin Bushing (49 through 55, figure 5-28) for:
a. Loose, missing or Not serviceable Not repairable Replace pin bushing per
torn SWP 207 02
11. Rod End Bearings at Clevis Assembly (15, figure 5-29), for:
a. Spherical bearing
(1) Cracks Not serviceable Not repairable Replace rod end bearing
per WP 101 00
(2) Freedom of Maximum torque Not repairable Replace rod end bearing
movement 10 lb in. (1.1 N·m) per WP 101 00

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On-Site On-Site
(3) Looseness 0.005 inch (0.13 mm) Not repairable Replace rod end bearing
(wear) of the radial and 0.015 inch per WP 101 00
bearing (0.38 mm) axial
surface
(4) Looseness of Not serviceable Not repairable Replace rod end bearing
bearing race per WP 101 00
OD
b. Slot loaded bearing introduced as replacement item for spherical bearing.
See figure 5-29, Detail D.
(1) Cracks Not serviceable Not repairable Replace slot loaded bearing
per WP 206 00
(2) Freedom of Must rotate Not repairable Replace ball or the rod end
movement bearing per WP 206 00
(3) Looseness 0.005 inch Not repairable Replace ball per
(wear) of the (0.13 mm) radial and WP 206 00
bearing 0.015 inch (0.38 mm)
surface axial
(4) Looseness of Not serviceable Not repairable Replace with oversize bear-
bearing race ing per WP 206 00
OD
12. Pushrod Assembly (7 and 12, figure 5-29) for:
a. Missing, broken Not serviceable Any amount Replace safety wire
or loose safety
wire
b. Interference of the Not serviceable Any amount Adjust safety wire to pro-
safety wire vide clearance. Do not
between the clevis break the wire
and the actuation
lever
c. Loose lock nut Not serviceable Any amount Tighten the nut and adjust
or replace safety wire

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VOLUME I

On-Site On-Site
13. Clevis (12, figure 5-29) for:
a. Cracks Not serviceable Not repairable Replace clevis per
WP 206 00
b. Bending Not serviceable Not repairable Replace clevis per
WP 206 00
c. Nicks or dents 0.030 inch (0.76 mm) Not repairable Replace clevis per
deep WP 206 00
d. Wear (pushrod) Not serviceable Not repairable Replace clevis per
mounting hole) WP 206 00
e. Wear at bolthole Fit between bolt and Not repairable Replace clevis per
hole in clevis should WP 206 00
not exceed 0.004 inch
(0.10 mm) on diameter
14. Push Rod (7, figure 5-29) for:
a. Cracks, bent or Not serviceable Not repairable Replace push rod per
thread damage WP 206 00
15. Bolts at Bracket/Actuator (6, figure 5-29), Line up Pin (90, figure 5-28, Connector Link
(13, figure 5-27), Bellcrank (11, figure 5-29) and Clevis (10, figure 5-29) for:
a. Wear Clearance between the Not repairable Replace the bolt or the mat-
bolt and the mating ing hardware per
bushing or hole should WP 206 00
not exceed 0.004 inch
(0.10 mm) maximum
on diameter
b. Looseness Not serviceable Any amount Tighten the bolts to the
required torque value per
WP 206 00
16. Actuation Lever Mount (13, figure 5-29) for:
a. Cracks Not serviceable Not repairable Replace mount per
WP 206 00
b. Bent stud Not serviceable Not repairable Replace mount per
WP 206 00

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On-Site On-Site
c. Wear at journal 0.498 inch (12.65 mm) Not repairable Replace mount per
diameter minimum diameter WP 206 00
d. Groove at mating Not serviceable Maximum depth Replace spacer per
surface with of groove WP 206 00
spacer 0.005 inch
(1, figure 5-29) (0.13 mm)
17. Spacer (1, figure 5-29) for:
a. Wear on thickness Maximum wear depth Not repairable Replace spacer per
of 0.010 inch WP 206 00
(0.25 mm)
b. Wear at ID Maximum diameter of Not repairable Replace spacer per
0.645 inch (16.38 mm) WP 206 00
c. Wear at lip Not serviceable Not repairable Replace spacer per
WP 206 00
18. Vane Actuation Lever (9, figure 5-29) for:
a. Loose attaching Not serviceable Any amount Retorque nut
aft end nut
b. Cracks Not serviceable Not repairable Replace lever per
WP 206 00
c. Nicks, dents or Any number 0.005 inch Not repairable Replace lever per
scratches (0.13 mm) deep WP 206 00
d. Wear at front 0.431 inch (10.95 mm) Not repairable Replace lever per
trunnion minimum OD WP 206 00
19. Bearings (Detail D, figure 5-29) and Actuator Bracket Bearings (5, figure 5-29) for:
a. Self aligning bearings
(1) Cracks Not serviceable Not repairable Replace next higher
assembly*
(2) Freedom of Maximum torque Not repairable Replace next higher
movement 10 lb in. (1.1 N·m) assembly*

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On-Site On-Site
(3) Looseness or 0.005 inch (0.13 mm) Not repairable Replace next higher
wear of bear- radial, 0.015 inch assembly*
ing surface (0.38 mm) axial
(4) Looseness of Not serviceable Not repairable Replace next higher
bearing OD assembly*
with mating
hole
b. Slot loaded bearings (introduced as replacement item for spherical bearing, Detail D,
figure 5-29)
(1) Cracks Not serviceable Not repairable Replace next higher
assembly*
(2) Freedom of Ball should move by Not repairable Replace ball
movement finger force
(3) Looseness or 0.005 inch (0.13 mm) Not repairable Replace ball
wear of bear- radial, 0.015 inch
ing surface (0.38 mm) axial
(4) Looseness of Not serviceable Not repairable Replace next higher
bearing OD assembly WP 206 00*
with mating
hole
20. Actuation Lever Guide (4, figure 5-29) for:
a. Cracks or Not serviceable Not repairable Replace guide
chipping
b. Wear 0.620 inch (15.76 mm) Not repairable Replace guide
minimum dimension
between the wear
surfaces

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On-Site On-Site
21. Actuator (3, figure 5-29) for:
a. External leakage Not serviceable Any amount cor- Refer to Volume II,
at tube fittings rectable by WP 100 00 and replace
replacing O-rings or replace actuator
attaching fit-
ting, O-rings or
retorquing of
fittings
b. Leakage at rod or 2 cc/min each actuator. Not repairable Replace actuator per
overboard drain (This limit is for trouble WP 100 00*
shooting, not routine
inspection)
c. Loose safety wire Not serviceable Not repairable Replace safety wire
d. Wear of the metal Maximum axial dimen- Not repairable Replace actuator per
bushing at the sion between bushing WP 100 00*
mounting ears flanges shall be
0.430 inch (10.92 mm)
22. Actuator Guide Bracket (5, figure 5-29) for:
a. Cracks Not serviceable Not repairable Replace bracket per
WP 100 00*
b. Looseness Not serviceable Any amount Retorque mounting bolts
c. Distortion (bent) Not serviceable Not repairable Replace actuator per
WP 100 00*
23. Feedback Bellcrank (11, figure 5-29) for:
a. Binding or fret- Not serviceable Not repairable Replace bracket per
ting with bracket WP 206 00*
b. Bushing wear Clearance between the Not repairable Replace bracket per
bushing and the mating WP 206 00*
bolt should not exceed
0.004 inch (0.10 mm)
maximum on diameter

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On-Site On-Site
c. Cracks Not serviceable Not repairable Replace bellcrank per
WP 206 00
d. Distortion (bent) Not serviceable Not repairable Replace bellcrank per
WP 206 00*
24. Speed Sensor to Servo Valve Link Rod End Bearings (see figure 5-26) for:
a. Looseness of 0.005 inch (0.13 mm) Not repairable Replace rod end bearing
bearing surface radial, 0.015 inch
(0.38 mm) axial
b. Cracks Not serviceable Not repairable Replace rod end bearing
c. Freedom of Maximum torque Not repairable Replace rod end bearing
movement 10 lb in. (1.1 N·m)
d. Looseness of Not serviceable Not repairable Replace rod end bearing
bearing race OD
25. Feedback Cable Assembly, (19, figure 5-29) for:
a. Missing safety Not serviceable Any amount Install safety wire
wire at rod end
bearings
b. Broken helix wire Not serviceable Not repairable Replace feedback cable per
on cable conduit WP 101 00
c. Excessive inter- 5 lbs maximum to Not repairable Replace feedback cable per
nal friction move inner cable over WP 101 00
full stroke
d. Visible kinks or Not serviceable Not repairable Replace feedback cable per
sharp bends in WP 101 00
conduit or sup-
port tubes

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VOLUME I
5-3.17 Variable Stator Vane Off-Schedule b. Inspect each stage for an off-schedule
Operation. vane condition using sight gages 2C6962G03
and 2C6966G05. See figure 5-31.
a. Missing lock nuts, or misassembled,
bent, or broken lever arms, connecting links, c. If an off-schedule condition is found,
or actuation rings can cause an off-schedule the degree of off-schedule determines the cor-
vane condition during engine operation. Spe- rective action required as listed below.
cial inspection is required.
Degree Off-Schedule
or Corrective Action
Condition
1. 2 degrees or less off-schedule No corrective action required

2. More than 2 degrees but not more Replace defective parts
than 4 degrees off-schedule
3. More than 4 degrees off-sched- VSV stage IGV:

ule, missing lock nut, or broken Replace defective parts and two down-stream stages of
actuation ring, connecting link or HPC rotor blades
lever arm
VSV stage 1:
Replace defective parts and one up-stream and two down-
stream stages of HPC rotor blades
VSV stage 2 through 6:
Replace defective parts and one up-stream and one down-
stream stages of HPC rotor blades

5-109
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VOLUME I
5-3.18 Lube And Scavenge Pump Inlet (4) If the suspect material is found in
Screens Inspection And Cleaning. Gas Gen- the A screen, the source must be further identi-
erator/Gas Turbine Models (Except GA101) fied. Inspect the inlet gearbox/A sump area for
See figure 5-34. any distress.
a. Shut off lube oil supply to engine. (5) If the suspect material is identified
as bolt or rivet fragments, replace component
b. Place a container under lube and scav- as indicated by screen identity.
enge pump. Remove the six inlet screens, one
at a time and identify the screen location. (6) If the suspect material is identified
Remove and discard O-rings from screens. as pieces of O-ring, gasket, safetywire, coke,
machining chip, or seal rub strip material,
c. Visually inspect screens for foreign place the engine on watch, e.g., check and
material and damage. If foreign material is clean scavenge pump screens daily and moni-
found, analyze as follows, and perform correc- tor lube system parameters until problem is
tive action. If any screens are damaged, located or screens are clean for two successive
replace them. days, then resume normal inspection intervals.
(1) Isolate source of foreign material d. Clean screens with solvent

by identifying screen as A, B, C, (D, Gas Tur- (P-D-680, Type II, or equivalent) and a soft
bine Models) or AGB (i.e., oil sump location). bristle brush. Dry with shop air at 40 psig
(276 kPa) maximum pressure.
(2) Visually examine suspect material
removed from screens for identification of e. Lubricate new O-rings, with engine
source. If the material can be visually identi- lube oil and install them on the screens.
fied as bearing materials, such as roller, ball
and/or race fragments, component replacement f. Install the screens in the same locations
is the required corrective action. Bearing from which they were removed, tighten to
races, rollers and balls are magnetic, therefore, 55-70 lb in. (6.2-7.9 N·m) of torque and
separating out any magnetic materials will safetywire.
help identification. A and C sump bearings
may be replaced on-site. Other main bearings g. Turn on lube oil supply to the engine.
may be replaced at a level 3 shop. Main GA101 Models Only. See figure 5-34,
engine bearing failures require replacement of sheets 2 and 3.
the gas generator or power turbine or both.
Inlet and transfer gearboxes can be replaced h. Shut off lube oil supply to gas
individually. generator.
(3) Main engine bearing distress usu-

ally also increases lube scavenge temperatures
and engine vibration, therefore, engine log
sheets should be reviewed for significant
changes in engine logged parameters.

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GEK 97310
VOLUME I
Figure 5-34. Lube and Scavenge Pump Inlet Screens (All Models Except GA101)
(Sheet 1 of 3)

5-111
GEK 97310
VOLUME I
Figure 5-34. Lube and Scavenge Pump Screen Cleaning (GA101 Models)
(Sheet 2 of 3)

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GEK 97310
VOLUME I
Figure 5-34. Lube and Scavenge Pump Filters (GA101 Models)

(Sheet 3 of 3)
i. Lube and Scavenge Pump Screen WARNING

Cleaning. Clean filter screens as follows:
ADEQUATE VENTILATION SHALL
NOTE BE PROVIDED IN THE WORK
AREA AS SOLVENT FUMES ARE
Accessories, screens, tubes, and hoses TOXIC. PROLONGED INHALA-
may have oil in them at time of TION OF THE FUMES IS TO BE
removal. Drain the fluids, from acces- AVOIDED.
sory being removed, into a suitable
container. NOTE
(1) Remove the lube inlet and the two Ultrasonic cleaning of screen is pre-
scavenge inlet screens. ferred if the equipment is available.
(2) Remove O-rings from screens; (3) Clean screens. Scrub the screens
discard O-rings. and bowl, using a soft-bristle brush dipped in
cleaning solvent (P-D-680, Type II, or equiva-
lent), or in a solution of one part soluble soap
to three parts water. If soap solution is used,
rinse the screen in clean water prior to drying.

5-113
GEK 97310
VOLUME I
(4) Lubricate the O-rings using WARNING

engine oil and install on screens.
• LUBRICATING OIL,
(5) Install screens, torque and MIL-L-23699 OR MIL-L-7808, IS
lockwire. TOXIC TO SKIN, EYES, AND
RESPIRATORY TRACT. SKIN
j. Forward Scavenge Pump Filter Clean- AND EYE PROTECTION IS
ing. Clean scavenge oil screen as follows: REQUIRED. AVOID REPEATED
OR PROLONGED CONTACT.
(1) Remove the three screens and USE IN A WELL-VENTILATED
O-rings. Discard O-rings. AREA.
• LIQUID IS HOT AND CAN

WARNING CAUSE SEVERE BURNS. SKIN
ADEQUATE VENTILATION SHALL AND EYE PROTECTION IS
BE PROVIDED IN THE WORK REQUIRED TO PREVENT
AREA AS SOLVENT FUMES ARE INJURY FROM SPLASH
TOXIC. PROLONGED INHALA- BURNS.
TION OF THE FUMES IS TO BE
AVOIDED. (1) Place approved waste container
under lube and scavenge pump to catch resid-
NOTE ual oil.
Ultrasonic cleaning of screens is pre-
ferred if the equipment is available. (2) Tag screen with location.
(2) Clean Screens. Scrub the filter WARNING

screens and bowl using a soft-bristle brush
ELECTRICAL POWER SHALL BE
dipped in cleaning solvent (P-D-680) or in a
OFF BEFORE CONNECTING OR
solution of one part soluble soap to three parts DISCONNECTING ELECTRICAL
water. If soap solution is used, rinse the filter CONNECTORS. ELECTRICITY
screen in clean water prior to drying. CAUSES SHOCK, BURNS, AND
DEATH.
(3) Lubricate new O-rings using
engine oil and install on screens. (3) Tag electronic chip detector elec-
trical connector with location. Remove electri-
(4) Install screens, tighten and lock- cal connector per packager’s instructions.
wire each filter.
(4) Remove safety wire from screen
5-3.18A Lube and Scavenge Pump Screen and electronic chip detector.
and Electronic Chip Detector Inspection
and Cleaning. (5) Loosen and remove screen. Allow
residual oil to flow into approved waste con-
a. Inspect lube and scavenge pump inlet tainer. Remove and discard preformed
screen (figure 5-34A or 5-34B) as follows: packing.

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GEK 97310
VOLUME I
Figure 5-34A. Five Element Lube and Scavenge Pump Screens
Figure 5-34B. Six Element Lube and Scavenge Pump Screens

5-115
GEK 97310
VOLUME I
(6) Remove electronic chip detector NOTE

from screen. The electronic chip detectors Electronic chip detectors are located in
thread into the screen assembly cap. Remove all sump scavenge screens.
and discard preformed packing.
(b) Remove electronic chip
(7) Inspect screen and electronic chip detector from screen. Visually inspect elec-
detector for foreign material as follows: tronic chip detector tip (figure 5-34C) for for-
eign material.
NOTE
• Bearing races, balls, and rollers are (c) If material found is identified
ferrous. The use of a magnet will as pieces of preformed packing, gasket, safety
help determine if these materials are wire, coke, machining chip, and/or rub strip
present on screen. material, place engine on watch as follows:
1 Inspect and clean lube
• Main engine bearing distress is associ- and scavenge pump screens and monitor lube
ated with increased lube scavenge tem- system parameters daily until source of con-
peratures and engine vibration. If tamination is located.
foreign material is found, review engine
log for significant changes in engine 2 Engine can be removed
operating temperature or vibration read- from watch status and returned to normal
ings. inspection schedule if screens are free of
debris for two consecutive days.
(a) If any material is found, note
screen location to further isolate probable (8) If materials are found, refer to
source of material. table 5-12A for disposition.

5-116
GEK 97310
VOLUME I
Figure 5-34C. Electronic Chip Detector Tip Buildup
Table 5-12A. POSSIBLE CAUSES OF FOREIGN MATERIAL
Screen Possible Cause

Accessory a. AGB failure
Gearbox b. Starter failure
(AGB)
Lube Inlet Packager oil supply system

A-sump No. 3R bearing failure, Inlet Gearbox (IGB),
Transfer Gearbox (TGB)
B-sump No. 4R and/or No. 4B bearing failure
C-sump a. No. 5R bearing failure
b. No. 6R bearing failure
D-sump No. 7R and/or No. 7B bearing failure

5-117
GEK 97310
VOLUME I
(9) Clean screen and electronic chip (b) Using multimeter, check for
detector as follows: continuity between electrical connector pins.
Resistance shall not be less than 10 kiloohms
when clean.
WARNING
ALCOHOL IS FLAMMABLE AND (c) If electronic chip detector
TOXIC TO SKIN, EYES, AND RES- does not meet parameters of substep (a) or (b),
PIRATORY TRACT. SKIN AND replace electronic chip detector.
EYE PROTECTION IS REQUIRED.
AVOID REPEATED OR PRO-
LONGED CONTACT. USE IN A WARNING
WELL-VENTILATED AREA. LUBRICATING OIL, MIL-L-23699
OR MIL-L-7808, IS TOXIC TO SKIN,
(a) Using isopropyl alcohol and EYES, AND RESPIRATORY
soft bristle brush, gently clean screen and elec- TRACT. SKIN AND EYE PROTEC-
tronic chip detector tip. TION IS REQUIRED. AVOID
REPEATED OR PROLONGED CON-
TACT. USE IN A WELL-VENTI-
WARNING
LATED AREA.
WHEN USING COMPRESSED AIR
FOR CLEANING, COOLING, OR (11) Coat new preformed packings for
DRYING, DO NOT EXCEED screen and electronic chip detector with
30 PSIG. WEAR EYE PROTECTION lubricating oil.
AND DO NOT DIRECT COM-
PRESSED AIR AT SELF OR (12) Install preformed packing onto
OTHERS. screen.
(b) Using shop air, dry screen (13) Reinstall screen into lube and
and electronic chip detector. scavenge pump. Tighten screen to 55-70 lb in.
(6.3-7.9 N·m) of torque and safety-wire.
(c) Replace any screen that is Remove location tag.
damaged.
(14) Install preformed packing onto
(10) If electronic chip detector is sus- electronic chip detector.
pected of malfunctioning, check as follows:
(15) Reinstall electronic chip detector
(a) Using multimeter, check for into screen. The electronic chip detectors
continuity between electrical connector pins thread into the screen assembly cap. Tighten to
and electronic chip detector housing. There 480-570 lb in. (54.2-64.4 N·m) of torque and
shall be no continuity between pins and safety-wire.
housing.

5-118
GEK 97310
VOLUME I
5-3.19 Lube Oil Test.

WARNING
ELECTRICAL POWER SHALL BE
OFF BEFORE CONNECTING OR WARNING
DISCONNECTING ELECTRICAL • OBSERVE SAFETY PRECAU-
CONNECTORS. ELECTRICITY TION OF CHAPTER 1.
CAUSES SHOCK, BURNS, AND
DEATH. • AVOID CONTACT WITH LUBE
OIL SINCE TEMPERATURES
(16) Reinstall electronic chip detector MAY REACH 325°F (163°C)
electrical connector per packager’s manual. AND SERIOUS BURNS MAY
Remove tag. RESULT.
b. Inspect both lube and scavenge pump CAUTION

accessory gearbox (AGB) screens and
electronic chip detector per steps a.(1) OBSERVE MAINTENANCE PRAC-
through (16). TICES OF PARAGRAPH 5-5.4.
c. Inspect lube and scavenge pump a. While the engine is operating at idle,
A-sump screen and electronic chip detector per obtain an oil sample from the scavenge oil dis-
steps a.(1) through (16). charge lines using a clean container.
d. Inspect lube and scavenge pump b. Label the sample as follows:

B-sump screen and electronic chip detector per Location________________
steps a.(1) through (16). Engine S/N______________
Oil Type________________
e. Inspect lube and scavenge pump Date___________________
C-sump screen and electronic chip detector per Current Package
steps a.(1) through (16). Total Hours______________
NOTE
D-sump screen is located on six ele-
ment lube and scavenge pumps only.
f. Inspect lube and scavenge pump

D-sump screen and electronic chip detector per
steps a.(1) through (16).
g. Turn on lubricating oil supply flow to

lube and scavenge pump per packager’s
manual.
h. Motor engine for 2 minutes, to purge

lube system of air and check for leaks.

5-119
GEK 97310
VOLUME I
c. Send oil sample to the laboratory for

analysis. Test per the following:
Test for Procedure Limit
(1) Total Acid Test per ASTM D664-58 1.0 Mg kah/gm
Number (TAN)
(2) Viscosity Test per ASTM D445-65 Maximum change from new oil read-
(Kinematic) ing at 100°F (38°C); + 25%,-10%
(3) H2O -
(4) Oil Contamination Partial count 5% maximum
•Particle Size Limits
Range Count Limit (per 100 ml sample)
15-25µ 10,000
25-50µ 1,500
50-100µ 200
>100µ 20
•H2O Limit: 1,000
•TAN Limit 1.0 mg KOH/gm
•Viscosity Limit: -10% to +25% ref to new oil
(5) SDAP Analysis
Atomic Absorbtion Method
Element Normal On Watch Shutdown
Iron (Fe) 0-3 4-7 8+
Silver (Ag) 0-1 2-4 5+
Aluminum (Al) 0-1 2-4 5+
Chromium (Cr) 0-4 5-7 8+
Copper (Cu) 0-5 6-10 11+
Magnesium (Mg) 0-1 2-4 5+
Nickel (Ni) 0-3 4-6 7+
Silicon (Si) 0-20 21-36 37+
Titanium (Ti) 0-3 4-6 7+
Molybdenum (Mo) 0-3 4-6 7+
Lead (Pb) 0-3 4-6 7+
Tin (Sn) 0-15 16-22 23+

5-120
GEK 97310
VOLUME I
(5) SDAP Analysis (cont)

Atomic Emission Method
Element Normal On Watch Shutdown
Iron (Fe) 0-8 9-13 14+
Silver (Ag) 0-3 4-6 7+
Aluminum (Al) 0-3 4-6 7+
Chromium (Cr) 0-6 7-9 10+
Copper (Cu) 0-12 13-19 20+
Magnesium (Mg) 0-6 7-9 10+
Nickel (Ni) 0-5 6-8 9+
Silicon (Si) 0-25 26-64 65+
Titanium (Ti) 0-5 6-8 9+
Molybdenum (Mo) 0-5 6-8 9+
Lead (Pb) 0-2 3-4 5+
Tin (Sn) 0-20 21-39 40+
d. If limits are exceeded, completely e. Install nozzles per Volume II,

drain the lube supply system and fill with new WP 104 00, 104 01, 104 02, 104 03 or 104 04.
oil. Flushing will be required if contamination
is excessive. f. Perform leak check before operating
engine.
5-3.20 Fuel Nozzle Inspection.
5-3.21 Engine Exterior Inspection And
a. Remove fuel nozzles at the 6 and Cleaning.
12 o’clock positions per Volume II,
WP 104 00, 104 01, 104 02, 104 03 or 104 04. a. Inspect the exterior of the engine and
its components for excessive dirt buildup. Par-
b. Inspect the removed nozzles for burn- ticular attention should be given to the variable
ing and erosion, plugged orifices, and carbon stator vane system.
buildup. If these conditions are noted, remove
the remaining 28 nozzles for inspection. b. If cleaning is required, wash
engine exterior and its components with
c. Replace nozzles which are burned or 50 to 60 gallons of clean potable water using a
eroded. flexible garden type hose with an adjustable
spray nozzle. Maintain a water pressure of
d. Clean all nozzles which exhibit either 40-45 psi.
plugged orifices or excessive carbon buildup.

5-121
GEK 97310
VOLUME I
CAUTION c. Transfer Gearbox. Inspect the transfer

gearbox. Refer to table 5-15 for inspection
DO NOT USE TRICHLOROETH- limits.
ANE OR CHLORINATED HYDRO-
CARBON SOLVENTS ON d. Compressor Front Frame. Inspect the
TITANIUM OR TITANIUM ALLOY compressor front frame. Refer to table 5-16
PARTS. for inspection limits.
c. In extreme cases where water will not e. Compressor Stator and Variable Vane
remove the dirt, 1-1-1 trichloroethane solvent, Components. Inspect the compressor stator
or equivalent, should be applied and allowed case and variable vane components. Refer to
to soak for two hours minimum. Flush with table 5-12 for inspection limits.
clean, potable water. Start the engine and run
at idle speed for 5 minutes to dry excessive f. Compressor Rear Frame. Inspect the
water. compressor rear frame. Refer to table 5-17 for
inspection limits.
NOTE
• Refer to paragraph 1-2.2 for infor- g. Turbine Mid Frame. Inspect the tur-
mation concerning the safety precau- bine mid frame exterior. Refer to table 5-18
tions for handling and use of for inspection limits.
solvents.
h. Power Turbine Stator Case. Inspect the
• If portable steam cleaning equipment is power turbine stator case. Refer to table 5-19
available, steam cleaning may be used. for inspection limits.
5-3.22 Gas Turbine Gas Generator i. Turbine Rear Frame. Inspect the tur-
External Inspection. bine rear frame. Refer to table 5-20 for inspec-
tion limits.
a. Tubes, Hoses, and Cables. Inspect
engine tubes, hoses, tube/hose fittings, electri- j. Accessories. Check for security, dam-
cal cable assemblies, and electrical connectors. age, or leakage.
Refer to table 5-13 for inspection limits.
b. Inlet Duct and Centerbody. Inspect

engine inlet duct and centerbody. Refer to
table 5-14 for inspection limits.

5-122
GEK 97310
VOLUME I
Table 5-13. ENGINE TUBES, HOSES, TUBE/HOSE FITTINGS, ELECTRICAL CABLE

ASSEMBLIES AND ELECTRICAL CONNECTORS
On-Site On-Site
TUBE ASSEMBLIES (ALL ASSEMBLIES UNLESS OTHERWISE SPECIFIED)
1. Tubing for:
a. Cracks, splits Not serviceable Not repairable Replace assembly*
b. Wrinkles, 2% of tube OD Not repairable Replace assembly*
kinks in bend
ID
c. Dents, flat Any amount of devia- Not repairable Replace assembly*
areas tion from contour
within 20% of origi-
nal tube OD
d. Nicks, scores Limited service - Any Any amount to Blend to remove dam-
amount to 0.005 inch 0.010 inch age but not beyond
(0.127 mm) deep (0.254 mm) deep depth of damage. Con-
tour must be smooth
and polished
2. Fittings and Connectors for:
a. Leakage Not serviceable Light polishing of Polish sealing surface
entire sealing (mat- and retorque or replace
ing) surfaces to tube assembly
remove scratches is
allowed
b. Looseness Not serviceable Any amount Retorque. Refer to
paragraph 5-5.4
3. Liquid Fuel Manifold Shrouds for:
a. Leakage Not serviceable. Test
per Volume II,
WP 123 00,
123 01,
123 02,
123 03 or
123 04. No leakage
allowed.

5-123
GEK 97310
VOLUME I

ASSEMBLIES AND ELECTRICAL CONNECTORS - Continued
On-Site On-Site
4. Dual Fuel Gas/Water Manifolds for:
a. Manifold No cracks allowed Not serviceable Replace manifold with
integrity welded manifold
assembly
b. Attaching Inspect cushion Not serviceable Replace cushion
hardware clamps for inadequate clamps
clamping
HOSE ASSEMBLIES (ALL ASSEMBLIES UNLESS OTHERWISE SPECIFIED)
1. Hose for:
a. Broken braid Three wires per plait Not repairable Replace hose assembly
wires (a band of interwoven
wires) and no more
than six broken wires
per assembly
b. Crimps Not serviceable Not repairable Replace hose assembly
2. Fittings and Connectors for:
ELECTRICAL CABLE ASSEMBLIES (ALL ASSEMBLIES UNLESS OTHERWISE
SPECIFIED)
1. Cables for:
a. Broken braid 50% of exterior braid Not repairable Replace assembly*
wires may be broken
provided circuit con-
tinuity is maintained
b. Kinks/crimps Any amount provided Not repairable Replace assembly*
circuit continuity is
maintained. Insula-
tion resistance pin to
pin and pin to shell
shall be 1 megohm
minimum

5-124
GEK 97310
VOLUME I

On-Site On-Site
c. Security/ Supported at maxi- Any amount Re-clamp cable
installation mum of 12 inch
(305 mm) intervals.
No relative motion
between cable and
contacted hardware
2. Connectors for:
a. Pin, insert and (See ELECTRICAL
shell damage CONNECTORS, this
table.)
b. Back shell Not serviceable Not repairable Replace assembly*
potting sepa-
ration, tears,
cracks
c. Loose nut Not serviceable Any amount Tighten hand-tight
d. Seal Each connector joint Any amount Replace seal if dam-
must have seal aged or missing
installed
e. Braid/ 50% of wires must be Not repairable Replace assembly*
connector secure and circuit
separation continuity maintained
ELECTRICAL CONNECTORS
1. Pins for:
a. Distortion Must assemble to Any amount correct- Straighten pins or
mating connector able by straightening replace assembly
pins
b. Fracture Not serviceable Not repairable Replace assembly*
c. Corrosion No visible corrosion Not repairable Replace assembly*
permitted

5-125
GEK 97310
VOLUME I

On-Site On-Site
2. Insert for:
a. Cracks Any amount provided Not repairable Replace assembly*
continuity is main-
tained. Insulation
resistance pin to pin
and pin to shell shall
be one megohm
minimum
3. Shell for:
a. Distortion Must assemble to Not repairable Replace assembly*
mating connector and
seal
b. Cracks Not serviceable Not repairable Replace assembly*

5-126
GEK 97310
VOLUME I
Table 5-14. INLET DUCT AND CENTERBODY
On-Site On-Site
INLET DUCT (BELLMOUTH)

1. Assembly (Unless otherwise specified) for:
a. Cracks Not serviceable Replace inlet duct per
WP 212 00*
b. Nicks, scores Any number, any Blend to remove high
(except on length 0.031 inch metal
water inlet (0.78 mm) deep after
fitting) removal of high metal
c. Dents Any number smooth
dents 0.25 inch
(6.4 mm) deep except
on mating surfaces
d. Missing paint Any amount provided Any amount Touch up paint
no parent metal
exposed
e. Plugged water Not serviceable Any amount Remove contamina-
wash dis- tion using a small wire
charge holes or No. 57 [0.043 inch
(1 mm)] drill bit
f. Dirty airflow Serviceable. Wipe
path surfaces clean if inlet screen
has been removed for
other maintenance
actions
g. Loose Not serviceable Any amount Re-torque
installation
fasteners
h. Leakage at Not serviceable Any amount Re-torque
water inlet
connection

5-127
GEK 97310
VOLUME I
Table 5-14. INLET DUCT AND CENTERBODY - Continued
On-Site On-Site
CENTERBODY
1. Assembly for:
a. Cracks Not serviceable Not repairable Replace centerbody
per WP 211 00*
b. Nicks, Any number, any Any number, Blend to remove high
scratches and length 0.031 inch 0.063 inch (1.60 mm) metal
gouges (0.78 mm) deep, deep, 0.063 inch
0.031 inch (0.78 mm) (1.60 mm) wide and
wide with min sepa- 0.50 inch (12.7 mm)
ration of 1.00 inch long provided none
(25.4 mm) extend into bolt holes
c. Missing paint Any amount provided Any amount Touch up paint
no parent metal
exposed
d. Dirty airflow Serviceable. Wipe
path surface clean if inlet screen
has been removed for
other maintenance
actions
e. Loose bolts Not serviceable Any amount Re-tighten and safety-
wire. Apply adhesive,
RTV-106, red (GE Co.,
Silicone Products
Dept., Waterford, NY)
to cover safety wire

5-128
GEK 97310
VOLUME I
Table 5-15. TRANSFER GEARBOX
On-Site On-Site
1. Transfer Gearbox and Air/Oil Separator for:

a. Cracks Not serviceable Not repairable Replace transfer gear-
box per WP 205 00 or
WP 214 00*
b. Nicks, scores, Any number, any
scratches on length 0.031 inch
nonmachined (0.78 mm) deep
surfaces
c. Leaking plugs Not serviceable Any amount Re-tighten loose fit-
or fittings tings or replace dam-
aged O-ring
NOTE
Excessive oil leakage from the transfer gearbox may be due to the omission of the fuel
pump gear plug. Two plugs (fwd plug L21431G01 and aft plug L21431G02) are required,
except aft plug is not required on engines with gearbox-mounted fuel pumps.
d. Missing or Not serviceable Any amount Replace safety wire
broken safety
wire
2. Studs for:
a. Thread Not serviceable Total of 75% of one Remove damage with
damage full thread may be fine file
removed
b. Looseness Not serviceable See Corrective Tighten stud one turn.
Action column If still not tight, replace
transfer gearbox*

5-129
GEK 97310
VOLUME I
Table 5-16. COMPRESSOR FRONT FRAME
On-Site On-Site
1. All Surfaces (except forward mounts) for:

a. Dents Any number smooth Replace front frame
contour dents per WP 218 00*
0.125 inch (3.18 mm)
deep with a minimum
separation of
2.00 inches
(50.8 mm)
b. Nicks, Limited service Any number Remove high metal
scratches and 0.031 inch (0.78 mm)
gouges deep, with a min sep-
aration of 1.00 inch
(25.4 mm) after
2. Threaded Pads, Ports and Bosses for:
a. Damaged Not serviceable One full thread cumu- Chase threads
threads lative or continuous
may be removed
or
any amount thread Install helical coil
damage insert
3. Mounts for:
a. Cracks Not serviceable Replace front frame
per WP 218 00*

5-130
GEK 97310
VOLUME I
Table 5-17. COMPRESSOR REAR FRAME (CRF)
On-Site On-Site
1. Flanges for:
a. Cracks in bolt- One per flange radi- Replace CRF*
holes ally outward
2. All Pads for:
a. Cracks Two per weld, Replace CRF*
0.13 inch (3.3 mm)
long with a minimum
separation of
2.00 inches
(50.8 mm), provided
none extend into par-
ent metal. None
allowed in fuel noz-
zle pads
b. Nicks, scores, Any number on seal- Replace CRF*
and scratches ing surface,
0.031 inch (0.78 mm)
deep not extending
across more than 50%
of the sealing surface
metal
c. Thread dam- Not serviceable One complete thread Chase threads
age (except may be removed
nozzle pad) or
Any amount of Install helical coil wire
damage insert
d. Thread dam- Not serviceable One complete thread Chase threads
age fuel noz- may be removed
zle pad or
Any amount of Install helical coil wire
damage insert or threaded insert

5-131
GEK 97310
VOLUME I
Table 5-17. COMPRESSOR REAR FRAME (CRF) - Continued
On-Site On-Site
3. Tubes for:
a. Cracks Not serviceable Replace CRF*
b. Nicks and Any number Replace CRF*
scratches 0.010 inch (0.25 mm)
deep after removal of
high metal
c. Dents Any number smooth Replace CRF*
contour dents
0.063 inch (1.60 mm)
deep
4. Strut Pads for:
a. Cracks Bolt holes may be Replace CRF*
cracked through radi-
ally outward, one hole
per pad
b. Nicks and Any number, any Replace CRF*
scratches length 0.063 inch
(1.60 mm) deep after
removal of high
metal, provided metal
is not reduced to less
than 75% original
thickness
c. Dents Any number smooth Replace CRF*
contour dents
0.25 inch (6.4 mm)
deep except on mating
surfaces
5. Outer Casing Skin for:
a. Cracks Not serviceable Replace CRF*

5-132
GEK 97310
VOLUME I
Table 5-17. COMPRESSOR REAR FRAME (CRF) - Continued
On-Site On-Site
b. Dents Any number smooth Replace CRF*

contour dents
0.25 inch (6.4 mm)
deep
c. Nicks, scores, Any number in axial Replace CRF*
and scratches direction, 0.063 inch
(1.60 mm) deep,
1.00 inch (25.4 mm)
long. In circumferen-
tial direction,
0.031 inch (0.79 mm)
deep, 1.00 inch
(25.4 mm) long with a
min separation of
1 inch (25 mm) after
d. Inspection Not serviceable One complete thread Chase threads
bosses for may be removed
thread or
damage Any amount of Install helical coil wire
damage insert
e. Hot spots Any number pro- Replace CRF*
(discoloration) vided metal is not
crazed. No cracks
allowed. Perform a
borescope inspection
of combustion liner if
hot spots are noted
f. Bulges Not serviceable when Replace CRF*
associated with heat
discoloration. Per-
form a borescope
inspection of combus-
tion liner if bulges are
noted

5-133
GEK 97310
VOLUME I
Table 5-18. TURBINE MID FRAME EXTERIOR
On-Site On-Site
1. Casing for:
a. Cracks Any number 0.125 inch Replace frame per
(3.18 mm) long that will WP 201 00/SWP 201 01
not permit air or fluid or
leakage. 1.00 inch WP 208 00/SWP 208 01*
(25.4 mm) min separa-
tion between cracks
b. Nicks, dents, Any number 0.063 inch Replace frame per
gouges, etc. (1.60 mm) deep, WP 201 00/SWP 201 01
1.00 inch (25.4 mm) or
long, provided metal is WP 208 00/SWP 208 01*
not thinned to less than
75% of original
thickness
c. Distortion Acceptable if proper Replace frame per
assembly can be made WP 201 00/ SWP 201 01
or
WP 208 00/SWP 208 01*
d. Hot spots Serviceable if metal is Replace frame per
(discoloration) not crazed and cracks are WP 20100/ SWP 201 01
not present. Perform a or
borescope inspection of WP 208 00/SWP 208 01*
combustion area if
bulges are noted
e. Bulges Not serviceable when Replace frame per
associated with heat dis- WP 20100/ SWP 201 01
coloration. Perform a or
borescope inspection of WP 208 00/SWP 208 01*
combustion area if
bulges are noted

5-134
GEK 97310
VOLUME I
Table 5-18. TURBINE MID FRAME EXTERIOR - Continued
On-Site On-Site
2. Service Tube Pads and Instrumentation Bosses for:
a. Nicks, gouges, 0.031 inch (0.79 mm) Replace frame per
etc., on flange deep extending across WP 201 01/SWP 201 01
mating surface not more than 50% of the or
sealing surface after WP 208 00/SWP 208 01*
3. All Threaded Ports and Bosses for:
a. Damaged Not serviceable One complete Chase threads
threads thread may be
removed
4. Tubes for:
a. Cracks Not serviceable Replace frame per
WP 201 00/SWP 201 01
or
WP 208 00/SWP 208 01*
b. Nicks, scores, 0.010 inch (0.25 mm) Replace frame per
and scratches deep after removal of WP 201 00/SWP 201 01
high metal or
WP 208 00/SWP 208 01*
c. Dents Any number smooth Replace frame per
contour dents WP 201 00/SWP 201 01
0.125 inch (3.18 mm) or
deep WP 208 00/SWP208 01*

5-135
GEK 97310
VOLUME I
Table 5-18. TURBINE MID FRAME EXTERIOR - Continued
On-Site On-Site
5. Liner for:
a. Cracks in skin Any number not exceed- Replace frame per
(no separation ing 2.00 inches WP 201 00/SWP 201 01
through aft (50.8 mm) length and not or
ring) joining with adjacent WP 208 00/SWP 208 01*
cracks. Monitor for crack
propagation by bores-
cope inspection at each
opportunity but not later
than 500 hours of
operation
b. Missing Not serviceable Replace frame per
material WP 201 00/SWP 201 01
or
WP 208 00/SWP 208 01*
c. Buckling or Any amount 0.26 inch Replace frame per
distortion (6.4 mm) from original WP 201 00/SWP 201 01
contour or
WP 208 00/SWP 208 01

5-136
GEK 97310
VOLUME I
Table 5-19. POWER TURBINE STATOR CASE
On-Site On-Site
1. Front Flange for:

a. Cracks Not serviceable Replace cases per
extending WP 223 00**
from bolt
holes in any
direction
b. Cracks not Any number, Replace cases per
extending 0.016 inch (0.41 mm) WP 223 00**
from bolt long, with 2.00 inch
holes (50.8 mm) min spac-
ing between cracks
c. Nicks, scores, Any number, any Blend
and scratches length, 0.031 inch
(0.78 mm) deep not
extending across
more than 75% of
flange face after
2. Rear Flange for:
a. Cracks Not serviceable Replace cases per
extending WP 223 00*
between bolt
holes
b. Cracks Two cracks per flange Replace cases per
extending provided adjacent WP 223 00*
from bolt holes not cracked
holes to outer
edge of flange

5-137
GEK 97310
VOLUME I
Table 5-19. POWER TURBINE STATOR CASE - Continued
On-Site On-Site
c. Nicks, scores, Any number, any Blend

(0.78 mm) deep, not
extending across
more than 75% of
flange face after
3. Horizontal Flanges for:
a. Cracks Two cracks per flange Replace cases per
extending provided mating WP 223 00*
from bolt flange on outer half
holes to outer of casing does not
edge of flange have cracks at the
same holes
b. Nicks, scores, Any number, any Blend
(0.78 mm) deep not
extending across
more than 75% of
flange face after
4. Casing Body for:
a. Cracks Any number Replace cases per
0.063 inch (1.60 mm) WP 223 00*
long with 2.0 inch
(50.8 mm) min
spacing
b. Nicks Any number Replace cases per
0.020 inch (0.51 mm) WP 223 00*
high metal
c. Scratches Any number Replace cases per
0.010 inch (0.25 mm) WP 223 00*
deep, any length

5-138
GEK 97310
VOLUME I
Table 5-19. POWER TURBINE STATOR CASE - Continued
On-Site On-Site
d. Dents Any number Replace cases per

0.125 inch (3.18 mm) WP 223 00*
deep provided assem-
bly can be
accomplished
e. Distortion Free-state distortion Replace cases per
acceptable, provided WP 223 00*
assembly can be
accomplished

5-139
GEK 97310
VOLUME I
Table 5-20. TURBINE REAR FRAME (TRF)
On-Site On-Site
CASE
1. All Surfaces Unless Otherwise Specified for:
a. Cracks (all Not serviceable Replace TRF*
surfaces
except hat-
section stiff-
eners)
b. Cracks in hat- Total length of cracks Replace TRF*
section stiff- in each stiffener shall
eners (not in not exceed 0.50 inch
mounts) (12.7 mm) length
c. Nicks, scores, Any number, any Replace TRF*
on all surfaces
d. Dents Any number smooth Replace TRF*
contour dents,
0.25 inch (6.4 mm)
deep
STRUTS
1. All Surfaces for:
a. Nicks, scores, Any number, any Replace TRF*
b. Dents Any number smooth Replace TRF*
contour dents,
0.25 inch (6.4 mm)
deep

5-140
GEK 97310
VOLUME I
Table 5-20. TURBINE REAR FRAME (TRF) - Continued
On-Site On-Site
2. Strut Fairing for:

a. Loose or Forward-aft end riv- Replace TRF*
missing rivets ets (fairing-to-case),
any number
Side rivets (fairing to Replace TRF*
case) - one per strut
side if end rivets are
in place
Trailing edge (fair- Replace TRF*
ing) - one per strut
MOUNTS
1. All Surfaces for:
a. Cracks Not serviceable Replace TRF*

5-141
GEK 97310
VOLUME I
5-3.23 Spark Igniter Inspection. (1) Inspect transducer housing for

damage. Replace as required.
a. Remove both spark igniters per
WP 106 00. (2) Inspect transducer cover screws
for security. If loose, remove safety wire and
b. Visually inspect each igniter and reject torque screws to 8-9 lb in. (1-1.1 N·m). Install
those which exhibit any of the following new safety wire.
conditions:
(3) Inspect the three bolts securing
(1) Center electrode eroded in excess the transducer to the mount bracket. Torque
of 0.063 inch (1.6 mm). bolts to 24-27 lb in. (2.7-3 N·m).
(2) Radial cracks or pieces missing (4) Inspect the mount bolts securing
from ceramic between electrodes. the mount bracket to the gas generator flanges.
Torque must be as follows:
(3) Insulator broken, cracked or loose
on terminal end. • Compressor rear frame to rear stator case
flange bolts 160 to 180 lb in. (18-20 N·m).
NOTE • Turbine mid frame aft flange mount bolts -
Original igniter plugs, 80 to 90 lb in. (9-10.2 N·m).
PN 9101M37P36, are service life lim-
ited and require replacement at operat- (5) Inspect security of vibration
ing intervals of 4000 hours or transducer electrical interface connector. Con-
whenever service limits are nector shall be hand tight only. Install new
exceeded. Improved igniter plugs, safety wire.
PN 9101M37P68 and PN L43450P01,
are available and are not service life b. Perform electrical test of vibration
limited. General Electric Co. recom- transducer as follows:
mends installing the improved igniter
plugs when the P36 igniter plugs have NOTE
achieved the 4000 hours operating Electrical problems are evident by
interval or exceeded the maximum ser- erratic or no output from the transducer
viceable limits, whichever comes first. and are indicative of shorted or broken
Users having inventories of the original coil windings, contaminated connector
P36 igniter plugs may continue to place contacts, loose connector or damaged
those in service, as required, until the leads at the connector backshell.
supply is exhausted.
(1) Using volt-ohmmeter (VOM),
5-3.24 Vibration Transducer Inspection verify continuity of vibration transducer coil
and Verification. by performing resistance check across the con-
nector pins. When measured across the con-
a. Perform mechanical inspection of nector pins, the coil resistance should be
vibration transducer as follows: between 392 and 588 ohms at 70°F (21°C). If
not, replace transducer.

5-142
GEK 97310
VOLUME I
(2) Perform resistance checks 5-3.25 Engine Special Inspections. Refer

between transducer case and each connector to table 5-21.
output pin. Resistance should be 0.1 megohm
minimum. If out of limits, replace transducer.
Table 5-21. SPECIAL INSPECTION
Item Condition Disposition
Overtemperature Whenever T5.4 has exceeded Replace gas turbine per

serviceable limits of WP 300 00
figure 5-35
Overspeed Whenever NGG has Replace gas generator per
exceeded 9975 rpm WP 301 00
or
Whenever NPT has exceeded Replace power turbine per
4500 rpm WP 302 00
Engine Stalls at gas genera- Abnormal engine noise, If overtemperature occurs,
tor speeds less than 7500 rpm bangs, fluctuating parame- replace engine. If no over-
ters, sluggish throttle temperature, inspect per
response, high or rapid rise in paragraph 5-3.25
T5.4
Engine Stalls at gas genera- Abnormal engine noise, If overtemperature occurs,
tor speeds greater than bangs, fluctuating parame- replace engine. If no over-
7500 rpm ters, sluggish throttle temperature, inspect per
response, high or rapid rise in paragraph 5-3.25
T5.4
Engine Vibration Whenever gas generator or Troubleshoot per Chapter 4
power turbine vibration has and if vibration is not cor-
exceeded limits of table 4-1 rected, replace gas generator,
power turbine or both
Fire Damaged Engine Whenever engine has been Replace engine per
fire damaged or flooded with WP 300 00
fire extinguishing agent

5-143
GEK 97310
VOLUME I
Figure 5-35. Transient Temperature Limits

5-144
GEK 97310
VOLUME I
5-3.26 Engine Stalls - Below 7500 RPM (b) Compressor component

Gas Generator Speed. damage.
a. Stalls are categorized as steady state or (c) Severe and extensive com-
transient, and each type tends to have unique pressor contamination.
causes.
(d) Severe and extensive com-
b. High speed stalls can result in fatigue pressor erosion.
fractures of compressor blades and severe
deterioration of hot section parts. These (2) Accessory discrepancies
adverse effects may cause gas generator fail- (VSV schedule error).
ure, or malfunction, at the time of the stall, but
more commonly the full effects of a stall are (a) Rigging error.
deferred, and consequently become more diffi-
cult to relate directly to a specific stall inci- (b) Assembly error.
dent. The deferred effects are cumulative and
can affect gas generator reliability, durability, (c) VSV actuation feedback
and operating cost. discrepancies.
c. Steady state stalls occur at fixed throt- (d) Fuel control discrepancy.
tle settings and tend to be associated with dis-
crepancies in basic gas stream components. (e) Compressor inlet tempera-
Continued operation after this type of stall ture (CIT) sensor discrepancy.
tends to generate additional secondary
damage. (3) Operational discrepancies.
d. Transient stalls are associated with (a) Inlet distortion.

throttle movement (acceleration - deceleration)
and tend to be related to discrepancies in fuel (b) Operation outside of autho-
control, compressor inlet temperature sensor or rized operating envelope.
variable stator actuation mechanism. Rapid
throttle movements tend to increase stall prob- g. Corrective Action.
ability when the above mentioned components
are discrepant. (1) If a transient stall occurs during
start, shut down to clear the stall. Restart and if
e. Discrepancies may exist simulta- stall recurs, troubleshoot per Chapter 4.
neously in engine and accessories.
(2) If a transient stall occurs during
f. Typical specific stall causes: acceleration or deceleration below 7500 rpm
gas generator speed, retard throttle to idle to
(1) Engine discrepancies. clear the stall. Shutdown and troubleshoot per
Chapter 4.
(a) Compressor foreign object
damage.

5-145
GEK 97310
VOLUME I
(3) Record operating conditions at c. Steady state stalls occur at fixed throt-
time of stall. tle settings and tend to be associated with dis-
crepancies in basic gas stream components.
(a) Verify that T5.4 and NGG Continued operation after this type of stall
are normal at idle. If the stall cannot be tends to generate additional secondary
cleared, shutdown, troubleshoot and correct damage.
the cause of the stall. Refer to step f.
d. Transient stalls are associated with
(b) If the stall is cleared by throttle movement (acceleration - deceleration)
retarding the throttle to idle, slowly advance and tend to be related to discrepancies in fuel
the throttle to determine if stall recurs. control, compressor inlet temperature sensor or
variable stator actuation mechanism. Rapid
(c) If stall does not recur, pro- throttle movements tend to increase stall prob-
ceed with normal operation. At the earliest ability when the above mentioned components
opportunity, troubleshoot and correct the cause are discrepant.
of the stall. Refer to step f.
e. Discrepancies may exist simulta-
(d) If stall does recur, the gas neously in gas turbine and accessories.
turbine may be operated, if necessary, up to
5 percent below the gas generator speed at f. Typical specific stall causes:
which stall occurs. At the earliest opportunity,
troubleshoot and correct the cause of the stall. (1) Engine discrepancies.
Refer to step f.
(a) Compressor foreign object
5-3.27 Engine Stalls - Above 7500 Rpm damage.
Gas Generator Speed.
(b) Compressor component
a. Stalls are categorized as steady state or damage.
transient, and each type tends to have unique
causes. (c) Severe and extensive com-
pressor contamination.
b. High speed stalls can result in fatigue
fractures of compressor blades and severe (d) Severe and extensive com-
deterioration of hot section parts. These pressor erosion.
adverse effects may cause gas generator fail-
ure, or malfunction, at the time of the stall, but (2) Accessories discrepancies
more commonly the full effects of a stall are (VSV schedule error).
deferred and consequently become more diffi-
cult to relate directly to a specific stall inci- (a) Rigging error.
dent. The deferred effects are cumulative and
can affect gas generator reliability, durability, (b) Assembly error.
and operating cost.
(c) VSV actuation/feedback
discrepancies.

5-146
GEK 97310
VOLUME I
(d) VSV control discrepancy. b. Foam Agents.
(3) Operational discrepancies. WARNING

(a) Inlet distortion. PERSONNEL SHALL NOT ENTER
THE ENCLOSURE AFTER A FIRE
(b) Operation outside of autho- OR AFTER RELEASE OF FIRE
rized operating envelope. EXTINGUISHING AGENTS UNTIL
THE ENCLOSURE IS PURGED OF
g. Corrective Action. POTENTIALLY TOXIC GASES
AND ADEQUATELY COOLED.
(1) Record operating conditions at
time of stall. (1) Before entering the enclosure,
open the ventilation damper and operate the
(2) Shut down engine. Troubleshoot ventilation fan for a minimum of ten minutes
and correct cause of stall per Chapter 4. to dispel any toxic vapors and cool the enclo-
sure to permit safe entry. Continue to operate
5-3.28 Removal Of Fire Extinguishing the fan until the engine is sufficiently cool
Agents From Engine External Surfaces. If (T5.4 at or below 200°F [93.3°C]).
the engine has been exposed to fire extinguish-
ing agents on its external surfaces, perform the (2) Disconnect all electrical power to
following, as appropriate. the engine and enclosure.
NOTE (3) Attach adjustable spray nozzle to

flexible water hose. Attach hose to potable or
• If the engine has sustained fire dam- distilled water source at 45-55 psig
age, it must be removed for (310-379 kPa).
inspection.
CAUTION
• Consult Marine and Industrial Customer
Service for aid in disposition of engines AVOID DIRECT WATER SPRAY ON
exposed to fire or fire extinguishing ELECTRICAL CONNECTORS AND
agents. ELECTRICAL COMPONENTS.
MASK OR PROTECT CONNEC-
a. CO2. Engine parts at an elevated tem- TORS FROM WATER CONTACT.
perature when exposed to CO2 must be
removed for inspection per the Industrial (4) Water wash engine exterior and
Repair Manual, GEK 50356. Parts not exposed enclosure interior by flushing thoroughly with
to sustained elevated temperatures, such as water from nozzle adjusted to a heavy spray.
during start attempts, require no maintenance
action. (5) Exit enclosure, connect power to
ventilating damper. Operate ventilating fan for
at least 15 minutes to expel excess water and
dry interior or enclosure.

5-147
GEK 97310
VOLUME I
(6) Stop ventilating fan, enter enclo- (2) Disconnect all electrical power to
sure and inspect for water accumulation. the engine and enclosure.
Remove excess water as necessary.
(3) Attach adjustable spray nozzle to
(7) Connect electrical power to flexible water hose. Attach hose to potable or
engine and enclosure. distilled water source at 45-55 psig
(310-379 kPa).
c. Dry Chemical Powder Agents.
CAUTION
(1) Remove all loose powder from
engine using vacuum tools and compressed air AVOID DIRECT WATER SPRAY OF
at 30-40 psi (207-276 kPa). ELECTRICAL CONNECTORS AND
ELECTRICAL COMPONENTS.
(2) If powder has turned to glaze due MASK OR PROTECT CONNEC-
to elevated temperatures, scrub with a mixture TORS FROM WATER CONTACT.
of 60 percent isopropyl alcohol/40 percent
isobutyl alcohol until all glaze is removed. (4) Water wash engine exterior and
enclosure interior by flushing thoroughly with
d. Halon Extinguishing Agents. water from nozzle adjusted to a heavy spray.
(5) Exit enclosure. Connect power to

WARNING ventilating damper. Operate ventilating fan for
PERSONNEL SHALL NOT ENTER at least 15 minutes to expel excess water and
THE ENCLOSURE AFTER A FIRE dry interior of enclosure.
OR AFTER RELEASE OF FIRE
EXTINGUISHING AGENTS UNTIL (6) Stop ventilating fan, enter enclo-
THE ENCLOSURE IS PURGED OF sure and inspect for water accumulation.
POTENTIALLY TOXIC GASES Remove excess water enclosure.
AND ADEQUATELY COOLED.
(7) Connect electrical power to
(1) Before entering the enclosure, engine and enclosure.
open the ventilation damper and operate the
ventilation fan for a minimum of ten minutes
to dispel any toxic vapors and cool the enclo-
sure to permit safe entry. Continue to operate
the fan until the engine is sufficiently cool
(T5.4 at or below 200°F (93.3°C).

5-148
GEK 97310
VOLUME I
5-3.29 Removal Of Fire Extinguishing (2) Remove engine for disassembly,

Agents From Engine Internal Surfaces. If cleaning and inspection per the Industrial
the engine has been exposed to fire extinguish- Repair Manual.
ing agents on its internal surfaces, perform the
following as appropriate. d. Halon Extinguishing Agents. Flush per
paragraph 5-3.21 using water only and motor
NOTE engine, if possible. Remove engine for disas-
• If the engine has sustained fire dam- sembly, cleaning and inspection per the Indus-
age, it must be removed for trial Repair Manual.
inspection.
5-3.30 High Pressure Recoup Pressure
• Consult Marine and Industrial Customer Preferred Operating Range (GE, PE And
Service for aid in disposition of engines PH Series).
exposed to fire or fire extinguishing
agents. a. For engines with less than 500 hours
since new or from last hot section replacement
a. CO2. Engine parts at an elevated tem- or overhaul, monitor HP recoup pressure and
adjust orifice sizes as required at 100 hour
perature when exposed to CO2 must be
intervals (up to 500 hours) per Chapter 4.
removed for inspection per the Industrial
Repair Manual. Parts not exposed to sustained b. For engines with over 500 hours but
elevated temperatures, such as during start less than 2000 hours since new or from last hot
attempts, require no maintenance action. section replacement or overhaul, monitor
HP recoup pressure and adjust orifice sizes as
b. Foam Agents. Flush per required at 500 hour intervals (up to
paragraph 5-3.21, using water only and motor 2000 hours) per Chapter 4.
engine, if possible, to remove foam residue.
Remove engine for disassembly, cleaning and c. For engines with over 2000 hours since
inspection per the Industrial Repair Manual. new or from last hot section replacement or
overhaul, monitor HP recoup pressure and
c. Dry Chemical Powder Agents. adjust orifice sizes as required at semi-annual
intervals per Chapter 4.
(1) Remove all accessible loose pow-
der from engine using vacuum tools and com- 5-3.31 Lube Oil Pressure Corrections For
pressed air at 30-40 psi (207-276 kPa). Industrial LM2500 Gas Turbines And Gas
Generators. The following tables and figures
provide corrections and limits for lube supply
pressure.

5-149
GEK 97310
VOLUME I
Table 5-22. LUBE OIL PRESSURE CORRECTION FOR INDUSTRIAL LM2500 GAS TURBINES.
MIL-L-23699 OIL WITH V.G. CONTROL PN L34379 AND 3R DAMPER BEARING
NOTE
The following values are for corrections to 9000 rpm NGG and 150°F (66°C) lube inlet tempera-
ture. Read oil pressure and temperature then algebraically add the pressure additive as indicated
for that particular rpm and lube temperature to the observed lube pressure. Corrected lube pressure
limit is 45 to 55 psig (310-279 kPa).
Gas Generator Speed (RPM)
Oil
Supply
Temp
(°F)(°C) 8000 8100 8200 8300 8400 8500 8600 8700 8800 8900 9000
100 (38) -7.74 -8.93 -10.14 -11.35 -12.58 -13.81 -15.05 -16.31 -17.57 -18.85 -20.14
110 (43) -3.52 -4.64 -5.76 -6.89 -8.03 -9.18 -10.34 -11.51 -12.69 -13.88 -15.08
120 (49) -0.02 -1.10 -2.19 -3.30 -4.42 -5.54 -6.64 -7.75 -8.86 - 9.98 -11.11
130 (54) +2.91 +1.93 +0.94 -0.06 -1.07 -2.09 -3.12 -4.14 -5.16 -6.19 -7.23
140 (60) +5.82 +4.92 +4.01 +3.11 +2.19 +1.27 +0.33 -0.60 - 1.55 -2.50 -3.46
150 (66) +8.60 +7.77 +6.93 +6.09 +5.24 +4.38 +3.52 +2.65 +1.77 +0.89 0
160 (71) +11.13 +10.34 +9.55 +8.75 +7.95 +7.14 +6.32 + 5.50 +4.67 +3.84 +3.00
170 (77) +13.35 +12.61 +11.87 +11.12 +10.33 +9.52 +8.71 +7.90 +7.07 +6.24 +5.40
180 (82) +15.07 +14.33 +13.58 +12.83 +12.07 +11.31 +10.54 +9.77 +8.99 +8.18 +7.36
190 (88) +16.53 +15.80 +15.06 +14.31 +13.55 +12.77 +11.98 +11.18 +10.38 +9.56 + 8.74
200 (93) +17.57 +16.84 +16.10 +15.36 +14.60 +13.83 +13.06 +12.27 +11.46 +10.66 +9.83
210 (99) +18.40 +17.67 +16.93 +16.18 +15.42 +14.65 +13.88 +13.10 +12.31 +11.51 +10.71
220 (104) +19.08 +18.36 +17.64 +16.90 +16.16 +15.41 +14.65 +13.89 +13.12 +12.34 +11.55

Oil
Supply
Temp
(°F)(°C) 9100 9200 9300 9400 9500 9600 9700 9800 9900 10000
100 (38) -12.43 -22.74 -24.05 -25.37 -26.70 -28.04 -29.39 -30.76 -32.13 -33.50
110 (43) -16.30 -17.52 -18.74 -19.99 -21.27 -22.56 -23.86 -25.18 -26.51 -27.85
120 (49) -12.25 -13.39 -14.55 -15.71 -16.87 -18.05 -19.23 -20.42 -21.62 -22.83
130 (54) -8.28 -9.33 -10.38 -11.43 -12.49 -13.56 -14.64 -15.72 -16.81 -17.91
140 (60) -4.43 -5.39 -6.36 -7.33 -8.31 -9.30 -10.29 -11.29 -12.30 -13.31
150 (66) -0.09 -1.81 -2.72 -3.64 -4.56 -5.49 -6.43 -7.37 -8.32 -9.27
160 (71) +2.16 +1.31 +0.46 -0.40 -1.27 -2.16 -3.09 -4.02 -4.96 -5.91
170 (77) +4.55 +3.70 +2.84 +1.99 +1.12 +0.25 -0.62 -1.05 -2.39 -3.28
180 (82) +6.53 +5.69 +4.84 +3.99 +3.13 +2.24 +1.34 +0.43 -0.48 -1.41
190 (88) +7.91 +7.08 +6.23 +5.38 +4.52 +3.66 +2.77 +1.86 +0.95 +0.03
200 (93) +9.00 +8.16 +7.31 +6.45 +5.59 +4.72 +3.85 +2.96 +2.07 +1.17
210 (99) +9.90 +9.08 +8.25 +7.42 +6.57 +5.72 +4.86 +4.00 +3.12 +2.24
220 (104) +10.76 +9.95 +9.14 +8.33 +7.50 +6.67 +5.83 +4.98 +4.13 +3.26
NOTE: Oil MIL-L-23699
Example: Observed NGG 8700 rpm
Observed Oil Pressure 56 psig (386 kPa)
Oil Temperature 130°F (54°C)
Pressure Additive -4.14 psig (28.5 kPa)
Corrected Pressure 56 - 4.14 = 51.86 psig (357.6 kPa)

5-150
GEK 97310
VOLUME I
Figure 5-36. Lube Oil Pressure Correction for Industrial LM2500 Gas Turbines.
MIL-L-23699 Oil with V.G. Control PN L34379 and 3R Damper Bearing

5-151
GEK 97310
VOLUME I
NOTE

Oil
Supply
Temp
(°F)(°C) 8000 8100 8200 8300 8400 8500 8600 8700 8800 8900 9000
100 (38) -4.69 -5.63 -6.58 -7.54 -8.51 -9.50 -10.48 -11.46 -12.44 -13.44 -14.43
110 (43) -1.72 -2.58 -3.45 -4.32 -5.20 -6.08 -6.97 -7.87 -8.78 -9.69 -10.61
120 (49) +1.08 +0.29 -0.51 -1.32 -2.13 -2.95 -3.77 -4.61 -5.44 -6.29 -7.14
130 (54) +3.59 +2.84 +2.08 +1.32 +0.56 -0.21 -0.99 -1.77 -2.56 -3.35 -4.15
140 (60) +5.79 +5.08 +4.34 +3.58 +2.82 +2.06 +1.28 +0.50 -0.28 -1.08 -1.88
150 (66) +7.41 +6.70 +6.00 +5.29 +4.57 +3.84 +3.11 +2.34 +1.57 +0.79 0
160 (71) +8.79 +8.09 +7.38 +6.64 +5.90 +5.15 +4.40 +3.64 +2.87 +2.10 +1.31
170 (77) +9.77 +9.07 +8.37 +7.65 +6.92 +6.17 +5.42 +4.66 +3.89 +3.11 +2.33
180 (82) +10.55 +9.85 +9.14 +8.43 +7.71 +6.98 +6.24 +5.50 +4.75 +3.99 +3.22
190 (88) +11.23 +10.55 +9.86 +9.16 +8.46 +7.75 +7.03 +6.30 +5.57 +4.83 +4.08
200 (93) +11.89 +11.22 +10.55 +9.86 +9.17 +8.48 +7.78 +7.07 +6.35 +5.62 +4.89
210 (99) +12.52 +11.87 +11.21 +10.54 +9.86 +9.17 +8.47 +7.76 +7.04 +6.31 +5.58
220 (104) +13.08 +12.43 +11.76 +11.10 +10.42 +9.74 +9.05 +8.35 +7.64 +6.92 +6.19

Oil
Supply
Temp
(°F)(°C) 9100 9200 9300 9400 9500 9600 9700 9800 9900 10000
100 (38) -15.44 -16.46 -17.46 -18.47 -19.50 -20.52 -21.56 -22.60 -23.65 -24.70
110 (43) -11.53 -12.45 -13.37 -14.31 -15.24 -16.19 -17.14 -18.10 -19.07 -20.04
120 (49) -8.00 -8.87 -9.74 -10.61 -11.50 -12.39 -13.28 -14.18 -15.08 -15.99
130 (54) -4.95 -5.76 -6.57 -7.42 -8.29 -9.17 -10.05 -10.94 -11.84 -12.75
140 (60) -2.67 -3.48 -4.29 -5.10 -5.92 -6.75 -7.58 -8.43 -9.31 -10.19
150 (66) -0.79 -1.59 -2.41 -3.25 -4.09 -4.95 -5.80 -6.67 -7.54 -8.42
160 (71) +0.52 -0.27 -1.08 -1.90 -2.75 -3.59 -4.45 -5.32 -6.19 -7.07
170 (77) +1.54 +0.74 -0.07 -0.88 -1.70 -2.53 -3.37 -4.21 -5.06 -5.92
180 (82) +2.45 +1.67 +0.88 +0.09 -0.71 -1.52 -2.34 -3.16 -3.99 -4.83
190 (88) +3.32 +2.56 +1.79 +1.01 +0.23 -0.56 -1.36 -2.16 -2.98 -3.80
200 (93) +4.15 +3.40 +2.64 +1.87 +1.09 +0.29 -0.51 -1.31 -2.13 -2.95
210 (99) +4.84 +4.09 +3.34 +2.57 +1.80 +1.02 +0.23 -0.58 -1.39 -2.20
220 (104) +5.45 +4.71 +3.96 +3.20 +2.44 +1.66 +0.88 +0.09 -0.70 -1.51
Pressure Additive +1.28 psig (8.8 kPa)
Corrected Pressure 40 + 1.28 = 41.28 psig (284.6 kPa)

5-152
GEK 97310
VOLUME I
MIL-L-7808 Oil with V.G. Control PN L34379 an 3R Damper Bearing

5-153
GEK 97310
VOLUME I
Table 5-24. LUBE OIL PRESSURE CORRECTION FOR INDUSTRIAL LM2500 GAS GENERATORS.
NOTE
limit is 56 to 68 psig. (386-469 kPa).
Oil
Supply
Temp
(°F)(°C) 8000 8100 8200 8300 8400 8500 8600 8700 8800 8900 9000
100 (38) -10.52 -12.01 -13.52 -15.04 -16.58 -18.12 -19.68 -21.25 -22.84 -24.43 -26.04
110 (43) -5.20 -6.60 -8.03 -9.49 -10.98 -12.48 -14.00 -15.53 -17.07 -18.59 -20.10
120 (49) -0.99 -2.30 -3.62 -4.96 -6.29 -7.64 -9.01 -10.38 -11.77 -13.18 -14.56
130 (54) +3.19 +2.02 +0.83 -0.37 -1.57 -2.79 -4.01 -5.24 -6.48 -7.72 -8.98
140 (60) +7.26 +6.16 +5.05 +3.93 +2.80 +1.67 +0.52 -0.63 -1.80 -2.97 -4.15
150 (66) +10.75 +9.71 +8.66 +7.61 +6.54 +5.47 +4.39 +3.31 +2.22 +1.11 0
160 (71) +13.80 +12.83 +11.84 +10.79 +9.73 +8.65 +7.57 +6.48 +5.38 +4.27 +3.15
170 (77) +15.99 +15.00 +14.01 +13.01 +12.00 +10.99 +9.97 +8.94 +7.87 +6.77 +5.66
180 (82) +17.80 +16.77 +15.73 +14.67 +13.62 +12.55 +11.47 +10.38 +9.28 +8.17 +7.05
190 (88) +18.85 +17.84 +16.83 +15.82 +14.79 +13.74 +12.69 +11.62 +10.55 +9.47 +8.37
200 (93) +19.85 +18.87 +17.88 +16.88 +15.88 +14.86 +13.83 +12.79 +11.74 +10.68 +9.61
210 (99) +20.79 +19.83 +18.87 +17.89 +16.91 +15.91 +14.91 +13.89 +12.87 +11.83 +10.79
220 (104) +21.68 +20.75 +19.80 +18.85 +17.89 +16.91 +15.93 +14.94 +13.93 +12.92 +11.90

Oil
Supply
Temp
(°F)(°C) 9100 9200 9300 9400 9500 9600 9700 9800 9900 10000
100 (38) -27.67 -29.30 -30.95 -32.61 -34.28 -35.96 -37.66 -39.37 -41.10 -42.85
110 (43) -21.62 -23.15 -24.70 -26.25 -27.80 -29.38 -30.97 -32.57 -34.18 -35.80
120 (49) -15.95 -17.35 -18.73 -20.11 -21.51 -22.93 -24.35 -25.78 -27.22 -28.67
130 (54) -10.25 -11.52 -12.80 -14.10 -15.40 -16.72 -18.03 -19.36 -20.70 -22.05
140 (60) -5.34 -6.54 -7.75 -8.97 -10.19 -11.43 -12.67 -13.92 -15.18 -16.45
150 (66) -1.11 -2.23 -3.36 -4.50 -5.64 -6.87 -8.11 -9.36 -10.62 -11.88
160 (71) +2.02 +0.88 -0.27 -1.41 -2.56 -3.72 -4.89 -6.06 -7.25 -8.44
170 (77) +4.50 +3.33 +2.14 +0.93 -0.28 -1.49 -2.72 -3.96 -5.21 -6.47
180 (82) +5.92 +4.77 +3.63 +2.46 +1.29 +0.10 -1.10 -2.31 -3.53 -4.76
190 (88) +7.27 +6.15 +5.03 +3.89 +2.74 +1.58 +0.42 -0.76 -1.95 -3.15
200 (93) +8.54 +7.45 +6.34 +5.23 +4.11 +2.98 +1.84 +0.69 -0.47 -1.64
210 (99) +9.73 +8.67 +7.59 +6.51 +5.41 +4.30 +3.19 +2.06 +0.93 -0.21
220 (104) +10.86 +9.80 +8.73 +7.64 +6.54 +5.43 +4.31 +3.17 +2.03 +0.88

5-154
GEK 97310
VOLUME I
Figure 5-38. Lube Oil Pressure Correction for Industrial LM2500 Gas Generator.

5-155
GEK 97310
VOLUME I
NOTE
limit is 47.6 to 58.5 psig. (328-403 kPa).

Oil
Supply
Temp
(°F)(°C) 8000 8100 8200 8300 8400 8500 8600 8700 8800 8900 9000
100 (38) -4.08 -5.20 -6.34 -7.49 -8.65 -9.82 -10.99 -12.18 -13.37 -14.57 -15.78
110 (43) +0.05 -1.01 -2.07 -3.14 -4.22 -5.31 -6.41 -7.52 -8.63 -9.76 -10.89
120 (49) +3.54 +2.54 +1.54 +0.54 -0.48 -1.50 -2.53 -3.57 -4.61 -5.66 -6.72
130 (54) +6.58 +5.59 +4.60 +3.59 +2.57 +1.55 +0.51 -0.53 -1.58 -2.64 -3.71
140 (60) +8.65 +7.71 +6.77 +5.82 +4.87 +3.90 +2.88 +1.85 +0.80 -0.30 -1.40
150 (66) +10.25 +9.27 +8.27 +7.27 +6.26 +5.25 +4.22 +3.18 +2.13 +1.07 0
160 (71) +11.32 +10.36 +9.40 +8.42 +7.44 +6.45 +5.44 +4.43 +3.40 +2.37 +1.33
170 (77) +12.33 +11.39 +10.45 +9.50 +8.54 +7.57 +6.59 +5.60 +4.60 +3.59 +2.58
180 (82) +13.27 +12.37 +11.45 +10.52 +9.59 +8.64 +7.68 +6.72 +5.74 +4.75 +3.76
190 (88) +14.19 +13.30 +12.40 +11.49 +10.58 +9.65 +8.72 +7.78 +6.80 +5.83 +4.83
200 (93) +15.04 +14.15 +13.25 +12.34 +11.42 +10.49 +9.55 +8.60 +7.64 +6.67 +5.69
210 (99) +15.71 +14.84 +13.95 +13.65 +12.14 +11.21 +10.27 +9.33 +8.37 +7.41 +6.43
220 (104) +16.31 +15.44 +14.56 +13.67 +12.77 +11.86 +10.94 +10.00 +9.06 +8.11 +7.15

Oil
Supply
Temp
(°F)(°C) 9100 9200 9300 9400 9500 9600 9700 9800 9900 10000
100 (38) -16.99 -18.22 -19.45 -20.70 -21.95 -23.21 -24.49 -25.76 -27.05 -28.35
110 (43) -12.03 -13.18 -14.34 -15.51 -16.68 -17.86 -19.05 -20.25 -21.46 -22.67
120 (49) -7.78 -8.89 -9.93 -11.07 -12.24 -13.41 -14.60 -15.79 -17.00 -18.21
130 (54) -4.79 -5.86 -6.94 -8.04 -9.13 -10.24 -11.35 -12.48 -13.66 -14.85
140 (60) -2.52 -3.65 -4.78 -5.94 -7.09 -8.25 -9.41 -10.60 -11.79 -13.00
150 (66) -1.09 -2.17 -3.28 -4.40 -5.52 -6.65 -7.79 -8.94 -10.11 -11.28
160 (71) +0.27 -0.79 -1.87 -2.95 -4.05 -5.15 -6.27 -7.39 -8.53 -9.67
170 (77) +1.55 +0.51 -0.54 -1.60 -2.67 -3.74 -4.83 -5.93 -7.03 -8.15
180 (82) +2.76 +1.74 +0.72 -0.32 -1.36 -2.41 -3.49 -4.57 -5.67 -6.79
190 (88) +3.82 +2.80 +1.78 +0.74 -0.31 -1.37 -2.44 -3.52 -4.61 -5.71
200 (93) +4.69 +3.68 +2.65 +1.62 +0.58 -0.48 -1.54 -2.62 -3.70 -4.80
210 (99) +5.44 +4.44 +3.44 +2.42 +1.39 +0.35 -0.69 -1.75 -2.82 -3.90
220 (104) +6.18 +5.20 +4.21 +3.20 +2.19 +1.17 +0.14 -0.90 -1.95 -3.02

5-156
GEK 97310
VOLUME I
Figure 5-39. Lube Oil Pressure Correction for Industrial LM2500 Gas Generators.

5-157
GEK 97310
VOLUME I
MIL-L-23699 OIL WITH V.G. CONTROL PN L34379
NOTE

Oil
Supply
Temp
(°F)(°C) 8000 8100 8200 8300 8400 8500 8600 8700 8800 8900 9000
100 (38) -8.86 -10.16 -11.46 -12.77 -14.08 -15.41 -16.75 -18.11 -19.47 -20.84 -22.22
110 (43) -4.32 -5.52 -6.73 -7.94 -9.17 -10.41 -11.66 -12.93 -14.20 -15.48 -16.78
120 (49) -0.65 -1.81 -2.95 -4.10 -5.25 -6.40 -7.57 -8.74 -9.92 -11.11 -12.30
130 (54) +2.80 +1.74 +0.70 -0.35 -1.40 -2.47 -3.54 -4.62 -5.71 -6.80 -7.89
140 (60) +6.11 +5.15 +4.19 +3.22 +2.25 +1.26 +0.27 -0.73 -1.73 -2.73 -3.74
150 (66) +9.16 +8.27 +7.38 +6.48 +5.58 +4.67 +3.75 +2.82 +1.89 +0.94 0
160 (71) +11.87 +11.04 +10.19 +9.34 +8.49 +7.63 +6.76 +5.89 +5.01 +4.12 +3.23
170 (77) +14.25 +13.42 +12.58 +11.73 +10.87 +10.01 +9.14 +8.27 +7.39 +6.50 +5.61
180 (82) +15.96 +15.17 +14.38 +13.58 +12.75 +11.91 +11.05 +10.18 +9.31 +8.43 +7.55
190 (88) +17.39 +16.59 +15.77 +14.93 +14.09 +13.24 +12.38 +11.51 +10.64 +9.75 +8.86
200 (93) +18.37 +17.57 +16.77 +15.94 +15.10 +14.24 +13.38 +12.51 +11.63 +10.73 +9.83
210 (99) +19.12 +18.32 +17.51 +16.69 +15.86 +15.02 +14.18 +13.32 +12.46 +11.59 +10.70
220 (104) +19.79 +19.01 +18.21 +17.40 +16.59 +15.77 +14.94 +14.10 +13.25 +12.40 +11.54

Oil
Supply
Temp
(°F)(°C) 9100 9200 9300 9400 9500 9600 9700 9800 9900 10000
100 (38) -23.61 -25.01 -26.42 -27.84 -29.27 -30.72 -32.17 -33.64 -35.11 -36.60
110 (43) -18.12 -19.46 -20.82 -22.18 -23.57 -24.96 -26.36 -27.78 -29.17 -30.56
120 (49) -13.51 -14.72 -15.94 -17.17 -18.42 -19.68 -20.95 -22.20 -23.46 -24.73
130 (54) -8.98 -10.08 -11.20 -12.32 -13.45 -14.58 -15.73 -16.88 -18.04 -19.21
140 (60) -4.75 -5.77 -6.80 -7.83 -8.87 -9.92 -10.98 -12.05 -13.12 -14.20
150 (66) -0.96 -1.92 -2.89 -3.87 -4.85 -5.84 -6.84 -7.84 -8.85 -9.86
160 (71) +2.33 +1.41 +0.45 -0.52 -1.50 -2.48 -3.48 -4.47 -5.48 -6.49
170 (77) +4.71 +3.81 +2.90 +1.99 +1.07 +0.10 -0.87 -1.86 -2.85 -3.85
180 (82) +6.65 +5.73 +4.78 +3.83 +2.87 +1.90 +0.93 -0.06 -1.05 -2.06
190 (88) +7.96 +7.05 +6.11 +5.16 +4.19 +3.22 +2.24 +1.25 +0.25 -0.76
200 (93) +8.92 +8.01 +7.08 +6.15 +5.21 +4.25 +3.29 +2.32 +1.34 +0.36
210 (99) +9.81 +8.92 +8.01 +7.09 +6.17 +5.24 +4.30 +3.35 +2.39 +1.42
220 (104) +10.66 +9.78 +8.89 +8.00 +7.09 +6.18 +5.25 +4.32 +3.28 +2.44
Corrected Pressure 63 - 11.11 = 51.9 psig (358 kPa)

5-158
GEK 97310
VOLUME I
MIL-L-23699 Oil with V.G. Control PN L34379

5-159
GEK 97310
VOLUME I
NOTE
limit is 39.5 to 48.5 psig. (272-334 kPa).
Oil
Supply
Temp
(°F)(°C) 8000 8100 8200 8300 8400 8500 8600 8700 8800 8900 9000
100 (38) -4.96 -5.97 -6.97 -7.98 -8.99 -10.02 -11.05 -12.09 -13.14 -14.18 -15.22
110 (43) -1.59 -2.50 -3.42 -4.35 -5.29 -6.23 -7.19 -8.14 -9.09 -10.04 -11.01
120 (49) +1.48 +0.63 -0.22 -1.08 -1.94 -2.81 -3.69 -4.58 -5.47 -6.37 -7.28
130 (54) +4.16 +3.37 +2.56 +1.76 +0.94 +0.12 -0.70 -1.53 -2.37 -3.21 -4.09
140 (60) +6.42 +5.63 +4.83 +4.02 +3.21 +2.39 +1.56 +0.73 -0.10 -0.94 -1.79
150 (66) +8.14 +7.39 +6.60 +5.81 +5.01 +4.20 +3.38 +2.56 +1.73 +0.87 0
160 (71) +9.42 +8.64 +7.86 +7.06 +6.26 +5.44 +4.63 +3.80 +2.96 +2.13 +1.25
170 (77) +10.37 +9.59 +8.80 +8.00 +7.19 +6.38 +5.55 +4.72 +3.88 +3.03 +2.17
180 (82) +11.08 +10.32 +9.54 +8.76 +7.97 +7.17 +6.36 +5.55 +4.73 +3.90 +3.06
190 (88) +11.76 +11.01 +10.25 +9.48 +8.71 +7.93 +7.14 +6.35 +5.54 +4.73 +3.91
200 (93) +12.41 +11.68 +10.94 +10.19 +9.43 +8.66 +7.89 +7.12 +6.31 +5.51 +4.68
210 (99) +13.03 +12.31 +11.57 +10.82 +10.05 +9.29 +8.51 +7.72 +6.93 +6.13 +5.32
220 (104) +13.54 +12.81 +12.09 +11.35 +10.60 +9.84 +9.08 +8.30 +7.52 +6.73 +5.93

Oil
Supply
Temp
(°F)(°C) 9100 9200 9300 9400 9500 9600 9700 9800 9900 10000
100 (38) -16.28 -17.34 -18.41 -19.49 -20.57 -21.67 -22.77 -23.88 -24.99 -26.12
110 (43) -11.98 -12.96 -13.94 -14.93 -15.93 -16.94 -17.95 -18.97 -20.00 -21.03
120 (49) -8.19 -9.11 -10.04 -10.97 -11.91 -12.86 -13.81 -14.77 -15.73 -16.69
130 (54) -4.99 -5.90 -6.82 -7.75 -8.68 -9.62 -10.57 -11.52 -12.48 -13.44
140 (60) -2.64 -3.49 -4.38 -5.29 -6.21 -7.13 -8.06 -9.00 -9.94 -10.89
150 (66) -0.89 -1.78 -2.68 -3.59 -4.50 -5.43 -6.36 -7.30 -8.25 -9.21
160 (71) +0.36 -0.53 -1.43 -2.34 -3.26 -4.20 -5.13 -6.08 -7.03 -7.99
170 (77) +1.31 +0.43 -0.45 -1.34 -2.24 -3.15 -4.06 -4.99 -5.92 -6.86
180 (82) +2.21 +1.35 +0.49 -0.38 -1.26 -2.15 -3.05 -3.95 -4.86 -5.79
190 (88) +3.08 +2.24 +1.39 +0.54 -0.32 -1.19 -2.09 -2.98 -3.89 -4.82
200 (93) +3.85 +3.01 +2.16 +1.30 +0.44 -0.44 -1.32 -2.22 -3.12 -4.03
210 (99) +4.50 +3.67 +2.83 +1.99 +1.14 +0.27 -0.06 -1.47 -2.36 -3.25
220 (104) +5.13 +4.31 +3.49 +2.66 +1.82 +0.97 +0.12 -0.75 -1.62 -2.50
Pressure Additive -5.9 psig (41 kPa)
Corrected Pressure 53 - 5.9 = 47.1 psig (325 kPa)

5-160
GEK 97310
VOLUME I

5-161
GEK 97310
VOLUME I
NOTE
limit is 60.0 to 74.0 psig (414-510 kPa).
Oil
Supply
Temp
(°F)(°C) 8000 8100 8200 8300 8400 8500 8600 8700 8800 8900 9000
100 (38) -12.24 -13.89 -15.53 -17.18 -18.85 -20.54 -22.23 -23.95 -25.67 -27.41 -29.16
110 (43) -6.58 -8.14 -9.72 -11.32 -12.92 -14.48 -16.05 -17.63 -19.23 -20.83 -22.46
120 (49) -1.58 -2.99 -4.42 -5.86 -7.30 -8.73 -10.17 -11.62 -13.07 -14.50 -15.96
130 (54) +3.30 +2.03 +0.76 -0.52 -1.81 -3.10 -4.42 -5.74 -7.07 -8.41 -9.76
140 (60) +7.75 +6.56 +5.37 +4.17 +2.95 +1.73 +0.50 -0.74 -1.99 -3.25 -4.52
150 (66) +11.53 +10.42 +9.30 +8.16 +7.02 +5.87 +4.71 +3.54 +2.37 +1.19 0
160 (71) +14.72 +13.59 +12.46 +11.31 +10.17 +9.00 +7.82 +6.64 +5.45 +4.25 +3.06
170 (77) +16.97 +15.91 +14.84 +13.72 +12.57 +11.42 +10.25 +9.02 +7.77 +6.51 +5.24
180 (82) +18.47 +17.34 +16.20 +15.05 +13.88 +12.70 +11.50 +10.30 +9.08 +7.85 +6.61
190 (88) +19.51 +18.40 +17.28 +16.14 +15.00 +13.85 +12.68 +11.50 +10.31 +9.11 +7.89
200 (93) +20.48 +19.40 +18.30 +17.19 +16.07 +14.94 +13.80 +12.64 +11.48 +10.30 +9.11
210 (99) +21.41 +20.34 +19.27 +18.18 +17.09 +15.98 +14.86 +13.73 +12.59 +11.43 +10.27
220 (104) +22.30 +21.25 +20.20 +19.13 +18.06 +16.97 +15.87 +14.74 +13.60 +12.44 +11.26

Oil
Supply
Temp
(°F)(°C) 9100 9200 9300 9400 9500 9600 9700 9800 9900 10000
100 (38) -30.93 -32.71 -34.50 -36.31 -38.16 -40.04 -41.94 -43.86 -45.79 -47.73
110 (43) -24.09 -25.73 -27.39 -29.06 -30.72 -32.40 -34.09 -35.81 -37.54 -39.30
120 (49) -17.41 -18.88 -20.36 -21.85 -23.35 -24.86 -26.28 -27.92 -29.46 -31.01
130 (54) -11.12 -12.50 -13.88 -15.27 -16.67 -18.08 -19.50 -20.93 -22.37 -23.82
140 (60) -5.80 -7.09 -8.39 -9.69 -11.01 -12.33 -13.67 -15.01 -16.36 -17.73
150 (66) -1.24 -2.53 -3.83 -5.14 -6.47 -7.80 -9.14 -10.49 -11.86 -13.23
160 (71) +1.85 -0.63 -0.59 -1.82 -3.12 -4.43 -5.76 -7.10 -8.48 -9.91
170 (77) +3.96 +2.67 +1.36 +0.04 -1.29 -2.63 -3.99 -5.36 -6.74 -8.14
180 (82) +5.36 +4.09 +2.80 +1.51 +0.21 -1.10 -2.43 -3.77 -5.12 -6.48
190 (88) +6.66 +5.42 +4.17 +2.91 +1.63 +0.35 -0.95 -2.26 -3.58 -4.92
200 (93) +7.90 +6.69 +5.47 +4.23 +2.98 +1.72 +0.45 -0.83 -2.13 -3.43
210 (99) +9.09 +7.90 +6.70 +5.49 +4.26 +3.00 +1.74 +0.45 -0.86 -2.17
220 (104) +10.07 +8.87 +7.66 +6.44 +5.20 +3.95 +2.69 +1.41 +0.12 -1.17

5-162
GEK 97310
VOLUME I

5-163
GEK 97310
VOLUME I
NOTE
Oil
Supply
Temp
(°F)(°C) 8000 8100 8200 8300 8400 8500 8600 8700 8800 8900 9000
100 (38) -3.53 -4.74 -5.97 -7.20 -8.44 -9.68 -10.94 -12.22 -13.50 -14.79 -16.09
110 (43) -0.98 -0.16 -1.30 -2.45 -3.62 -4.79 -5.97 -7.16 -8.36 -9.57 -10.78
120 (49) +4.76 +3.70 +2.62 +1.54 +0.45 -0.65 -1.75 -2.87 -3.99 -5.12 -6.33
130 (54) +7.80 +6.73 +5.65 +4.56 +3.46 +2.34 +1.22 +0.11 -1.02 -2.15 -3.30
140 (60) +10.07 +9.01 +7.94 +6.86 +5.75 +4.59 +3.42 +2.24 +1.05 -0.15 -1.37
150 (66) +11.35 +10.27 +9.18 +8.07 +6.96 +5.83 +4.69 +3.53 +2.37 +1.20 0
160 (71) +12.39 +11.33 +10.26 +9.18 +8.09 +6.99 +5.87 +4.75 +3.61 +2.46 +1.30
170 (77) +13.38 +12.34 +11.30 +10.24 +9.17 +8.09 +7.00 +5.90 +4.79 +3.66 +2.53
180 (82) +14.32 +13.30 +12.28 +11.25 +10.20 +9.15 +8.08 +7.00 +5.91 +4.82 +3.70
190 (88) +15.23 +14.23 +13.23 +12.21 +11.17 +10.11 +9.03 +7.94 +6.85 +5.74 +4.62
200 (93) +15.96 +14.96 +13.95 +12.93 +11.89 +10.85 +9.79 +8.72 +7.64 +6.55 +5.44
210 (99) +16.61 +15.63 +14.63 +13.62 +12.60 +11.57 +10.53 +9.48 +8.42 +7.34 +6.25
220 (104) +17.24 +16.28 +15.30 +14.30 +13.30 +12.29 +11.26 +10.23 +9.18 +8.12 +7.05

Oil
Supply
Temp
(°F)(°C) 9100 9200 9300 9400 9500 9600 9700 9800 9900 10000
100 (38) -17.40 -18.72 -20.05 -21.38 -22.73 -24.08 -25.45 -26.83 -28.22 -29.61
110 (43) -12.01 -13.24 -14.49 -15.74 -17.00 -18.27 -19.55 -20.84 -22.13 -23.44
120 (49) -7.56 -8.80 -10.05 -11.30 -12.57 -13.84 -15.13 -16.42 -17.73 -19.04
130 (54) -4.44 -5.61 -6.83 -8.07 -9.32 -10.58 -11.90 -13.24 -14.59 -15.96
140 (60) -2.59 -3.83 -5.08 -6.35 -7.62 -8.91 -10.21 -11.52 -12.84 -14.18
150 (66) -1.20 -2.41 -3.63 -4.86 -6.11 -7.37 -8.63 -9.92 -11.21 -12.51
160 (71) +0.13 -1.06 -2.25 -3.46 -4.67 -5.90 -7.14 -8.40 -9.66 -10.93
170 (77) +1.38 +0.23 -0.94 -2.12 -3.31 -4.51 -5.73 -6.95 -8.18 -9.43
180 (82) +2.59 +1.43 +0.28 -0.91 -2.10 -3.32 -4.54 -5.77 -7.02 -8.28
190 (88) +3.48 +2.34 +1.18 +0.01 -1.17 -2.36 -3.56 -4.78 -6.00 -7.24
200 (93) +4.33 +3.20 +2.06 +0.91 -0.25 -1.42 -2.61 -3.80 -5.01 -6.23
210 (99) +5.16 +4.05 +2.93 +1.79 +0.65 -0.50 -1.67 -2.85 -4.04 -5.23
220 (104) +5.97 +4.88 +3.77 +2.66 +1.53 +0.40 -0.75 -1.91 -3.08 -4.26

5-164
GEK 97310
VOLUME I
5-165
GEK 97310
VOLUME I
5-3.32 Lube Supply Pressure at Pressure

Tap for Temperature vs Gas Generator
Speed. The following figures provide nominal
lube supply pressure at pressure tap vs gas
generator speed and lube supply temperature.

5-166
GEK 97310
VOLUME I
Figure 5-44. LM2500 Gas Turbine Lube Supply Pressure at Pressure Tap vs Gas Generator
Speed Using MIL-L-7808 Lube Oil and V.G. Control PN L34379
5-167
GEK 97310
VOLUME I
Figure 5-45. LM2500 Gas Generator Lube Supply Pressure at Pressure Tap vs Gas Generator
5-168
GEK 97310
VOLUME I
5-169
GEK 97310
VOLUME I
5-170
GEK 97310
VOLUME I
Speed Using MIL-L-7808 Lube Oil with V.G. Control PN L34379 and 3R Damper Bearing
5-171
GEK 97310
VOLUME I
5-172
GEK 97310
VOLUME I
5-173
GEK 97310
VOLUME I
5-174
GEK 97310
VOLUME I
5-4 SERVICING (3) In order to eliminate as many vari-

ables as possible, an attempt should be made to
5-4.1 Oil Tank. Service lube oil storage record all data points at approximately the
tank per packager’s manual. same gas generator speed (± 100 RPM).
5-4.2 Water Servicing and Pumping (4) Any adjustment or change made
Requirements (NOx Suppression). For gas to the gas generator variable stator system will
generators equipped with Nox suppression have an effect on gas generator performance
systems, refer to Chapter 4. parameters. If a variable stator system adjust-
ment is made, a new baseline curve must be
5-4.3 Compressor Efficiency Trending. established.
a. General. The efficiency of an engine is (5) A trend curve is valid only as long
adversely affected by a contaminated (dirty) as the gas generator remains in the same instal-
compressor section. Cleaning the compressor lation, with the same instrumentation.
section can return the engine to a high effi-
ciency condition. A procedure for monitoring (6) The following operating data are
engine performance over extended operating suggested for monitoring the condition of the
periods is provided in succeeding sub-para- LM2500 engine compressor. These items
graphs. The procedure encompasses the collec- should be recorded at a gas generator speed of
tion and correction of certain engine operating 9000 RPM. Readings should be taken after a
data and the plotting of this data on a curve. five minute stabilization period.
The results are then compared with like data
obtained when the engine was in a new and Item Units Accuracy
clean condition. This comparison will aid the
Discharge gas °F (°F=°C x ±5°F(±3°C)
operator in determining when to clean the
temperature 1.8+32)
engine compressor section. (T5.4)
b. Compressor Condition Trend Curve. Ambient °F 1°F (0.5°C)
temperature
(1) The establishment of a Compres- (Tamb)
sor Condition Trend Curve may be useful in
determining the efficiency of the compressor. Discharge gas psig (psig= ±1/4%
This data may be useful in establishing an opti- pressure (P5.4) kPa/
mum wash interval. 6.89476)
(2) In formulating a compressor con- Inlet Pressure inches of ±0.1 inch
dition trend curve it is necessary that good (P2) water (2.54 mm)
baseline data be obtained when the particular
engine is known to be in a clean condition. (inches =
This baseline data is used to develop the initial mm/25.4)
zero-time point on the trend curve and is repre-
sented by the A° line on the sample curve in Ambient inches of ±0.1 inch
figure 5-52. pressure mercury (2.54 mm)
(Pamb) (absolute)

5-175
GEK 97310
VOLUME I
Figure 5-52. Sample Trend Curve of Discharge Gas Temperature at a

Constant Pressure Ratio vs. Operating Time
5-176
GEK 97310
VOLUME I
(7) Observed instrumentation read- 2 Convert observed gas

ings must be converted to like units and cor- generator inlet total pressure (inches of water)
rected to standard conditions of pressure and to P2 (gas generator inlet total pressure in
temperature. The temperature correction factor pounds per square inch absolute) by using the
is designated THETA (Θ) and the pressure formula P2 = Pamb – (observed reading x
correction is designated Pamb. 0.03613).
(a) Convert temperatures read in 3 Convert observed gas

°C to °F, pressures read in kPa to psig, and generator discharge gas pressure (pounds per
pressures read in mm to inches per formulas in square inch) to P5 (gas generator discharge
step (6). pressure in pounds per square inch absolute)
by adding Pamb to observed reading.
(b) Calculate corrected gas gen-
erator discharge temperature as follows: 4 Divide P5 by P2.
1 In table 5-30, opposite (8) Using corrected data developed in

the ambient temperature (°F), find Θ (theta). step (7), plot a curve of corrected gas generator
discharge temperature against gas generator
NOTE pressure ratio. See sample shown in
figure 5-53.
If the ambient temperature is beyond
the range of the table 5-30, calculate Θ (9) Establish performance analysis
using the following formula: curve as follows:
Θ= Ambient temperature (°F) + 460 (a) Select pressure ratio within
519 range plotted in step (7)(c). This pressure ratio
will be used throughout the performance anal-
2 Convert observed gas ysis period.
generator discharge temperature, °F to °R by
adding 460. (b) Establish curve of corrected
gas generator discharge temperature against
3 Divide gas generator dis- gas generator operating hours (figure 5-52).
charge temperature, °R by Θ.
1 Periodically, as deter-
(c) Calculate gas generator pres- mined by the engine operator, repeat this
sure ratio (P5/P2). procedure.
1 Convert observed ambi- 2 Using new curve plotted

ent pressure (inches of mercury absolute) to per step (8), and the same pressure ratio used
Pamb (ambient pressure in pounds per square to establish the first point on the performance
inch absolute) by multiplying observed read- curve, plot the second, third, etc. points.
ing (step (6)) by 0.49116.

5-177
GEK 97310
VOLUME I
Table 5-30. STANDARD DAY TEMPERATURE CORRECTION FACTOR

Theta Θ =Ambient Temperature °R=T(°F) + 460
Standard Temperature °R 519
T(°F) Θ T(°F) Θ T(°F) Θ T(°F) Θ T(°F) Θ
129 1.135 90 1.060 51 0.986 12 0.910 -27 0.834
128 1.133 89 1.058 50 0.984 11 0.908 -28 0.832
127 1.131 88 1.056 49 0.982 10 0.907 -29 0.831
126 1.129 87 1.055 48 0.980 9 0.905 -30 0.829
125 1.127 86 1.053 47 0.978 8 0.903 -31 0.827
124 1.125 85 1.051 46 0.976 7 0.901 -32 0.825
123 1.123 84 1.049 45 0.974 6 0.899 -33 0.823
122 1.122 83 1.049 44 0.972 5 0.897 -34 0.821
121 1.120 82 1.045 43 0.970 4 0.895 -35 0.819
120 1.118 81 1.043 42 0.968 3 0.893 -36 0.817
119 1.116 80 1.041 41 0.966 2 0.891 -37 0.815
118 1.114 79 1.039 40 0.964 1 0.889 -38 0.813
117 1.112 78 1.037 39 0.962 0 0.887 -39 0.811
116 1.110 77 1.035 38 0.960 -1 0.884 -40 0.809
115 1.108 76 1.033 37 0.959 -2 0.883 -41 0.807
114 1.106 75 1.031 36 0.957 -3 0.881 -42 0.805
113 1.104 74 1.029 35 0.955 -4 0.879 -43 0.804
112 1.102 73 1.028 34 0.953 -5 0.877 -44 0.802
111 1.100 72 1.026 33 0.951 -6 0.875 -45 0.800
110 1.098 71 1.024 32 0.949 -7 0.873 -46 0.798
109 1.096 70 1.022 31 0.947 -8 0.871 -47 0.796
108 1.095 69 1.020 30 0.945 -9 0.869 -48 0.794
107 1.093 68 1.018 29 0.943 -10 0.867 -49 0.792
106 1.091 67 1.016 28 0.941 -11 0.865 -50 0.790
105 1.089 66 1.014 27 0.939 -12 0.863 -51 0.788
104 1.087 65 1.014 26 0.937 -13 0.861 -52 0.786
103 1.085 64 1.010 25 0.935 -14 0.859 -53 0.784
102 1.083 63 1.008 24 0.934 -15 0.857 -54 0.782
101 1.082 62 1.006 23 0.932 -16 0.856 -55 0.780
100 1.080 61 1.004 22 0.930 -17 0.854 -56 0.778
99 1.078 60 1.002 21 0.928 -18 0.852 -57 0.777
98 1.076 59 1.000 20 0.926 -19 0.850 -58 0.775
97 1.0764 58 0.999 19 0.924 -20 0.848 -59 0.773
96 1.072 57 0.997 18 0.922 -21 0.846 -60 0.771
95 1.070 56 0.995 17 0.920 -22 0.844 -61 0.769
94 1.068 55 0.993 16 0.918 -23 0.842 -62 0.767
93 1.066 54 0.991 15 0.916 -24 0.840 -63 0.765
92 1.064 53 0.989 14 0.914 -25 0.838 -64 0.763
91 1.062 52 0.987 13 0.912 -26 0.836 -65 0.761

5-178
GEK 97310
VOLUME I
Figure 5-53. Sample Curve of Discharge Gas Temperature vs. Pressure Ratio

5-179
GEK 97310
VOLUME I
(10) At any time corrected gas genera- b. Definitions.

tor discharge temperature has increased a total
of 30°F (16.6°C) above initial temperature (1) Liquid Detergent: A concentrated
(clean condition temperature), it is recom- solution of water soluble, surface active agents
mended that the compressor be cleaned. and emulsifiable solvent.
5-4.4 Compressor Cleaning. (2) Wash Solution: A solution or

emulsion of liquid detergent and water or
a. General. Compressor cleaning is detergent and antifreeze mixture.
accomplished by periodically spraying a clean-
ing solution into the bellmouth to remove air- (3) Antifreeze Mixture: A mixture of
foil deposits. Cleaning periods and intervals antifreeze and water to be used for preparing
depend upon the type and accumulation of the cleaning solution or rinsing the compressor
deposits to be removed. The gas turbine bell- when the ambient air temperature is 50°F
mouth is equipped with a manifold for inject- (10°C) or below.
ing cleaning solutions and rinse water into the
compressor after the gas turbine is shut down (4) On-line Compressor Cleaning: A
(Off-Line Compressor Cleaning). As an method of removing buildup of deposits on
option, the installation may be equipped with a compressor components while the engine is
waterwash manifold system for injecting operating.
cleaning solution into the compressor during
engine operation (On-Line Compressor Clean- (5) Off-line Compressor Cleaning: A
ing). Injection systems for on-line cleaning are method of removing buildup of deposits on
available from packagers and/or other com- compressor components while the engine is
mercial sources. motored by the starter (also referred to as
Cranksoak Compressor Cleaning).

5-180
GEK 97310
VOLUME I
c. Off-Line (Cranksoak) Compressor OR ADDITIVES CONTAINING

Cleaning. CHLORINE, SODIUM OR POTAS-
SIUM ARE NOT PERMITTED
WARNING SINCE THEY MAY ATTACK THE
• METHYL ETHYL KETONE, TT- TITANIUM AND OTHER METALS
M-261, IS FLAMMABLE AND IN THE GAS GENERATOR.
TOXIC TO SKIN, EYES, AND NOTE
RESPIRATORY TRACT.
SKIN AND EYE PROTECTION • Cleaners conforming to
IS REQUIRED. AVOID MID-TD-0000-5 have been found to
REPEATED OR PROLONGED be capable of compressor cleaning
CONTACT. USE IN A WELL- without being detrimental to the
VENTILATED AREA. engine. Water purity for wash and
rinse shall conform to
• ACETONE, O-A-51: EXPLO- MID-TD-0000-4.
SIVE. FLAMMABLE. AVOID
SOURCES OF IGNITION, • The following compressor cleaning pro-
SPARKS, OR FLAMES. DO NOT cedure should be initiated only after
INHALE, INGEST, OR LET THIS T5.4 (Engine Exhaust Gas Temperature)
MATERIAL TOUCH YOU. has returned to below 200°F (93°C) after
ASPHYXIANT. CENTRAL NER- shutdown. Cooling may be expedited by
VOUS SYSTEM DAMAGE/ motoring unit with the starter. If it is
ADVERSE EFFECTS. LIVER impossible to shut down the engine,
AND KIDNEY DAMAGE. cleaning can be accomplished with the
ALLERGEN. IRRITANT. PER- engine operating per step d.
SONAL PROTECTIVE EQUIP- • The amount of cleaning and rinse solu-
MENT REQUIRED. DO NOT tion required is a function of the contam-
USE IN AN ENCLOSED SPACE. inants present. The cleaning interval is
USE IN A WELL-VENTILATED dependent upon the time required for
AREA OR WITH LOCAL contaminant buildup on the compressor
MECHANICAL EXHAUST VEN- flow path surfaces. The bellmouth mani-
TILATION - IF NOT AVAIL- fold will flow 15 gallons (5.7 liters) of
ABLE, USE AN APPROVED wash solution per minute at a pressure of
RESPIRATOR. 45 psig (310 kPa).
• ALCOHOL IS FLAMMABLE • The time allotted for soak in step (5) of
AND TOXIC TO SKIN, EYES, the sequence is the minimum. Addi-
AND RESPIRATORY TRACT. tional soak time may be required
SKIN AND EYE PROTECTION depending on contamination type.
IS REQUIRED. AVOID
REPEATED OR PROLONGED (1) If outside air temperature is at or
CONTACT. USE IN A WELL- below 50°F (10°C), add either isopropyl alco-
VENTILATED AREA. hol, acetone, or MEK to prevent the wash solu-
tion from freezing. Refer to Appendix A,
CAUTION MID-TD-0000-5. Off-line wash should not be
accomplished with outside air temperature
THE USE OF NONISOPROPYL
below -30°F (-34°C).
ALCOHOLS, ETHYLENE GLYCOL,

5-181
GEK 97310
VOLUME I
NOTE
WARNING
LIQUID DETERGENT CAN BE • During the wash and rinse cycle,
HARMFUL. COMPLY WITH MAN- approximately 10% of the solution
UFACTURER’S RECOMMENDED may leak through the engine casings
HANDLING PROCEDURES. USE and openings to the exterior of the
ONLY IN A WELL VENTILATED engine.
AREA. DO NOT SMOKE OR USE
NEAR OPEN FLAME. AVOID • Residual waste following water wash
INHALATION OF FUMES AND with detergent should be disposed of in
DIRECT CONTACT OF LIQUID accordance with local environmental
WITH EYES OR SKIN. regulations for specific location. Users
should contact the specific detergent
(2) Prepare 20 gallons (76 liters) of manufacturer for details relative to safe
water wash solution by mixing 19 gallons disposal of the product.
(72 liters) of water/antifreeze solution to 1 gal-
lon (3.8 liters) of detergent in water wash tank. (5) Allow engine to coast to a stop.
Refer to step e. for water and detergent chemi- Wait 10 minutes minimum and then rinse as
cal requirements. Wash solution temperature to follows:
be 100°-150°F (37.8°-66°C).
(a) If outside air temperature is
at or below 50°F (10°C), add either isopropyl
NOTE
alcohol, acetone, or MEK to prevent the rinse
The suggested dilution requirement is solution from freezing. Refer to Appendix A,
based on experience with several deter- MID-TD-0000-5.
gents. Refer to specific detergent man-
ufacturer instructions for proper (b) Fill water wash tank with
dilution requirements. 40 gallons (151 liters) of water or water/anti-
freeze solution. Refer to step e. for water
(3) Apply 45-55 psi (310-379 kPa) air chemical requirements. Rinse solution temper-
pressure to water wash tank. ature to be 100°-l50°F (37.8°-66°C).
(4) Energize the starter to motor the (c) Apply 45-55 psig
gas generator. When the compressor begins to (310-379 kPa) air pressure to water wash tank.
rotate, open the water supply valve to the spray
manifold. As the gas generator speed reaches (6) Repeat step (4) until all rinse
1200 rpm, de-energize the starter and close the water is used.
water supply valve. Allow the gas generator
speed to decrease. As the speed reaches (7) Inspect engine inlet. If not suffi-
0-100 rpm, re-energize the starter and repeat ciently clean, repeat cleaning cycle. If all
the cycle until all the solution is used. detergent is not rinsed, repeat rinse cycle.

5-182
GEK 97310
VOLUME I
Figure 5-54. Deleted

5-183
GEK 97310
VOLUME I
Figure 5-55. Deleted

5-184
GEK 97310
VOLUME I
Table 5-31. Deleted
(8) Within 30 minutes of off-line d. On-Line Compressor Cleaning. Refer

wash/rinse cycle completion, start and operate to particular manufacturer’s operating
the engine at idle for a period of five minutes instructions.
to dry. Normal operation may then be initiated.
(a) If the gas turbine operation is

prohibited during this period, motor the gas
generator on the starter at 1200 rpm minimum
for a period of five minutes minimum.

5-185
GEK 97310
VOLUME I
TED SINCE THEY MAY ATTACK

WARNING
THE TITANIUM AND OTHER
• METHYL ETHYL KETONE, TT- METALS IN THE GAS
M-261, IS FLAMMABLE AND GENERATOR.
TOXIC TO SKIN, EYES, AND
RESPIRATORY TRACT. • DETERGENT DILUTION REC-
SKIN AND EYE PROTECTION OMMENDATIONS AND INJEC-
IS REQUIRED. AVOID TION RATES MUST BE
REPEATED OR PROLONGED STRICTLY FOLLOWED. EXCES-
CONTACT. USE IN A WELL- SIVE CLEANING SOLUTION
VENTILATED AREA. MAY LEAD TO FLAMMABLE
AIR/CLEANER MIXTURE CAPA-
• ACETONE, O-A-51: EXPLO- BLE OF AUTO-IGNITION IN THE
SIVE. FLAMMABLE. AVOID COMPRESSOR. CONSULT
SOURCES OF IGNITION, DETERGENT MANUFACTURER
SPARKS, OR FLAMES. DO NOT TO INSURE DILUTION AND
INHALE, INGEST, OR LET THIS FLOW REQUIREMENTS FOR
MATERIAL TOUCH YOU. THE ONLINE CLEANER ARE
ASPHYXIANT. CENTRAL NER- PROPERLY MATCHED TO THE
VOUS SYSTEM DAMAGE/ ENGINE.
ADVERSE EFFECTS. LIVER
AND KIDNEY DAMAGE. NOTE
ALLERGEN. IRRITANT. PER- • Experience has shown that the use of
SONAL PROTECTIVE EQUIP- water alone, without the addition of
MENT REQUIRED. DO NOT detergents, may be effective at
USE IN AN ENCLOSED SPACE. online compressor cleaning. The
USE IN A WELL-VENTILATED addition of a cleaning solution may
AREA OR WITH LOCAL be required dependent upon the type
MECHANICAL EXHAUST VEN- and amount of deposits on the com-
TILATION - IF NOT AVAIL- pressor gas path surfaces.
ABLE, USE AN APPROVED
RESPIRATOR. • On-line compressor cleaning may be
beneficial to those users who are partic-
• ALCOHOL IS FLAMMABLE ularly sensitive to decreased compressor
AND TOXIC TO SKIN, EYES, performance and the down time required
AND RESPIRATORY TRACT. for off-line (Cranksoak) compressor
SKIN AND EYE PROTECTION cleaning. On-line compressor cleaning is
IS REQUIRED. AVOID intended to supplement the off-line
REPEATED OR PROLONGED cleaning procedure and is not intended
CONTACT. USE IN A WELL- as a replacement.
VENTILATED AREA.
CAUTION (1) If outside air temperature is at or
below 50°F (10°C), add either isopropyl alco-
• THE USE OF NON-ISOPROPYL hol, acetone, or MEK to prevent the wash solu-
ALCOHOLS, ETHYLENE GLY- tion from freezing. Refer to Appendix A,
COL, OR ADDITIVES CONTAIN- MID-TD-0000-5. On-line wash should not be
ING CHLORINE, SODIUM OR performed with inlet air temperature below
POTASSIUM ARE NOT PERMIT- 20°F (-6.7°C).
5-186
GEK 97310
VOLUME I
(3) The liquid detergents listed below

WARNING
have been used for crank soak cleaning on the
LIQUID DETERGENT CAN BE LM2500:
HARMFUL. COMPLY WITH MAN-
UFACTURER’S RECOMMENDED • B & B 3100, TC-100
HANDLING PROCEDURES. USE
ONLY IN A WELL VENTILATED • Ardrox 6322
AREA. DO NOT SMOKE OR USE
NEAR OPEN FLAME. AVOID • R-MC Turbine/Engine cleaner
INHALATION OF FUMES AND
DIRECT CONTACT OF LIQUID • Airworthy ZOK27/ZOK27LA
WITH EYES OR SKIN.
• Turbotect 950
NOTE
Recommended maximum duration of For on-line cleaning the detergents listed
on-line cleaning is 10 minutes per wash below have been used on the LM2500:
and the recommended maximum clean-
ing solution use is 100 gallons (378.5 • B & B TC-100
liters) per 24 hour period. Performance
monitoring may indicate that duration • Rochem Fyrewash
and frequency of washing may be
• R-MC Turbine/Engine Cleaner
adjusted.
• Airworthy ZOK27/ZOK27LA
e. Chemical properties of compressor
cleaning water and detergent. • Airworthy 20K.mx
(1) Chemical properties of the • Turbotect 950
wash and rinse water must conform to
GE Marine & Industrial Engines Specification • Contest 5000
MID-TD-0000-4. See Appendix A.
• Castrol Techniclean GT
(2) Chemical properties of the deter-
gent must conform to GE Marine & Industrial • Turboklenz
Engines Specification MID-TD-0000-5. See
Appendix A. • Protoklenz
• JAD MA-109C
• Turbo K

5-187
GEK 97310
VOLUME I
5-4.5 Gas Generator Pneumatic Starter CAUTION

Servicing. See figure 5-56.
WHEN REMOVING THE RELIEF
VALVE IN THE TOP OF THE
WARNING STARTER, DO NOT TURN THE
PROLONGED EXPOSURE OF THE SCREW IN THE CENTER OF THE
SKIN TO GAS TURBINE LUBE OIL RELIEF VALVE PLUG. THE RELIEF
MAY CAUSE DERMATITIS. SKIN VALVE STEM HAS EITHER TWO
SHALL BE THOROUGHLY OR THREE O-RINGS. USE CARE
WASHED AFTER CONTACT. SATU- WHEN REMOVING THE VALVE TO
RATED CLOTHING SHALL BE PREVENT CUTTING OR DISLODG-
REMOVED IMMEDIATELY AND ING THE O-RINGS.
WASHED.
(4) Loosen the relief valve and back it
NOTE out until the threads disengage. Carefully lift it
straight out of the port.
Periodic servicing is not required when
the Continuous Lube Starter is (5) Place a clean plastic pail or other
installed. An initial fill with 400 ±50 cc suitable container under the starter. Remove
of oil is required before first operation. the drain plug at 6 o’clock and allow the starter
Refer to Volume II SWP’s 122 01 and to drain completely.
122 02 for specific instructions.
(6) When the starter has drained com-
a. Service pneumatic starter with lube oil pletely, install the drain plug. If damaged,
MIL-L-23699 or MIL-L-7808 as follows: replace the metal gasket on the drain plug.
Carefully install the drain plug fingertight,
(1) Ensure engine is inoperable. making sure the plug is not cross-threaded.
Tighten to 135-150 lb in. (16.3-17.0 N·m) of
(2) Enclosure door must be open. torque and safety-wire.
(3) Deactivate fire extinguisher (7) Pour the drained oil into a beaker
(graduated in cc) and record the quantity. The
system.
amount of oil drained should be greater than
400 cc. If not, and the fill port plug, drain plug
and/or relief valve show no evidence of leak-
ing, proceed as follows:
(a) If the amount of oil drained
is 300 to 400 cc, proceed with servicing, but
hereafter, starter must be serviced every six
weeks or 700 hours of gas generator operation
until corrective action is taken.
(b) If the amount of oil drained
is less than 300 cc, replace the starter.

5-188
GEK 97310
VOLUME I
Figure 5-56. Pneumatic Starter

(8) Visually inspect the oil for con- NOTE
tamination. If contamination is present, per-
The relief valve stem may have had
form oil analysis. Isolate the source of the
two O-rings in the groove; however,
contamination and take appropriate corrective
when relief valve is reinstalled, use
action.
only one O-ring.
(9) If metal particles are found in the
(11) Install a new O-ring,
drained oil, replace the starter.
PN S9413-556 on the relief valve under the
(10) Fill the starter as follows: head. Install one new O-ring, PN S9413-12 (or
alternate MS9388-12 or MS17413-12) into the
(a) Pour 900 cc of the same type groove on the relief valve stem.
oil as already used in the starter into a 1 quart
or 1 liter beaker which is graduated in cubic CAUTION
centimeters (cc).
DO NOT TURN THE SLOTTED
(b) Use a long, flexible necked- SCREW IN THE CENTER OF THE
funnel to pour the oil into the starter. RELIEF VALVE PLUG.
(12) Lubricate the O-rings with engine

lube oil, and carefully install the relief valve
into the starter port. Tighten to 135-150 lb in.

5-189
GEK 97310
VOLUME I
5-5 STANDARD MAINTENANCE 5-5.3 Performance Of Maintenance

PRACTICES Within The Enclosure.
5-5.1 Purpose. This section covers basic WARNING

maintenance practices and procedures to be
followed during maintenance operations. • THE FOLLOWING STEPS MUST
BE PERFORMED BEFORE
5-5.2 Point of Reference. The points of ENTERING THE ENCLOSURE
reference, forward, aft, right, left, top, bottom, AND THESE CONDITIONS
and clock position, are used throughout this MUST BE MAINTAINED
section. They apply only to the engine assem- WHILE INSIDE THE ENCLO-
bly. Points of reference are established as SURE FOR MAINTENANCE
follows: ACTIONS, TO PREVENT
INJURY TO PERSONNEL.
Forward - The air intake end of the engine.
• FIRE EXTINGUISHING SYS-
Aft - The power turbine end of the engine. TEM (CO2) MUST BE DEACTI-
VATED BEFORE PERSONNEL
Right - The right side of the engine when ENTER THE ENCLOSURE FOR
viewed from the aft end and when the CORRECTIVE MAINTENANCE
engine is in the normal operating position IF THERE IS A POSSIBILITY
(gearbox down). THAT SUFFOCATION COULD
OCCUR IF SYSTEM WERE
Left - The side opposite the right side. ACTIVATED.
Top - The side of the engine which is up a. Deactivate the fire extinguishing sys-
when the engine is in the normal operating tem if CO2.
position.
b. Wear protective clothing, gloves,
Bottom - The side of the engine on which safety glasses, etc. as required by the mainte-
the gear boxes are mounted. nance action to be performed.
Clock Positions - The positions of the num- c. Ensure that the engine will not be
bers on a clock face as seen from the aft of started while personnel are inside the base/
the engine looking forward. The top posi- enclosure.
tion is at 12 o’clock; 3 o’clock is on the right
side, etc. d. Post an observer at exit while mainte-
nance is being performed inside enclosure.

5-190
GEK 97310
VOLUME I
5-5.4 Maintenance Practices.

WARNING
ELECTRICAL POWER TO SYS- NOTE
TEM ON WHICH MAINTENANCE
IS BEING PERFORMED MUST BE Most of the tasks outlined can be done
TURNED OFF TO PREVENT ARC- within the enclosure if the horizontal
ING AND POSSIBLY INJURY TO maintenance option is selected, pro-
PERSONNEL OR DAMAGE TO vided that the tooling is available.
COMPONENTS. TAG THE SWITCH Deviations from the procedures in the
OUT OF SERVICE TO PRECLUDE work packages in Volume II to adapt to
INADVERTENT ACTIVATION. the needs dictated by the enclosure
design are permitted, provided that
e. Turn off electrical power, liquid and air they do not compromise the intent of
service to system on which maintenance is to the instructions. The customer may
be performed. Tag the electrical switches “Out choose to do some modular change-out
of service for maintenance” to preclude inad- within the enclosure, and some outside,
vertent activation. as may suit his convenience. Consult
the General Electric Company for
f. Allow engine to cool. assistance in planning when questions
arise.
NOTE
a. Definition. The workscope for level 1
The following steps must be performed corrective maintenance allows replacement of
upon exiting the enclosure after com- external parts, adjustments, and other work
pletion of maintenance. (preventative and corrective) which can be
accomplished with the engine installed in the
g. Ensure that no personnel are inside the package or enclosure. See Volume II work
enclosure. packages. The workscope for level 2 corrective
maintenance allows replacement of major
h. Close enclosure door. engine sections and replacement or repair of
certain internal parts. Level 2 maintenance is
i. Turn on electrical power, liquid, and air performed on a non-installed engine at on-site
services. location, or on an installed engine in the pack-
age/enclosure insofar as the package/enclosure
NOTE design permits. Maintenance may be per-
Enclosure lights shall be turned on only formed with the engine vertical or horizontal,
when necessary for maintenance or depending on facilities and tooling. See
inspection in enclosure. Volume II.
j. Turn off enclosure lights when mainte-

nance and inspection are completed.

5-191
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VOLUME I
CAUTION c. Electrical Bonding Straps. Electrical

bonding strap contact surfaces shall be pre-
ALL HARDWARE ITEMS HAVE pared by removing all anodic film, grease,
BEEN MANUFACTURED TO paint lacquer, or other high-resistance material
ENGLISH MEASUREMENT UNITS. from an area at least one and one-half times the
USE OF SUBSTITUTE METRIC bonding surface contact area. Bonds shall be
SIZES IS NOT RECOMMENDED installed and contact surfaces sealed within
AND WILL VOID WARRANTY FOR 4 hours of cleaning. The area shall then be
INTERFACING PARTS. TOOLS IN painted to match the surrounding area.
METRIC SIZES SHOULD BE FUR-
NISHED WITH SUITABLE ADAPT- d. Torque. In these maintenance proce-
ERS TO MATE WITH ENGLISH dures, it is assumed that all threaded parts on
MEASUREMENT UNIT SIZES the gas turbine will be tightened to a specific
GIVEN. LIMITS, FITS, AND torque. Special torque values, if required, will
CLEARANCES MAY BE INTER- be stated in the text; otherwise, standard torque
PRETED IN EITHER ENGLISH OR values should be used.
METRIC UNITS AS SHOWN IN
THE TABLES. (1) Torque values are expressed in
lb in. (pound-inches) or lb ft (pound-feet)
b. V-Band Clamps. Install V-band clamps with the metric equivalent in N·m
as follows: (Newton-Meters). One pound-inch (or one
pound-foot) is the twisting force of one pound
(1) Tighten nut to half of required applied to a twist-type fastener (such as a bolt
torque value. or nut) with one inch (or one foot) of leverage.
This twisting force is applied to the fastener to
(2) Check around clamp for even secure the components.
seating over flanges.
CAUTION
(3) Using a non-metallic mallet,
lightly tap around clamp to distribute band IF TORQUE SHOULD INCREASE
tension. SIGNIFICANTLY PRIOR TO FINAL
SEATING OF ANY THREADED
(4) While increasing torque to FASTENER, REMOVE AND
required value, continue tapping around INSPECT THE FASTENER FOR
clamp. CAUSE OF TORQUE INCREASE.
(5) After reaching required torque, (2) Never over-torque any fastener.
tap around clamp again and recheck torque. Torque limits are provided in the text and in
tables 5-32 through 5-37; these limits must be
observed.

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Table 5-32. TORQUE WRENCH SIZE Table 5-33. MINIMUM BREAKAWAY

TORQUE FOR SELF–LOCKING NUTS
Torque Between Torque Wrench
Thread Threads Minimum Breakaway
0-25 lb in. 30 lb in. Size /Inch Torque
(0-2.8 N·m) (3.4 N·m)
0.136(6) 32/40 1.0 lb in. (0.113 N·m)
25-140 lb in. 50 lb in. 0.164(8) 32/36 1.5 lb in. (0.170 N·m)
(2.8-15.8 N·m) (17 N·m)
0.190(10) 32 2.0 lb in. (0.226 N·m)
140-550 lb in. 600 lb in. 1/4 28 3.5 lb in. (0.396 N·m)
(15.8-52 N·m) (68 N·m)
5/16 24 6.5 lb in. (0.735 N·m)
30-140 lb ft 150 lb ft 3/8 24 9.5 lb in. (1.084 N·m
(40.7-190 N·m) (203 N·m)
7/16 20 14.0 lb in. (1.6 N·m)
140-240 lb ft 250 lb ft 1/2 20 18.0 lb in. (2.0 N·m)
(190-325 N·m) (339 N·m)
9/16 18 32.0 lb in. (3.6 N·m)
240-1000 lb ft 1000 lb ft 5/8 18 50.0 lb in. (5.7 N·m)
(325-1356 N·m) (1356 N·m)
3/4 16 50.0 lb in. (5.7 N·m)
Table 5-34. TORQUE VALUES FOR STEEL BOLTS, NUTS, AND SELF-LOCKING NUTS
Size and Threads
Per Inch Torque Value
8-32 13-16 lb in. (1.5-1.8 N·m)
10-24 20-23 lb in. (2.3-2.6 N·m)
1/4-20 40-60 lb in. (4.6-6.8 N·m)
5/16-18 70-110 lb in. (7.9-12.4 N·m)
3/8-16 160-210 lb in. (18-23.7 N·m)
7/16-14 250-320 lb in. (28-36 N·m)
1/2-13 420-510 lb in. (47.5-57.6 N·m)
8-36 16-19 lb in. (1.8-2.1 N·m)
10-32 24-27 lb in. (2.7-3 N·m)
1/4-28 55-70 lb in. (6.2-7.9 N·m)
5/16-24 100-130 lb in. (11.3-14.7 N·m)
3/8-24 190-230- lb in. (21.5-26 N·m)
7/16-20 300-360 lb in. (34-40.7 N·m)
1/2-20 480-570 lb in. (54-64 N·m)

5-193
GEK 97310
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Table 5-35. TORQUE VALUES FOR PLUGS AND UNIONS
Tubing OD Fitting Dash No. Torque Value
1/8 2 40-50 lb in. (4.5-5.7 N·m)

3/16 3 90-100 lb in. (10-11.3 N·m)
1/4 4 135-150 lb in. (15.2-17 N·m)
5/16 5 155-175 lb in. (17.5-19.8 N·m)
3/8 6 180-200 lb in. (20.3-22.6 N·m)
1/2 8 270-300 lb in. (30.5-34 N·m)
5/8 10 360-400 lb in. (40.7-45.2 N·m)
3/4 12 45-50 lb ft (61-67.8 N·m)
1 16 58-70 lb ft (78.6-95 N·m)
1-1/4 20 75-87 lb ft (101.7-118 N·m)
1-1/2 24 83-100 lb ft (112.5-135.6 N·m)

5-194
GEK 97310
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Table 5-36. TORQUE VALUES FOR TUBING NUTS AND HOSE FITTINGS
Hose Aluminum Female Steel Female

Dash Sealing Surfaces Sealing Surfaces
Tube OD No. (See Note 1) (See Note 2) Torque Units
0.125 (1/8) -2 - 40-50 (4.5-5.7) lb in. (N·m)

0.1875 (3/16) -3 30-50 (3.4-5.7) 90-100 (10-11.3) lb in. (N·m)
0.250 (1/4) -4 40-65 (4.5-7.3) 135-150 (15-17) lb in. (N·m)

0.3125 (5/16) -5 60-80 (6.8-9) 180-200 (20.3-22.6) lb in. (N·m)
0.375 (3/8) -6 75-125 (8.5-14) 270-300 (30.5-34) lb in. (N·m)
0.500 (1/2) -8 150-250-(17-28) 450-560 (50.8-62) lb in. (N·m)
0.625 (5/8) -10 200-350 (22.6-40) 650-770 (73-87) lb in. (N·m)
0.750 (3/4) -12 25-41 (34-55.6) 75-91 (102-123.4) lb ft (N·m)
1.000 (1) -16 41-58 (55.6-78.6) 112-128 (152-174) lb ft (N·m)
1.250 (1-1/4) -20 50-75 (67.8-102) 133-150 (180-203) lb ft (N·m)
1.500 (1-1/2) -24 50-76 (67.8-103) 158-183 (214-248) lb ft (N·m)
Note 1 These values apply when female sealing surface is aluminum. Male connector and
nut may be either steel or aluminum.
Note 2 These values apply when female sealing surface is steel. Male connector and nut
may be either aluminum or steel.

5-195
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Table 5-37. TORQUE VALUES FOR PLUGS AND UNIONS USED IN BOSSES AND
FOR UNIVERSAL BULKHEAD FITTING LOCKNUTS
Size Thread Size Torque, lb in. (N·m) Torque, lb ft (N·m)
-2 0.3125-24 40-50 (4.5-5.7) –
-3 0.375-24 90-100 (10-11.3) –
-4 0.4375-20 135-150 (15-17) –
-5 0.500-20 155-175 (17.5-19.8) –
-6 0.5625-18 180-200 (20.3-22.6) –
-8 0.750-16 270-300 (30.5-34) –
-10 0.875-14 360-400 (40.7-45.2) –
-12 1.0625-12 540-600 (61-68) 45-50 (61-67.8)
-16 1.3125-12 700-850 (79-96) 58-70 (78.6-95)
-20 1.635-12 900-1050 (102-119) 75-87 (102-118)
-24 1.875-12 1000-1200 (113-135.6) 83-100 (112.5-135.6)
(3) Do not use lubricant on bolt parts cause a slow permanent set, be sure to
threads unless specified in assembly proce- hold the torque at the desired value until the
dures. Start threads at least two turns by hand material is seated.
to ensure proper engagement.
(b) Apply a uniform torque to a
(4) Tightening Procedures: series of bolts that have different diameters
and are installed on one flange or in one area.
CAUTION This torque shall be less than the required final
torque for the smallest diameter bolt. This pre-
WHEN CHILLING OR HEATING vents shearing or breaking of tight bolts
GAS TURBINE PARTS DURING because of force concentrations.
ASSEMBLY, DO NOT TORQUE
SPANNER NUTS, LOCKNUTS, OR (c) It is not desirable to tighten
RETAINING BOLTS UNTIL THE to the final torque value during the first draw-
PART HAS RETURNED TO ROOM down; uneven tension can cause distortion or
TEMPERATURE. THE FASTENER overstressing of parts. Torque mating parts by
MAY LOOSEN AS THE PART drawing down the bolts or nuts gradually until
COOLS OR MAY BE OVER- the parts are firmly seated; then loosen each
STRESSED AS THE PART WARMS one separately, 1/4-turn, and apply final tight-
UP AND EXPANDS. ening. Tightening in a diametrically opposite
(staggered) sequence is desirable in most
(a) If possible, tighten at a uni- cases. See figure 5-57. Do not exceed listed
formly increasing rate until the desired torque maximum torque values.
is obtained. In cases where gaskets or other
5-196
GEK 97310
VOLUME I
(5) All bolts are installed with heads (9) Inspect all nuts and bolts after
forward and up with nuts aft and down, unless tightening to ensure they are seated. If nut/bolt
otherwise specified. is not seated after required torque has been
applied, remove it and inspect for thread
(6) Washers are always installed damage.
beneath the part which turns when tightening,
unless otherwise specified. (10) Lubricate tube/hose connector
threads and between the B-nut and ferrule of a
(7) The torque wrenches listed in connector. Run B-nuts onto fittings with the
table 5-32 are recommended for use within the fingers to ensure tubes and hoses are aligned
indicated ranges. Larger wrenches have too and threads are free of burrs. Two wrenches
great a tolerance, and use of these wrenches must be used when loosening or tightening
can result in inaccuracies. B-nuts, one on the fitting to which the tube or
hose is being connected to hold it stationary,
(8) Torque values specified in this and one on the B-nut for torquing. This not
manual are actual values to be applied to fas- only prevents twisting the tube, but also pre-
teners. Whenever an adapter (crowfoot, span- vents loosening or overtorquing the fitting.
ner wrench, etc.) is used with a torque wrench, When using an extension on a torque wrench,
torque must be calculated per figure 5-58. calculate the correct torque input before apply-
ing torque. See figure 5-58.
Figure 5-57. Sequence of Tightening Threaded Fasteners

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Figure 5-58. Determining Torque Wrench Correction Factor

5-198
GEK 97310
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(11) Breakaway (Running) Torque. (c) Use the torque values given
Refer to table 5-33 for minimum breakaway in tables 5-34 and 5-35 for gasketed fittings.
torque on self-locking nuts. This table applies Install fittings as illustrated in figure 5-59.
to silverplated, lubricated, and non-lubricated Torque values given in tables 5-35 and 5-36
self-locking nuts. Values given are for nuts are for packings or O-rings made of synthetic
with no axial load. To check minimum break- material or asbestos compounds or soft metal
away torque, screw the nut into a bolt until two (copper, aluminum, etc.). These values do not
to five threads are exposed beyond the nut. apply to steel gaskets or special boss seals.
Measure the amount of torque required to turn
the nut on or off the bolt. Nuts that do not meet (13) Loose Fasteners. Prior to retorque,
these minimum frictional requirements should examine fastener for cause of looseness. If
be replaced. safety wire is missing, tighten to required
torque and safety wire. If fastener has self-
(12) Standard Torque. Use the follow- locking feature, check breakaway torque per
ing standard torque tables, unless otherwise preceding step. Replace defective fastener.
directed in the text.
e. Marking of Parts. Parts or assemblies
(a) Use the torque values given designated as matched sets will be maintained
in table 5-34 for steel bolts and nuts (including as matched sets throughout overhaul. Set num-
self-locking nuts). Values given are for clean bers, part numbers, and serial numbers will be
bolts and nuts that are free of nicks and burrs. protected during cleaning or rework to prevent
removal. When identification is removed or is
(b) Use half of the value given in no longer legible, the item must be remarked
table 5-34 for the following applications: per the approved marking method and at the
original location.
1 Thin steel hex nuts.
(These nuts have a height of less than 0.6 of CAUTION
the inside diameter for plain nuts and less than
0.8 of the inside diameter for self-locking WHENEVER IT IS NECESSARY TO
nuts.) MARK ANY ENGINE PARTS, ONLY
APPROVED MARKING COM-
2 Non-steel nuts and bolts POUNDS SHALL BE USED. USE OF
except titanium. UNAUTHORIZED MARKING COM-
POUNDS CAN CAUSE DAMAGE
3 All bolts threaded TO ENGINE PARTS.
directly into aluminum, magnesium or other
non-steel parts.

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GEK 97310
VOLUME I
(1) Permanent marking of parts NOTE

should be done in the area of lowest stress. Although not every possible combina-
Vibropeen is the acceptable method of perma- tion of safety-wiring is shown in the
nent marking. Electrochemical and electric illustration, all safety-wiring must gen-
etch is not approved on rotating hardware. erally correspond to the examples
shown in figure 5-60.
CAUTION
GREASE PENCILS OR LEAD (1) Observe the following rules for
(GRAPHITE) PENCILS MUST NOT safety-wiring, unless specific instructions to
BE USED TO MARK COMBUSTION the contrary are given in the text.
SECTION OR HOT-SECTION
PARTS. THESE MATERIALS PLUS (a) Safety wire shall consist of
HEAT CAN CAUSE PARTS MATE- two strands of wire twisted together (so called
RIAL DAMAGE. double-twist method), where one twist is
defined as being produced by twisting the
(2) Lead and sulphur-containing strands through an arc of 180 degrees, equiva-
materials should not be used for marking any lent to half a complete turn. Use the single
parts. Preferred marking materials are listed strand method only when specified.
below:
(b) Safety wire shall not be
Chalk installed in a manner to cause the wire to be
Dykem - red, yellow, black subjected to chafing, fatigue through vibration,
Ink - Justrite Slink black; Marco S-1141, or additional tension other than the tension
black Mark Stencil Ink imposed on the wire to prevent loosening.
Carters Marks-A-Lot - Black
Carters Marks-A-Lot - Blue (c) In all cases, wiring must be
Dixon - Black done through the holes provided. If no wire
Dixon - Yellow hole is provided, wiring shall be to a neighbor-
Dykem Steel Blue DX100 ing part in a manner not to interfere with the
Soapstone function of the parts and in accordance with
the basic principles described.
f. Safety-Wiring. Safety-wiring is the
securing of two or more parts with a wire (d) The maximum span of safety
installed in such a manner that any tendency wire between tension points shall be 6 inches
for a part to loosen will be counteracted by an (152 mm) unless otherwise specified. Where
additional tightening of the wire. It is not a multiple groups are safety-wired either by the
means of obtaining or maintaining torque, but double-twist or the single-strand method, the
rather a safety device used to prevent the dis- maximum number in a series shall be deter-
engagement of the safety-wired parts. See mined by the number of units that can be
figure 5-60. safety-wired with a 24-inch (610 mm) length
of wire. When safety-wiring widely spaced
multiple groups with the double-twist method,
three units shall be the maximum number in a
series.

5-200
GEK 97310
VOLUME I
Figure 5-59. Installation of Universal Fittings

5-201
GEK 97310
VOLUME I
Figure 5-60. Safety-Wiring Practices (Sheet 1 of 2)

5-202
GEK 97310
VOLUME I
Figure 5-60. Safety-Wiring Practices (Sheet 2 of 2)

5-203
GEK 97310
VOLUME I
(e) Both 0.020 inch (0.51 mm) (c) If the free strand is to be bent
and 0.032 inch (0.81 mm) safety-wire are used around the head of the second part, insert the
throughout the engine. The application is upper strand through the hole in this part, then
determined by the size of the hole in the unit to repeat substep b. If the free strand is to be bent
be safety-wired. Whenever possible, use the over the unit, the direction of twist is unimpor-
0.032 inch (0.81 mm) safety-wire. Only new tant. If there are more than two units in the
safety wire shall be used in each application. series, repeat the preceding steps.
(f) The safety wire shall be (d) After wiring the last part,
pulled taut while being twisted, and shall have continue twisting the wire to form a pigtail of
9 to 12 twists per inch (25 mm) for 0.020 inch 3 to 8 twists [0.25 to 0.50 inch (6 to 13 mm)
(0.508 mm) diameter wire and 7 to 10 twists long] and cut off the excess wire. Bend the pig-
per inch for 0.032 inch (0.813 mm) diameter tail in toward the part in a manner to prevent it
wire. from becoming a hazard to personnel.
(g) Hose and electrical coupling NOTE

nuts shall be safety-wired in the same manner Apply light finger pressure at the mid-
as tube coupling nuts. point of the safety wire span, and flex
in both directions to check for tautness.
(h) Caution must be exercised
during twisting operation to keep the wire tight (3) If the safety wire is not taut after
without overstressing it or allowing it to safety-wiring per the preceding instructions,
become nicked, kinked, or otherwise use the following limits to determine its
mutilated. acceptability:
(2) The following safety-wiring pro-
cedures are to be used throughout the engine
during assembly: Length of safety wire Total flexing at
between parts center
(a) Insert the safety wire through inches millimeters inches millimeters
the first part, and bend the upper end either
0.50 (13) 0.125 (3)
over the head of the part or around it. If bent
around it, the direction of wrap and twist of the 1.0 (25) 0.25 (6)
strands shall be such that the loop around the 2.0 (51) 0.375 (10)
part comes under the strand protruding from 3.0 (76) 0.50 (13)
the hole. Done this way, the loop will not tend
to slip up and become slack. 4.0 (102) 0.75 (19)
5.0 (127) 0.75 (19)
(b) Twist the strands while taut 6.0 (152) 0.75 (19)
until the twisted part is just short of a hole in
the next part. The twisted portion should be (4) If the safety wire fails to meet
within 0.125 inch (3.18 mm) of the hole in these limits, remove it and install new
each part. safety wire.

5-204
GEK 97310
VOLUME I
(5) Always cut, rather than break, (4) Inspect threaded fasteners for
safety wire so that safety wire holes are not thread damage and ensure fasteners seat prop-
torn or pulled out. The instructions for disman- erly when torqued to specified values.
tling and disassembly do not include safety
wire removal because of its obvious necessity. (5) Replace non-serviceable parts and
assemble connection using new seals, gaskets
or O-rings as required.
WARNING
USE EXTREME CAUTION IN MON- h. Unpacking and Repacking. The follow-
ITORING THE SAFE AND COM- ing general instructions apply during unpack-
PLETE REMOVAL OF ALL EXCESS ing and repacking to minimize possible part
SAFETY WIRE. CARE MUST BE damage and contamination.
TAKEN WHEN CUTTING OFF THE
ENDS OF INSTALLED WIRE TO (1) Initially remove only that portion
ENSURE COMPLETE RETRIEVAL, of the pack necessary to mount the part. Where
PREVENTING INJURY TO PER- possible, remove the remainder of the pack,
SONNEL AND/OR SUBSEQUENT including protective closures; one at a time as
ENGINE DAMAGE. each connection (fluid, air, or electrical) is
made.
(6) When removing safety wire,
ensure all pieces are removed to prevent them (2) Retain protective closures and
from entering engine parts or otherwise caus- reusable pack components for repack
ing damage. purposes.
g. Correction of Leaks. (3) Install protective closures on each

connection (fluid, air, or electrical) as it is dis-
CAUTION connected.
DO NOT OVER-TORQUE
(4) When possible, repack part for
THREADED FASTENERS AS
storage or shipment using the same pack in
METHOD OF CORRECTING LEAK-
which replacement part was received.
ING CONNECTIONS. PARTS FAIL-
URE COULD RESULT.
(5) When original pack components
are not available, use locally available packing
(1) Disassemble connection.
materials and container to pack the part. Make
sure that all ports, openings, connections and
(2) Discard seal, gasket or O-ring if
mating surfaces are capped or covered and that
present.
the part is protected from potential handling or
environmental damage.
(3) Inspect mating surfaces for con-
tamination, scratches, dents, or other surface
(6) Bearings shall be handled per
defects.
step r.

5-205
GEK 97310
VOLUME I
i. Jackscrews. When using jackscrews to (2) Accessories, tubes, and hoses may
remove components, do not bend flanges, or have oil or fuel in them at time of removal.
strip threads. Lubricate jackscrews with engine Drain these fluids from accessory being
lube oil before installing. Turn jackscrews in removed, and cap all connecting hoses or
evenly and in small increments. Always check tubes. Do not use tape.
jackscrews for burrs or rough edges before
using. Remove all burrs or rough edges. If reg- (3) Do not remove plugs, caps, etc.,
ular bolts are used as jackscrews, the tips must until part is ready for assembly. Check both
be blunt and polished. Do not allow compo- seating surfaces for removal of plugs, etc.,
nents to fall free as jackscrews are tightened. prior to assembly.
Jackscrew holes are often in flanges only thick
enough for three or four threads. The ends of k. Universal Fittings. See figure 5-59.
most standard bolts are chamfered, and the
first couple of threads are missing or incom- (1) Pipe Fittings.
plete. These should not be used as jackscrews
without modification, since only one or two (a) Inspect visually.
threads will engage, and the threads in the
flange are likely to strip. Jackscrews, fre- (b) Clean if necessary.
quently designed as such and identified as spe-
cial tools, are not chamfered and full thread (c) Lubricate fittings.
engagement will occur. If you find yourself
without specially manufactured jackscrews (d) Install fitting, screwing down
and you must manufacture them locally, be to within one-half of final position.
sure that the ends are ground to remove the
chamfer and the incomplete thread, so that a (e) Remove fitting, clean, and
maximum number of threads may be engaged. inspect male thread.
j. Protective Closures and Caps. Prevent- (f) Lubricate.

ing foreign material from lodging in drilled
passages, fuel lines, oil lines, air lines, and (g) Reinstall and screw down to
open engine ports is extremely important. final position.
Machined surfaces must be properly protected
to prevent damage. (2) Union.
(1) Wrap precision parts and cap or (a) Lubricate the O-ring and roll
plug all openings and connections. It is most the O-ring over the threads into the groove on
important that all gas turbine parts be kept the union.
clean and free of corrosion. All instructions
which require special handling of parts must (b) Screw the union into the boss
be followed without exception. until the O-ring contacts the surface of the
boss.
(c) Tighten the union to the

proper torque value.

5-206
GEK 97310
VOLUME I
(3) Bulkhead Fitting. (f) Screw the fitting and nut

simultaneously into the boss until the O-ring
(a) Lubricate the fitting end. contacts the chamfer at the face of the boss.
Screw the nut onto the fitting until the washer
face of the nut lines up with upper corner of (g) Hold the nut and turn the fit-
the seal groove. ting into the boss 1-1/2 turns. The fitting may
be positioned further by one additional turn.
(b) Lubricate the O-ring and roll
the O-ring over the threads into the groove on (h) Attach the line to the fitting
the fitting so that it contacts the nut. and check the alignment of the fitting.
(c) Screw the fitting and nut (i) Hold the fitting and tighten
simultaneously into the boss until the seal con- the nut to the proper torque.
tacts the chamfer at the face of the boss and
until the nut contacts the boss. l. Cleanliness. Cleanliness is important
for equipment life and proper operation. The
(d) Position the fitting either by major cause of premature engine removal is
turning in as much as 3/4 turn (270 degrees foreign object damage (FOD).
clockwise) or turning out as much as 1/4 turn
(90 degrees counterclockwise). Attach the line (1) The enclosure must be kept clean
to the fitting and check the alignment of the fit- and free of dirt and loose objects. It is recom-
ting. Tighten the nut to the proper torque. mended that small FOD containers be at work
area or in tool box.
(4) Fitting with backup rings.
(2) All parts shall be inspected for
(a) Lubricate male threads of fit- cleanliness before they are installed.
tings, backup ring, and O-ring.
(3) Gasket and O-rings shall be free
(b) Screw the nut on the fitting, from dirt, lint, and/or grit.
with the counterbore side facing the fitting
end. (4) Mating flanges, tube flanges and
couplings shall be wiped clean to make sure a
(c) Put the backup ring on the good seal will be obtained.
fitting and seat it in the counterbore of the nut,
with its convex side facing the fitting end. (5) Hands and gloves must be clean
when handling machined surfaces.
(d) Roll the O-ring over the
threads into the groove on the fitting. (6) The engine shall not be used as a
shelf for holding tools or parts while mainte-
(e) Adjust the nut so that the nance is being performed.
backup ring forces the O-ring firmly against
the lower threaded portion of the fitting.

5-207
GEK 97310
VOLUME I
(7) After performing any mainte- (6) Distance between faces of mating
nance, the work area shall be thoroughly surfaces or flanges shall not exceed 0.063 inch
inspected for loose parts, rags, tools and mate- (1.60 mm).
rials. The area shall be cleaned to remove grit,
dust, chips, safety wire and other small (7) If tubes are reworked, bend radii
objects. shall not be less than twice the tube diameter
and bend angle shall not be changed by more
m. Gaskets and O-ring Seals. than 3 degrees. No kinks or wrinkles are
allowed.
(1) Gaskets, O-ring seals, key wash-
ers, and coffer pins shall not be reused, unless (8) Do not bend at fitting or weld
otherwise specified. areas.
(2) Gaskets and O-ring seals shall be (9) Original bends in tube may be
lightly lubricated with engine lube oil, prior to bent in the same direction; but, reverse bend-
installation, unless otherwise specified. Make ing is not allowed.
sure that parts are properly seated. When a fit-
ting with a jamnut and O-ring is used, see (10) Bend tube in existing straight sec-
figure 5-59 for the proper installation tions, if possible.
procedure.
(11) Use bending tools on tubes one
n. Tubes. When installing tubes, the fol- inch or more in diameter, to prevent tube from
lowing precautions and instructions apply: collapsing.
(1) As tubes are installed, tighten all (12) On those couplings where sealant
end fittings and clamps fingertight. After a is required, carefully apply a thin coat of Plas-
complete system is installed, torque clamps tiseal F (Johns-Manville Corp., N. Main,
first and then end fittings. Mainville, New Jersey 08835) to each face of
gaskets and coupling mating surfaces. Allow
(2) Maintain a minimum clearance of sealant to dry 10 minutes minimum before
0.125 inch (3.18 mm) between tubes and adja- assembly. Wipe off any sealant on inside of
cent parts. tube with a clean rag and water. Do not allow
sealant to enter air systems.
(3) Tubes and manifolds must fit
within 0.063 inch (1.60 mm) radius in a free o. Hoses. No hose should be bent more
state during assembly or be replaced or modi- than the bend radius specified in table 5-38,
fied by bending. especially when parts are cold, because of pos-
sible damage to Teflon liners. Kinked hoses
(4) Coupling nuts shall thread freely must not be used. During installation, be sure
by hand. See figure 5-61. no hose is twisted or stretched. Never over-
torque connectors. When hoses are removed,
(5) Mating flanges on tubes shall seal cap the open ends. Do not use tape to cover
flush within 0.005 inch (0.13 mm). open ends. See figure 5-62.

5-208
GEK 97310
VOLUME I
Figure 5-61. Flexible Coupling Assembly

5-209
GEK 97310
VOLUME I
(3) Before installing preformed hoses,

Table 5-38. HOSE MINIMUM BEND visually inspect the hose interior to assure that
RADII the Teflon lining has not been damaged. If
damaged, replace the hose.
Minimum Bend
Dash Size
Radius p. Clamps. Chafing of hoses and tubes
must be avoided. Use RTV under clamps to
inches millimeters prevent chafing. Clamp parts loosely in place,
-3 1.50 (38) shift the hoses until the best clearance is
obtained, and then tighten the clamps. See
-4 2.00 (51) figure 5-64. Clamps must be of the proper size
-5 2.00 (51) for the piping to permit slippage during engine
thermal growth. For Series J1153 and J1162
-6 4.00 (102) clamps, lining position must be checked.
Figure 5-65 shows correct lining location.
-8 4.62 (117)
-10 5.50 (140) q. Electrical Cables and Connectors. Dur-
ing electrical cable installation, adjust the
-12 6.50 (165) cable through the clamps to get the smoothest
-16 7.38 (187) and largest radius. Sharp bends, twists, and
kinks must be avoided. Minimum clearance
-20 11.00 (279) between the electrical cable and any compo-
-24 14.00 (356) nent other than hoses or other electrical cables
is 0.125 inch (3.18 mm).
-32 22.00 (559)
(1) A seal ring is located in coupling
(1) Fluid fittings shall be tightened nut of each electrical connector. Inspect to
gradually to the required torque value, backed make sure seal is present and serviceable
off 1/4 turn, and then tightened again. Do not before attaching the connector. Replace unser-
attempt to correct leaks by excessive tighten- viceable seals as follows:
ing. Always use two wrenches when tighten-
ing swivel coupling nuts on hoses, tubes, or (a) Remove unserviceable seal.
fittings. Hold the stationary part with one
wrench while applying torque with second
wrench. Apply engine lube oil between tube/
hose coupling nut and ferrule prior to tighten-
ing. See figure 5-62.
(2) Preformed hoses or hoses of large

diameter shall not be bent or straightened (see
figure 5-63). When hoses are removed, cap the
open ends. Do not use tape to cover open ends.

5-210
GEK 97310
VOLUME I
Figure 5-62. Installation of Hose Assemblies

5-211
GEK 97310
VOLUME I
Figure 5-63. Factory Preformed Hoses
Figure 5-64. Routing and Clamping Techniques

5-212
GEK 97310
VOLUME I
Figure 5-65. Installation of Cushion Clamps, Series J1153 and J1162
(b) Engage new seal over barrel (2) Inspect electrical connector pins
of connector. for straightness before connecting. Then insert
the mating cable connector, hand-tighten the
CAUTION retaining nut, push the mating parts together
DO NOT ALLOW THE SEAL TO TIP until seated, and tighten the retaining nut as
AND FLATTEN ON THE CONNEC- required.
TOR OR SEAL’S USEFULNESS
WILL BE DESTROYED. (3) Electrical connectors on flexible
harnesses and leads shall be hand-tightened
(c) Push the seal to seated posi-
tion against the internal shoulder in the con- beyond fingertight (20 degrees maximum)
nector using a mating connector or blunt screw until connecting parts are in solid contact with-
driver. out damage. Safety-wire the connectors only
when specified in procedure.
CAUTION
DO NOT FORCE THE CONNEC- (4) Rigid leads. Do not bend sharply,
TORS TOGETHER. IF PINS ARE kink or twist rigid leads. Always hold both
NOT ALIGNED, THEY WILL BE mating connectors when tightening the con-
BENT OR DISTORTED AND WILL nection to prevent damage to lead.
NOT MAKE CONTACT.

5-213
GEK 97310
VOLUME I
r. Bearing Handling. COLD AREA TO ROOM TEM-

PERATURE SO THAT CONDEN-
CAUTION SATION OF MOISTURE WILL
BE MINIMIZED. CHECK CARE-
BALL AND ROLLER BEARINGS FULLY FOR EVIDENCE OF
REQUIRE SPECIAL CARE TO PRE- MOISTURE, AND CONTINUE
VENT CORROSION. BEARINGS HEATING UNTIL THE BEARING
MUST NOT BE HANDLED WITH IS COMPLETELY DRY. APPLY
BARE HANDS NOR WITH ANY PRESERVATIVE OIL
DEVICE WHICH MIGHT CAUSE (MIL-C-6529, TYPE III) AT ONCE
CONTAMINATION. CLEAN RUB- TO THE BEARING AFTER COM-
BER OR NYLON GLOVES OR A PLETE DRYING.
PROTECTIVE HAND CREAM
SHALL BE USED AT ALL TIMES • WHEN HEAT IS REQUIRED TO
WHEN HANDLING BEARINGS. RELIEVE SHRINK FITS OF
BEARINGS, USE HEAT GUNS OR
(1) Preservation. OVENS. DO NOT USE DIRECT-
HEAT SOURCES TO APPLY THE
(a) At the point where bearings HEAT, AND DO NOT HEAT THE
are accessible in the disassembly cycle, the BEARINGS TO A TEMPERA-
bearings shall be thoroughly covered with oil, TURE HIGHER THAN 350°F
MIL-C-6529, Type III. (175°C). APPLY PRESERVATIVE
OIL (MIL-C-6529, TYPE III) TO
(b) Use of gas turbine lube oil as THE BEARINGS BEFORE HEAT-
a lubricant or preservative is specifically ING AND AFTER THEY HAVE
prohibited. COOLED TO ROOM
TEMPERATURE.
(c) Bearings returned to storage
shall be preserved with grease, MIL-C-11796, NOTE
Class 3 and wrapped in barrier paper,
MIL-B-121, Grade A, Type 1, Class 1. Heating and chilling is defined as any
temperature 10°F (6°C) above or below
(d) After installation, bearings room temperature.
shall be returned to room temperature, and be
preserved with oil, MIL-C-6529, Type III. (a) When it is necessary to chill
a bearing in Dry Ice, the bearing shall be thor-
(2) Heating and Chilling. oughly coated with oil, MIL-C-6529, Type III,
and placed in a plastic bag prior to chilling.
CAUTION
(b) Immediately after installa-
• IMMEDIATELY AFTER tion of a chilled bearing, heat shall be applied
INSTALLING OR REMOVING A with a heat gun until bearing and adjacent parts
CHILLED BEARING, USE A are brought to room temperature. Any mois-
HEAT GUN TO RESTORE THE ture shall be removed using clean, dry shop air,
BEARING, AND ANY ADJACENT

5-214
GEK 97310
VOLUME I
and bearing shall be protective coated with oil, (2) Exercise extreme care during
MIL-C-6529, Type III. assembly or disassembly operations to prevent
entrance of pieces of safety wire, nuts, wash-
(c) Heating of bearings shall be ers, or any other objects into the engine or
done using ovens or heat guns. No direct heat assembly. If anything is dropped into the
source, such as a blowtorch, may be used. engine during assembly or disassembly, stop
When bearing returns to room temperature, it and remove the object before proceeding.
shall be protective coated with oil,
MIL-C-6529, Type III. (3) Do not store tools or maintenance
equipment on or against engine. Account for
s. Spray Shields. Spray shields shall be and properly store all tools after use.
positioned on tubing to prevent fluid from
spraying on engine should a leak occur at (4) Clean fittings of contamination
shielded area of tube. before making or breaking connections.
t. General. CAUTION
CAUTION DO NOT USE EXTERNAL ENGINE

PIPING AS A LADDER OR HAND
USE OF MOTOR-DRIVEN HOLD WHILE PERFORMING
HYDRAULIC PUMPS TO OPER- MAINTENANCE. SERIOUS DAM-
ATE HYDRAULICALLY ACTU- AGE COULD RESULT. USE ONLY
ATED SPECIAL SUPPORT AUTHORIZED WORK STANDS
EQUIPMENT OTHER THAN AND PLATFORMS.
TORQUE MULTIPLIERS IS NOT
RECOMMENDED. EQUIPMENT (5) Handle all parts carefully. Lift
DAMAGE CAN RESULT FROM heavy parts with proper lifting fixtures and a
IMPROPER POWER APPLICATION. hoist to prevent damage to parts and physical
harm to personnel.
(1) Use hand-operated hydraulic
pumps to operate hydraulically actuated spe- (6) Always use fiber or plastic blocks
cial support equipment such as pushers or pull- and hammers with plastic, rawhide, or nylon
ers, unless otherwise specified. heads for driving operations.
(7) Tie groups or related parts

together when they are removed. Tag or mark
parts for identification.
(8) Coat parts that are to be stored for

any length of time with an appropriate
preservative.

5-215
GEK 97310
VOLUME I
(9) When installing or removing body WARNING

bound bolts, tap them straight through the
holes. Do not turn them. PROLONGED EXPOSURE OF THE
SKIN TO ENGINE LUBE OIL MAY
(10) Verify identification of all mating BE DETRIMENTAL. WASH SKIN
parts. THOROUGHLY AFTER CONTACT,
AND REMOVE SATURATED
(11) Observe tagged parts for proper CLOTHING IMMEDIATELY.
location.
WARNING
(12) During assembly, align match-
marks on all parts which were marked during ENGINE LUBE OIL MAY SOFTEN
disassembly. PAINT OR STAIN CLOTHING WITH
WHICH IT COMES IN CONTACT.
(13) Keep all protectors and caps CLEAN SPILLED OIL FROM
installed until removal is required. PAINTED SURFACES.
(14) Prior to final assembly, inspect all (17) Accessories, tubes and hoses may
cavities and openings for foreign material. have oil or fuel in them at time of removal.
Drain these fluids from accessory being
(15) Inspect all mating flanges for for- removed and cap all connecting hoses or tubes.
eign material prior to final assembly. Remove
any high metal with a fine stone. (18) Lubricate all gears and splines
with engine lube oil before installing them,
CAUTION unless otherwise specified.
PREVENT MIXING PLATED (19) Prior to installation of any part, a

HARDWARE WITH UNPLATED quick visual check should be made and any
HARDWARE. DO NOT USE SILVER obvious discrepancies noted and reported, so
OR CADMIUM-PLATED TOOLS OR that corrective action can be taken.
HARDWARE ON TITANIUM
PARTS. PLATING CONTAINS (20) Always read complete operation;
SMALL QUANTITIES OF CHLO- be sure you understand. It is better to stop and
RINE SALTS THAT ARE HARMFUL ask, than to continue on, and cause unneces-
TO TITANIUM. sary work and/or damage.
(16) Three types of tools, common, (21) Do not disassemble any further
improvised, and special, are used to perform than necessary to perform the required mainte-
maintenance. Common tools are identified nance, even though complete disassembly
only when used in special applications. Draw- instructions may be given. Remove piping and
ings for improvised tools are incorporated in electrical leads only as required to perform
the text when such tools are required. Special maintenance tasks.
tools are identified both by name and part
number when they are required.

5-216
GEK 97310
VOLUME I
(22) Attaching hardware (bolts, nuts, 5-6 PREVENTATIVE MAINTENANCE

plain washers, brackets, clamps, etc.) is gener- PROCEDURES.
ally reusable. When possible, it is recom-
mended that attaching hardware be left in 5-6.1 Tools And Parts. See Volume II,
place or temporarily reinstalled until replace- WP 001 00.
ment component is installed.
5-6.2 Lube Filter Cleaning. Refer to
(23) Parts or assemblies designated as packager’s manual for lube filter cleaning
matched sets elsewhere in this Technical Man- procedures.
ual or by the parts list, will be maintained as a
matched set throughout maintenance cycle. Set 5-6.3 Thermocouple System Test. Per-
numbers, part numbers, and serial numbers form thermocouple system test per Chapter 4.
shall be protected during cleaning or repair to
prevent removal. When identification is 5-6.4 Ignition System Test.
removed, or is no longer legible, the item shall
be re-marked per the approved marking WARNING
method and original location for the part.
• ENSURE POWER TO IGNITION
(24) When discrepancies are found SYSTEM IS OFF WHEN DIS-
during maintenance, refer to inspection tables CONNECTING AND CONNECT-
for limits and corrective action. ING IGNITION EXCITER INPUT
LEAD. TAG SWITCH “OUT OF
NOTE SERVICE” TO PRECLUDE
INADVERTENT ACTIVATION.
Mobile Assembly Fluid 403C may be
used in place of soft petrolatum. • ENSURE FUEL SHUTDOWN
VALVES ARE CLOSED
(25) Soft petrolatum, White Fonoline, THROUGHOUT THIS
(Witco Chemical Co., Sonneborn Div., 400 S. PROCEDURE.
Michigan Ave., Chicago, Illinois 60611) shall
be used as assembly aid for tight fitting parts, a. To clear combustor of any residual
bearings and O-rings unless otherwise speci- fuel, set starter air inlet pressure at 20-22 psig
fied. Ordinary petrolatum (VV-P-236) shall (138-152 kPa), motor engine for one minute,
not be used. and allow engine to coast down.
b. Disconnect number one ignition exciter

input lead at exciter. Temporarily secure input
lead away from the exciter.
c. Turn on electrical power to the ignition

system (No. 2 ignition exciter energized). An
audible report (approximately 2 sparks per sec-
ond) should be heard when the No. 2 igniter
plug fires.

5-217
GEK 97310
VOLUME I
d. Turn off electrical power to the ignition

system. Reconnect input lead to exciter and
safety-wire connector.
e. Repeat steps b, c, and d, disconnecting

the No. 2 exciter.
f. If an audible report is not heard on

No. 1 and/or No. 2 igniters, check out the sys-
tem to isolate the problem, and take appropri-
ate corrective action.
5-6.5 Oil Sampling And Analysis.
WARNING
WEAR THERMALLY INSULATED
GLOVES AND AVOID CONTACT
WITH THE LUBE SYSTEM COM-
PONENTS AS METAL TEMPERA-
TURES MAY REACH 325°F (163°C).
a. Perform this procedure with the engine

operating at idle. It is important that the lube
samples be obtained under the same condi-
tions, (i.e. Idle) every time. Obtain a lube oil
sample from the scavenge oil discharge line,
using a clean container.
b. Seal the sample bottle and attach a

gummed label, marked as follows:
Location__________________________
Gas Turbine S/N____________________
Oil Type__________________________
Date_____________________________
c. Send oil sample to laboratory for

analysis.

5-218
GEK 97310
VOLUME I
APPENDIX A
SPECIFICATION DESCRIPTION PAGE NO.

MID-TD-0000-1 NATURAL GAS FUEL A-3
MID-TD-0000-2 LIQUID FUEL A-7
MID-TD-0000-3 NOX SUPPRESSION WATER PURITY A-13
MID-TD-0000-4 COMPRESSOR CLEANING WATER PURITY A-15
MID-TD-0000-5 COMPRESSOR CLEANING DETERGENT A-17
MID-TD-0000-6 LUBRICATING OIL A-23

A-1/(A-2 Blank)
GEK 97310
VOLUME I
MID-TD-0000-1
November, 1991
NATURAL GAS FUEL

FOR
GENERAL ELECTRIC AIRCRAFT DERIVATIVE GAS TURBINES
IN
INDUSTRIAL APPLICATIONS
GENERAL ELECTRIC COMPANY

MARINE & INDUSTRIAL ENGINES
CINCINNATI, OHIO 45215

A-3
GEK 97310
VOLUME I
MID-TD-0000-1
November, 1991
This document provides requirements and 2.1.1 The solid materials in the gas, exclusive
application guidelines for natural gas fuels of hydrocarbon materials, shall not
which can be fired satisfactorily in General exceed 30 ppm by weight. The size and
Electric Aircraft Derivative Gas Turbines. density distribution of the solid particles
Other combustible gases from chemical pro- must be such that not more than 1.0 per-
cess industries may also meet the requirements cent by weight of the particles shall have
of this document. All gas mixtures proposed a terminal settling velocity in air at 70°F
for use in GE Gas Turbines should be charac- and 30 inches Hg absolute (Hga) greater
terized by complete compositional analysis than 14 inches per minute and not more
and be reviewed by GE/M&IE prior to than 0.1 percent shall have a terminal
extended use. settling velocity in excess of 23 inches
per minute.
1. APPLICABLE DOCUMENTS
For a solid spherical particle, Stoke’s
The following documents are referenced Law of settling permits calculating the
for testing procedures and requirements: terminal settling velocity if the particle
diameter and particle specific gravity are
ASTM D1072 Test for Total Sulfur in known. The following tabulation gives
Fuel Gases the particle diameters equivalent to the
limiting terminal settling velocity
ASTM D1142 Water Vapor Content of values.
Gaseous Fuels by Measurement of Dew
Point Temperatures Setting Equivalent Spherical Particle
Velocity Diameter in Microns
ASTM D1145 Procedure for Sampling In./Min. Sp. Gr. =2 Sp. Gr. =4
Natural Gas
14 10 7
ASTM D2009 Procedure for Collection 23 13 9
by Filtration and Determination of
Mass, Number and Optical Sizing of 2.1.2 Naphthalene, gas hydrates, solid or
Atmospheric Particulates semi-solid hydrocarbons shall not con-
dense from the gas when the the temper-
ASTM D3588 Procedure for Calculating ature of the gas is decreased 20°F at
Calorific Value and Specific Gravity of constant gas pressure.
Gaseous Fuels
2.1.3 Any water in the gas above the satura-
2. REQUIREMENTS tion amount at its point of use shall not
exceed a quarter of one percent by
2.1 Contaminants weight.

A-4
GEK 97310
VOLUME I
MID-TD-0000-1
November, 1991
2.2 Heating Value introduced in the compressor inlet air in

marine environments, as well as in cer-
2.2.1 Pipeline Natural Gas (Methane/CH4 tain adverse industrial environments.
Base) For this reason, the total amount of sul-
fur and alkali metals from all sources
The normal lower (net) heating value shall be limited to less than that required
should lie in the range of 800 to 1200 to form the equivalent of 0.6 ppm of
Btu per standard cubic foot. Modifica- alkali metal sulfates in the fuel.
tions to the fuel system components,
however, can be made to substantially 2.3.2 The total amount of alkali metals (a) in
broaden this range. Contact GE/M&IE gas fuels used with engines having
for specific applications. marinized (corrosion-resistant) coatings
on the high pressure turbine blading
2.2.2 Low Btu Gas Fuel shall not exceed 0.2 ppm (b).
Gas fuels with hydrocarbon constituents (a) Sodium, potassium, and lithium.
(CxHy) with CO2, N2 and/or steam dilu- Experience has shown that sodium
tion with a resulting lower heating value is by far the preponderant alkali
as low as 300 Btu per standard cubic metal, if any, found in gaseous
foot are acceptable for use at or above a fuels.
given partial power level which is
dependent upon the particular engine (b) This limit assumes zero alkali met-
model. als in the inlet air or injected water
or steam. When actual levels are
Gasifier fuels with combustible constitu- above zero, the maximum allow-
ents of H2, CO, CxHy having CO2, N2 able sodium content of the fuel
and/or steam dilution with a lower heat- must be reduced in accordance with
ing value as low as 200 Btu per standard the following relationship:
cubic foot may be acceptable for use at
or above a given partial power level ppm sodium in inlet air x Air ratio = +
depending upon the specific proportions Fuel
of the combustible mixture. +
During use of either of the above type ppm sodium in water or steam x
fuels, starting and accelerating may have Water or Steam ratio =+
to be accomplished on pipeline quality Fuel +
natural gas. ppm sodium in fuel =_____
Contact GE/M&IE for specific applica- Total fuel equivalence for sodium
tions utilizing low Btu gas fuels. from all sources. =
2.3 Contaminant Limits Must not exceed 0.2 ppm
2.3.1 There is no specific limit on natural gas 2.3.3 For non-marinized engines with stan-
fuel sulfur content if the engine is used dard coatings on the high pressure tur-
in an application where both the fuel and bine blading, the total amount of alkali
environment are free of alkali metals. metals from all sources shall not exceed
Sodium, potassium, and other alkali 0.1 ppm.
metals are not normally found in natural
gas fuels, but are typically found to be

A-5
GEK 97310
VOLUME I
MID-TD-0000-1
November, 1991
2.3.4 The presence of any liquid hydrocarbons 2.4 Dry Gas

in the gas fuel can cause large variations
in heat input and, in severe cases, slugs The gas shall be what is known in the
of liquid fuel in the engine combustor industry as “dry gas”, that is, the gaso-
can damage the engine hot section from line vapor in 1000 cubic feet of gas at
flames beyond the normal flame zone. standard conditions (60°F and 30 inches
For this reason, gaseous fuel mixtures Hg, absolute), shall be equivalent to not
must be maintained well above their more than 0.1 gallon liquid.
dew points at fuel manifold conditions.
Liquid hydrocarbons introduced in the 2.5 Flammability Limits
gas from lubricating oil leakage from a
gas pressure booster compressor may The minimum ratio of the upper to lower
result in restricting gas flow due to plug- flammability limit, determined at 60°F
ging of the fuel nozzle flow orifices. Gas and 1 atmosphere, is 2.2 to 1.
installations should include suitable sep-
arating equipment and liquid traps
located as close as possible to the fuel
system interface connection on the
engine.

A-6
MID-TD-0000-2 GEK 97310
March, 2000
LIQUID FUEL
FOR
GE AERODERIVATIVE GAS TURBINES
IN

INDUSTRIAL AERODERIVATIVE GAS TURBINES
CINCINNATI, OHIO 45215-6301

A-7
MID-TD-0000-2 GEK 97310
March, 2000
This document lists specifications and 1.7 MIL-F-16884 Fuel Oil - Diesel
describes application guidelines for liquid Marine (NATO F-75,
fuels that can be fired satisfactorily in GE F-76)
aeroderivative gas turbines. It is recommended
1.8 VV-F-800 Fuel Oil - Diesel,
that a complete specification analysis of all liq-
Grades DF-A,
uid fuels proposed for use in GE aeroderiva-
DF-1, and DF-2
tive gas turbines be reviewed by GE prior to
(NATO F-54)
use.
1. FUEL SPECIFICATIONS 1.9 ASTM D396 Grades No. 1, 2, 4,
and 4 (Light)
Fuels conforming to the following mili-
tary and industry specifications are 1.10 ASTM D2880 Gas Turbine Fuel
acceptable for use in GE aeroderivative Oils, Grades No.
gas turbines in industrial and shipboard 0-GT1,2, No. 1-GT,
applications, except as noted below, and No. 2-GT
provided they also meet criteria
described in paragraph 2. However, their 1.11 The pure hydrocarbon combustibles
use should be reviewed against applica- [e.g. propane (C2H8) and butane (C4H10),
both normal and iso], are acceptable
ble safety and regulatory requirements.
either alone or in various mixtures with
1.1 D50TF2 GEAE Aviation other liquid fuels, providing that fuel
Fuel Specification manifold pressures are sufficient to
1.2 ISO 8217 ISO-F-DMA maintain the fuel in the liquid state2.
(MGO) Alternate fuels may be required for start-
ing and low-power operation. Contact
1.3 MIL-DTL-5624 Grades JP-41, JP-5 GE for specific applications.
(NATO F40, F44)
1.12 Light distillate fuels, such as Naphtha
1.4 MIL-DTL-83133 Grade JP-8 (NATO (C10 down to C4 hydrocarbons), gaso-
F34/F35) line (C7 to C5 hydrocarbons), and
1.5 ASTM D975 Diesel Fuel Oil, D2880 Grade No. O-GT, are acceptable
Grades 1-D, 2-D, as fuels in GE aeroderivative gas tur-
1-D Low Sulfur, bines, provided that fuel manifold pres-
and 2-D Low sures are sufficient to maintain the fuel
Sulfur as a liquid, especially in hot climates2.
Alternative fuels may be necessary for
1.6 ASTM D1655 Aviation Turbine starting and low-power operation. Con-
Fuels (Jet-A, tact GE for specific applications.
Jet-A1, and Jet-B1)
__________________________ __________________________
1. Highly volatile wide-cut fuels (such as MIL-DTL-5624 2. Liquefied gas, light distillates, and alcohols, and liquefied
JP-4, ASTM D1655 Jet-B, and ASTM D2880 gas fuels may have inadequate lubricity, requiring the use of a
Grade No. 0-GT) are generally acceptable for industrial, fuel pump/system specifically designed to handle these types
but not shipboard applications. of fuels. See paragraph 2.3.

A-8
MID-TD-0000-2 GEK 97310
March, 2000
1.13 Various alcohols, [e.g. hydroxyl deriva- approved stabilizer additives used in the
tives of hydrocarbons, such as methanol long-term storage of diesel and distillate
(CH3OH) and ethanol (C2H5OH)], can fuels. This publication is periodically
burn in GE aeroderivative gas turbines2. revised, and is available from the
Contact GE for specific applications. U. S. Government Printing Office.
2. ADDITIONAL REQUIREMENTS 2.3 Viscosity
The following requirements supplement The viscosity of the fuel as supplied to
and supersede, where there is a conflict, the inlet connections of the gas turbine
the specifications listed in paragraph 1. shall be a minimum of 0.5 centistokes3
However, if the specification require- and shall be up to 6.0 centistokes maxi-
ment is more restrictive, it applies. mum for starting and 12.0 centistokes
2.1 Composition maximum during operation. The fuel
may be heated to meet this requirement.
The fuel shall consist of hydrocarbon
compounds only and must be compati- 2.4 Wax
ble between brands and batches.
Wax can be present in fuel oil, especially
While there is no specific requirement or the distillates with higher pour points. It
limit on the amount of fuel bound nitro- may be necessary to determine the per-
gen (FBN) contained in a liquid fuel, it cent of wax and its melting point and to
is recommended that the amount of FBN provide a suitable method to keep the
be understood for those applications that wax dissolved at all times.
are sensitive to levels of oxides of nitro-
gen (NOx) in the gas turbine exhaust. 2.5 Fuel Temperature Requirements
FBN is the amount of nitrogen in the The minimum temperature of liquid fuel
fuel that is chemically bound. During supplied to the gas turbine shall be the
the combustion process, the FBN is con- greater of:
verted, at least partially, to NOx (called
organic NOx) and adds to the total (a) 20°F (11°C) above the wax point
amount of NOx that is contained in the temperature of the fuel.
gas turbine exhaust. GE emissions data
provided for liquid fuels assumes a FBN or
content of less than 0.015 percent by (b) The temperature required to remain
weight unless otherwise noted. within maximum fuel viscosity
2.2 Additives requirements, or 35°F (2°C).
The use of any dyes or additives requires ________________________

approval of GE, unless such additives
are specifically approved in the fuel 3. Required for adequate GE aeroderivative gas turbine fuel
specifications (paragraph 1), or they pump lubrication and to prevent pump cavitation when using
conform to MIL-S-53021A. The pur- light fuels.
chaser may refer to the Qualified Parts
List (QPL-53021) for a summary of

A-9
MID-TD-0000-2 GEK 97310
March, 2000
The maximum temperature of liquid fuel should be pumped directly into raw fuel
supplied to the gas turbine should not storage tanks, and must be conditioned/
exceed 150°F (65.6°C). For liquid fuels treated before being placed in one of two
with high vapor pressure constituents clean fuel day storage tanks from which
(naphtha, NGL, etc.), the fuel tempera- gas turbines will be supplied. Redun-
ture in the manifold should be at least dant, clean day fuel storage tanks are
100°F (55.6°C) below the bubble point recommended to provide a primary set-
temperature of the lightest component at tled fuel supply and to allow tank repair
high pressure compressor discharge and/or cleaning with minimum down-
static pressure (PS3). time. Storage tanks must be constructed
of corrosion-resistant materials or
2.6 Property Requirements
appropriately lined to minimize inter-
Property requirements are listed in nally formed contaminants. Fuel shall
Table 1. Contaminant limits apply to not be transported, stored, or handled in
fuel samples taken at the gas turbine fuel system components containing copper,
manifold flange. It cannot be assumed e.g. ships that have copper heating coils,
that specification fuel supplied by a or storage tanks coated with zinc. Nei-
refinery still meets those specifications ther copper nor zinc are normally found
once it is delivered to the gas turbine. in refined fuels such as diesel and naph-
3. FUEL HANDLING tha, but, should they be present, they can
cause fuel degradation and additional
True distillate fuel as refined has low engine maintenance. No fuel should be
water, dirt, and trace metal contaminant used that contains detectable amounts of
levels that can be maintained with care- copper or zinc.
ful transportation, handling, and storage
methods. Most contamination occurs Duplex, primary strainers
during transportation of fuel. (150-200 micron absolute) should be
located between the offloading facility
Since fuel can be contaminated during and the raw fuel storage tanks. Duplex,
transportation from the refinery to the secondary filters (50-100 micron abso-
site, auxiliary fuel cleanup equipment lute) should be located between the raw
should be available to restore the fuel fuel storage tanks and the final fuel
quality. Available purification equip- treatment system. All fuel storage tanks
ment includes centrifuges and electro- must have inlets at the bottom of the
static dehydrators. In addition to tank. All fuel day storage tanks should
potential hot corrosion from salt in the be provided with a floating suction. The
water, water accumulated in the bottom distance between the inlet and outlet
of a storage tank can also cause prob- should be maximized.
lems. Microorganisms tend to grow at
the water/fuel interface, generating both After filling any tank or adding fuel to it,
chemicals corrosive to metals in the fuel a settling time of 24 hours should be
system and also slime that can plug fuel allowed before taking fuel from the
filters. In marine applications, shipboard tank. Initially, water and sludge should
systems that allow recycling of fuel be drained from all storage tanks on a
from the service tanks through the cen- daily basis. After experience is gained
trifugal purifiers are recommended. with a given fuel and fuel source, the
frequency of draining may be adjusted
When liquid fuel is supplied by barges by the customer.
or other bulk modes of transportation, it

A-10
MID-TD-0000-2 GEK 97310
March, 2000
4. FUEL SAMPLING For all fuel sampling, sufficient samples

(a minimum of three) must be taken to
A well-thought-out fuel sampling proto- assure that a representative sample is
col will ensure that quality fuel is deliv- obtained. Samples should be taken at
ered to the engine. For each delivery, different levels in large, volume tanks
fuel samples should be taken and ana- and at equally spaced time intervals dur-
lyzed at the following locations: ing fuel delivery or fuel treatment. To
avoid contamination, all samples should
(a) At the refinery before loading. be obtained in clean plastic bottles. Fuel
(b) At the port where the fuel is deliv- samples taken should be analyzed to
ered before unloading. meet all GE liquid fuel requirements. If
fuel samples taken after the above rec-
(c) From the pipeline just upstream of ommendations have been implemented
the raw fuel storage tanks as the indicate that the fuel system does not
fuel is being added to the tanks.
provide fuel per the requirements, the
customer must change his fuel source or
After the fuel is treated/conditioned,
modify the fuel treatment system. The
samples should be taken and analyzed at
end user is responsible for ensuring that
both the inlet and outlet of the fuel treat-
the fuel meets the requirements.
ment system. Fuel exiting the system
must meet the fuel specification. This
should be confirmed before the fuel is
placed in clean fuel day storage tanks.
Fuel samples should be taken and ana-
lyzed to ensure that the fuel discharged
from these tanks and at a practical loca-
tion at, or just upstream of, the gas tur-
bine fuel manifold flange meets the
specification.

A-11
MID-TD-0000-2 GEK 97310
March, 2000
Table 1. Liquid Fuel Property Requirements

Property Limit ASTM Test Method
Ash, %, maximum 0.01 D482
Sulfur, %, maximum 1.0a D129b
Vanadium, ppm, maximum 0.5 D3605
Sodium, Potassium, Lithium, ppm, maximum 0.2c,d D3605e
Lead, ppm, maximum 1.0 D3605
Calcium, ppm, maximum 2.0 D3605
Hydrogen content, %, minimum 12.7f D1018, D3701
Demulsification, minutes, maximum 20.0 D1401 and Note 3 therein
Carbon residue, %, maximum (100% sample) 1.0 D524
Carbon residue, %, maximum (10% Ramsbottoms) 0.25 D524
Particulates, mg/gal., maximum 10.0g D2276
Water and Sediment, volume %, maximum 0.10h D2709
Flash point, °F, maximum See i below D93
Copper corrosion, maximum No. 1j D130
Notes
a. Fuels with a higher sulfur content can be burned. Impact on hot section repair interval (HSRI) will be dependent upon alkali
metals present in the fuel, inlet air, and injected water and upon engine operating temperature. Consult GE for review of
higher sulfur fuels.
b. The following alternate methods are acceptable: ASTM D1552, ASTM D2622, and ASTM D1266.
c. This limit is considered to include all alkali metals, e.g. potassium and lithium as well as sodium. Experience, however, has
shown that sodium is generally the predominant alkali metal. This limit also assumes zero alkali metals in the inlet air or
injected water or steam. When actual levels are above zero, the maximum allowable sodium content of the fuel must be
reduced in accordance with the following relationship:
ppm Na in Inlet Air x Air/Fuel Ratio
+ppm Na in Water or Steam x Water or Steam/Fuel Ratio
+ppm Na in Fuel
Total fuel equivalence for sodium from all sources not to exceed 0.2 ppm
d. For nonmarinized engines (except for LM6000), the total amount of alkali metals from all sources shall not exceed 0.1 ppm.
e. To achieve the level of sensitivity for detection of sodium to the level required, an atomic absorption spectrometer or a rotat-
ing disc spectrometer may be necessary.
f. Care must be taken with the more viscous fuels to ensure that the minimum hydrogen content is met.
g. Maximum particle size is 20 microns.
h. For marine gas turbines using a hydromechanical main fuel control, the limit is 40 ppm.
i. Legal limits and applicable safety regulations must be met; however, it should be noted that use of fuels having a flash point
in excess of 200°F (93.3°C) may result in unsatisfactory starting characteristics. Blending for enhancement of spark ignition
or use of alternate fuels may be required for starting.
j. Copper corrosion test conditions are two hours at 212°F (100°C).

A-12
GEK 97310
VOLUME I
MID-TD-0000-3
May, 1996
NOX SUPPRESSION WATER PURITY SPECIFICATION

FOR
GE AIRCRAFT DERIVATIVE GAS TURBINES
IN


A-13
GEK 97310
VOLUME I
MID-TD-0000-3
May, 1996
1. SCOPE ASTM D1192 Equipment for Sam-

pling Water and Steam
1.1 This specification establishes the
requirements for purified water for NOx ASTM D1293 Tests for pH of Water
suppression in gas turbine engines.
ASTM D1428 Tests for Sodium and
1.2 Definitions. For the purpose of this Potassium in Water and
specification, the following definitions Water-Formed Deposits
shall apply: by Flame Photometry
NOx Suppression Water - Water intro- ASTM D1888 Tests for Particulate and
duced into the engine combustor for the Dissolved Matter in
purpose of suppressing the oxides of Water
nitrogen (NOx) in the engine exhaust
gases. ASTM D3370 Practices for Sampling
Water
2. APPLICABLE DOCUMENTS
3. REQUIREMENTS
2.1 American Society of Testing and Mate-
rials Publications. Available from 3.1 Sampling Requirements. The sampling
American Society for Testing and Mate- shall be in accordance with ASTM
rials, 1916 Race Street, Philadelphia, PA D3370. A minimum of one gallon or
19103. four liters shall be supplied.
ASTM D512 Tests for Chloride Ion in 3.2 Chemical Requirements. The water shall
Water and Waste meet the following requirements when
tested in accordance with the designated
ASTM D516 Tests for Sulfate Ion in test method:
Water and Waste
3.3 Filtration Requirements. The water
ASTM D859 Tests for Silica in Water shall contain no particles larger than
and Waste 20 microns absolute.
ASTM D1125 Tests for Electrical Con-
ductivity and Resistivity
of Water
Limit Test Method
Total matter, ppm, maximum 5 ASTM D5907
Dissolved matter, ppm, maximum 3 ASTM D5907
pH1 6.0-8.0 ASTM D1293
Conductivity, mocromhos/cm at 25°C, maximum1 0.5-1.0 ASTM D1125
Sodium + potassium, ppm, maximum 0.1 ASTM D4191 & ASTM D4192
Silicon dioxide, ppm, maximum 0.1 ASTM D859
Chlorides, ppm, maximum 0.5 ASTM D512
Sulfates, ppm, maximum 0.5 ASTM D516
Notes: (1) pH and/or conductivity shall be measured when water is free of carbon dioxide.

A-14
GEK 97310
VOLUME I
MID-TD-0000-4
May, 1996
COMPRESSOR CLEANING WATER PURITY SPECIFICATION

FOR
IN


A-15
GEK 97310
VOLUME I
MID-TD-0000-4
May, 1996
1. SCOPE cations to the extent specified herein.

1.1 Scope. This specification establishes the Unless a specific issue is specified, the
requirements for purified water for use latest revision shall apply.
in cleaning the compressor of gas tur- 2.2 The American Society of Testing and
bine engines where the intent is to Materials. Available from American
restore performance by removing the Society for Testing and Materials,
buildup of deposits on compressor com- 1916 Race Street, Philadelphia, PA
ponents. The water quality defined in 19103.
this specification applies to water used ASTM D1192 Equipment for Sampling
in both on-line compressor cleaning and Steam
crank-soak compressor cleaning.
ASTM D1293 Tests for pH of Water
1.2 Definitions. For the purpose of this
specification, the following definitions ASTM D4191 Tests for Sodium in Water by
shall apply: Atomic Absorption
Spectography
On-line Compressor Cleaning- A
method of removing the buildup of ASTM D4192 Tests for Potassium in Water
deposits on compressor components by Atomic Absorption
while the engine is operating. On-line Spectography
cleaning is accomplished by spraying ASTM D5907 Tests for Filterable and Non-
cleaning solution into the inlet of the Filterable Matter in Water
engine while the engine is operating.
ASTM D3370 Practices for Sampling Water
Crank-Soak Compressor Cleaning - A
3. REQUIREMENTS
method of removing the buildup of
deposits on compressor components 3.1 Sampling Requirements. The sampling
while the engine is motored by the shall be in accordance with ASTM
starter. Crank-soak cleaning is accom- D1192 and ASTM D3370. A minimum
plished by spraying cleaning solution sample of one gallon or four liters shall
into the inlet of the engine while the be supplied.
engine is operating unfired at crank 3.2 Chemical Requirements. The water shall
speed. meet the following requirements when
Liquid Detergent - A concentrated solu- tested in accordance with the designated
tion of water soluble surface active test method:
agents and emulsifiable solvents. 3.3 Filtration Requirements. The water shall
Cleaning Solution - A solution of emul- contain no particles larger than
sion of liquid detergent and water or a 100 microns absolute.
water and antifreeze mixture for direct
engine application. The recommended Limit Test Method
dilution of liquid detergent and water Total matter, 100 ASTM D5907
shall be specified by the liquid detergent maximum
manufacturer. pH 6.5-8.5 ASTM D1293
2. APPLICABLE DOCUMENTS Sodium+pota- 25 ASTM D4191 and
2.1 Issue of Documents. The following doc- sium, ppm ASTM D4192
uments shall form a part of this specifi- maximum

A-16
GEK 97310
VOLUME I
MID-TD-0000-5
July, 1989
LIQUID DETERGENT FOR COMPRESSOR CLEANING

FOR
IN
GE Aircraft Engines
Marine & Industrial Engine Projects Department

A-17
GEK 97310
VOLUME I
MID-TD-0000-5
July, 1989
1. SCOPE 2.1.2 SAE Publications

1.1 Scope. This specification establishes the
requirements for liquid detergent prod- ARP 1795 Stress-Corrosion of Tita-
ucts used to prepare cleaning solutions nium Alloys, Effect of
Cleaning Agents on Air-
for cleaning the compressors of gas tur-
craft Engine Materials.
bine engines, where the intent is to
restore performance by removing the 3. MATERIAL COMPOSITION
buildup of deposits on compressor com- 3.1 Materials. The chemical composition of
ponents. Such deposits include salt, the detergent is not limited, other than as
soils, or oils that may be ingested from
specified herein.
the atmosphere.
3.2 Biodegradability. Use of the liquid
The cleaning process shall be carried out by
detergent/cleaning solution shall con-
spraying the cleaning solution into the bell-
mouth of the engine while the engine is run- form to local regulations for water pollu-
ning at power (on-line cleaning) or while the tion. Use of biodegradable ingredients is
engine is being cranked (crank soak cleaning). recommended.
1.2 Definitions. For the purposes of this 3.3 Toxicity. Use of the liquid detergent/
specification, the following definitions cleaning solution shall conform to local
shall apply: regulations for industrial hygiene and air
pollution. Use of nontoxic ingredients is
Liquid Detergent - A concentrated solution of recommended.
water soluble surface active agents and emulsi-
fiable solvents. 3.4 Health and Safety Information. The liq-
uid detergent manufacturer shall make
Cleaning Solution - A solution or emulsion of
available health and safety information
liquid detergent in water or a water and anti-
for the liquid detergent as required by
freeze mixture for direct engine application.
The recommended dilution of liquid detergent applicable local, state and federal
and water shall be determined by the liquid regulations.
detergent manufacturer. 3.5 Solids. The liquid detergent shall con-
2. APPLICABLE DOCUMENTS tain no particles larger than 20 microns.
2.1 Issue of Documents. The following doc- 3.6 Physical and Chemical Properties. The
uments shall form a part of this specifi- liquid detergent shall meet the test
cation to the extent specified herein. requirements.
Unless a specific issue is specified, the 4. TEST REQUIREMENTS
latest revision shall apply.
4.1 Liquid Detergent
2.1.1 American Society of Testing and
Materials. 4.1.1 Residue or Ash Content. Residue or ash
content shall not exceed 0.01 percent
ASTM D88 Standard Test Method for when tested in accordance with
Saybolt Viscosity paragraph 5.1.

A-18
GEK 97310
VOLUME I
MID-TD-0000-5
July, 1989
4.1.2 Low Temperature Stability. The liquid 4.1.7 Viscosity. The liquid detergent shall
detergent shall show no evidence of sep- have a viscosity of 50 to 200 SUS at
aration of component parts when main- 77°F (25°C) when tested in accordance
tained at 40°F ±3° (5°C ±2°). It is highly with ASTM D88.
desirable although not mandatory that
the fluid shall remain liquid below 32°F 4.1.8 pH. The pH of the liquid detergent as
(0°C). received shall be from 6.5 to 8.5 when
measured with a suitable pH meter
4.1.3 Cold Weather Solution Compatibility. employing a glass electrode.
The liquid detergent shall show no sepa-
ration, layering, or precipitation when 4.2 Cleaning Solution.
mixed to the liquid detergent manufac-
turer’s recommended dilution in one or 4.2.1 Corrosive Elements. Maximum levels of
more of the following antifreeze solu- elements in the cleaning solution which
tions after 2 hours at 10°F ±3° may promote various types of corrosion,
(-12°C ±2°): shall be no greater than as shown in
Table 1, when analyzed by methods if
• Isopropyl Alcohol paragraph 5.5.
• Methyl Ethyl Ketone (MEK) Table 1
• Acetone Total alkali metals

(sodium + potassium +
See paragraph 7.1 for more information lithium, etc.) 25 ppm maximum
regarding liquid detergent and antifreeze Magnesium + calcium 5 ppm maximum
mixtures.
Vanadium 0.1 ppm maximum
4.1.4 Hard Water Compatibility. The liquid Lead 0.1 ppm maximum
detergent shall show no separation or
Tin + copper 10 ppm maximum
layering when mixed with synthetic hard
water prepared in accordance with Sulfur 50 ppm maximum
paragraph 5.2. Chlorine 40 ppm maximum
4.1.5 Acid and Alkali Acceptance. The liquid 4.2.2 pH. The pH of the cleaning solution
detergent shall show no separation, lay- shall be from 6.5 to 8.5 when measured
ering, or precipitation when tested in with a suitable pH meter employing a
acidic or alkali media in accordance glass electrode.
with paragraph 5.3.
4.1.6 Salt Water Tolerance. The liquid deter-
gent shall show no separation or gelling
when mixed with 3.5 percent salt water
in accordance with paragraph 5.4

A-19
GEK 97310
VOLUME I
MID-TD-0000-5
July, 1989
5. TEST METHODS 5.3 Acid and Alkali Acceptance. The liquid

detergent shall be mixed with distilled
5.1 Residue or Ash Content. Weigh 10 ±0.1 water in accordance with the liquid
gram sample of liquid detergent in a detergent manufacturer’s recommended
weighed 30 cc porcelain crucible. Heat dilution. To 50 cc of the solution, add
gently to volatilize any water or sol- 1 cc of 75 percent phosphoric acid. To
vents. (Crucible may be placed in air another 50 cc of the solution, add 5 cc of
oven at 105°C ±2° for 24 hours, fol- 75 percent phosphoric acid. To another
lowed by 240°C ±2° for 24 hours to 50 cc of the solution, add 1 cc of 50 per-
ensure all volatile matter is evaporated.) cent potassium hydroxide. Let all three
Finally, ignite contents over Bunsen mixtures stand for one hour at 77°F +5°
burner, first at low temperature under (25°C +3°), and then examine for acid or
good oxidizing conditions until all ignit- alkali acceptance.
able material is consumed, then place a
crucible in a muffle furnace at 1040° to 5.4 Salt Water Tolerance. Prepare a 3.5 per-
1100°C for 2 hours. Cool in desiccator, cent by weight solution of sodium chlo-
and weigh. ride in distilled water. Add 15 cc of salt
solution to 35 cc of liquid detergent and
Percent residue or ash = (100 x A)/W let stand for 1 hour at 77°F ±5°
(25°C ±3°). Examine for salt water
Where: A = grams of residue
tolerance.
W = grams of sample
5.5 Elemental Content. Elemental content
5.2 Hard Water Compatibility
shall be determined using the following
5.2.1 Preparation of Synthetic Hard Water. A methods.
hard water solution is prepared by dis-
solving the following in one liter of just Element Method
boiled and cooled distilled water: Sulfur, Phosphorus Inductively Cou-
(a) 0.20 ±0.005 gram Calcium Acetate, pled Plasma Spec-
reagent grade Ca (C2H302)2 H2O troscopy - Atomic
Emission Spectros-
(b) 0.15 ±0.005 gram Magnesium Sul- copy (ICP-AES)
fate, reagent grade MgSO4 7H2O Chlorine Microcoulometric
5.2.2 Hard Water Test. 5 cc of liquid deter- filtration
gent shall be added to a clean 50 cc cyl- Sodium, Potassium Atomic Absorption
inder. 45 cc of synthetic hard water (AA)
shall be added and mixed well. The
solution shall be examined for compat- Other metals ICP-AES or AA
ibility after 16 hours at 77°F ±5°
(25°C ±3°).

A-20
GEK 97310
VOLUME I
MID-TD-0000-5
July, 1989
6. MATERIAL COMPATIBILITY • Methyl Ethyl Ketone (MEK)

6.1 Compatibility with Engine Materials. • Acetone
Use of the detergent gas turbine cleaner Antifreeze mixtures are shown in Table 2. The
shall not have adverse effects on engine liquid detergent manufacturer must specify
system materials such as titanium stress which, if any, of the antifreezes specified
corrosion, hot corrosion of turbine com- above (also specified in paragraph 4.1.3) are
ponents or damage to lubrication system not compatible with the liquid detergent.
components.
The use of nonisopropyl alcohol, ethylene gly-
6.2 Titanium Stress Corrosion. A titanium col or additives containing chlorine, sodium or
stress corrosion test in accordance with potassium are not permitted since they may
ARP 1795 or equivalent may be run on attack the titanium and other metals in the gas
the liquid detergent at the discretion of turbine.
GE Aircraft Engines.
It is extremely important that the liquid deter-
7. NOTES gent and antifreeze solution be a homogeneous
7.1 Cold Weather Usage. In cold weather, mixture when sprayed into the bellmouth of
liquid detergent must be added to anti- the gas turbine. If after two hours the liquid
freeze mixture rather than to water detergent and antifreeze solution separates,
alone. At present, the only acceptable (see paragraph 4.1.3) agitation of the mixture
antifreeze solutions are: in the wash water tank is permissible. How-
ever, the liquid detergent manufacturer shall
• Isopropyl Alcohol
specify that agitation is required.
Table 2. Water Wash Antifreeze Mixtures
Water Antifreeze Mixtures for Washing Compressor
Isopropyl
Outside Air Temperature, MEK H2O Acetone H2O Alcohol H2O
°F (°C) % Vol % Vol % Vol % Vol % Vol % Vol
+20 to +50 (-7 to +10) 28 72 25 75 22 78
10 to +20 (-12 to -7) 47 53 40 60 34 66
0 to +10 (-18 to -12) 59 41 53 47 47 53
-10 to 0 (-23 to -18) 69 31 63 37 72 28
-20 to -10 (-29 to -23) 75 25 69 31 88 12
-30 to -20 (-34 to -29) 78 22 75 25 97 3
Water Antifreeze Mixtures for Rinsing Compressor
Isopropyl
Outside Air Temperature, MEK H2O Acetone H2O Alcohol H2O
°F (°C) % Vol % Vol % Vol % Vol % Vol % Vol
+20 to +50 (-7 to +10) 23 77 20 80 18 82
10 to +20 (-12 to -7) 38 62 33 67 27 73
0 to +10 (-18 to -12) 48 52 43 57 39 61
-10 to 0 (-23 to -18) 55 45 50 50 58 42
-20 to -10 (-29 to -23) 60 40 55 45 70 30
-30 to -20 (-34 to -29) 63 37 60 40 77 23

A-21/(A-22 Blank)
GEK 97310
VOLUME I
MID-TD-0000-6
July, 1996
LUBRICATING OIL SPECIFICATION

FOR
GE AIRCRAFT DERIVATIVE
GAS TURBINES


A-23
GEK 97310
VOLUME I
MID-TD-0000-6
July, 1996
This document provides the requirements and 2.1 US DoD Specifications

application guidelines for selection of lubricat-
ing oils which can be satisfactorily utilized in MIL-L-23699 Lubricating Oil, Aircraft
GE Marine and Industrial Applications. It is Turbine Engines, Synthetic
recommended that the lubricating oil selected Base
be reviewed with M&IE prior to its use. MIL-L-7808 Lubricating Oil, Aircraft
Turbine Engines, Synthetic
1.0 Oil Specifications Base, Type 1
Oils conforming to the US Department of 2.2 American Society of Testing and
Defense (DoD) Specifications shown in para- Materials
graph 2.1 are acceptable for use in GE Aircraft
Derivative gas turbines, provided they are The following documents are available from
listed on the Qualified Product List (QPL) for American Society for Testing and Materials,
the specific Specification. Customer Service, 100 Barr Harbor Drive,
West Conshohocken, PA 19428-2959:
1.1 Commercial Specifications
ASTM D2532 Low Temperature Viscosity
Commercially available synthetic based lubri-
ASTM D97 Pour Point
cating oils, per the Supplier’s Specification,
are acceptable for use in GE Aircraft Deriva- ASTM D445 Kinetic Viscosity
tive gas turbines, provided they are listed in
3.0 Requirements
Section 4 of this document. Such oils largely
conform to the primary requirements of the The lubricating oil shall conform to the
oils in Section 1.0, but certain variations have requirements of MIL-L-23699, however,
been approved. Such oils have been qualified exceptions to the following requirements will
by the Supplier to meet the requirements of be considered:
this document.
• Low temperature Viscosity when tested per
2.0 Applicable Documents ASTM D2532
The following documents shall form a part of • Pour Point when tested per ASTM D97
this document to the extent specified herein. • Viscosity at 40°C and 100°C when tested
Unless a particular issue is specified, the latest per ASTM D445
revision shall apply. • Base Stock Composition

A-24
GEK 97310
VOLUME I
MID-TD-0000-6
July, 1996
The specific variations to MIL-L-23699 shall material presented for review shall include, as
be provided by the oil supplier, along with per- minimum, the following:
formance difference impacts, for review by
GE. • Physical/Chemical Properties and varia-
tions to MIL-L-23699
3.1 Material Compatibility • Expected impact to operating systems due
to Property variations
The lubricating oil shall be compatible with • Material Compatibility Lists & Test results
the same elastomer seal and metallic materials • Oil Coking Test Results
as the MIL-L-23699 compliant lubricating oils
are. 4.2 Service Evaluation Tests
The lubricating oil shall be mixable with The oil shall undergo service evaluation test-
MIL-L-23699 or MIL-L-7808 compliant oil in ing in a LM Series gas turbine application(s).
a ratio of up to 5% of either oil, without The sponsoring operator will accept total
adversely affecting the property integrity of responsibility for all results related to operat-
the majority, or operating, oil. Mixing of oils is ing with the candidate lubricating oil. The ser-
not intended, but will result due to engine loca- vice evaluation engine shall have a known
tion changes. hardware condition baseline, based on depot
inspection or new delivery, immediately prior
4.0 Qualification to the service evaluation test.
Lubricating oil shall be considered qualified Service evaluation testing shall be conducted
and acceptable for use in GE M&I Aircraft on a minimum of three LM series gas turbines,
Derivative gas turbines demonstrating con- each accumulating at least 8,000 operating
formance to the requirements and after being hours, at a baseload operating site, prior to
listed in paragraph 4.4. The qualification pro- inspection. During operation, periodic oil sam-
gram shall be carried out by the oil supplier in ples shall be tested and trended for physical
conjunction with a sponsoring gas turbine and chemical property changes. Inspection
owner/operator. GE M&I’s participation will shall be performed at an authorized depot, and
be limited to technical consultation, review shall be in accordance with the applicable
and final approval only. repair manual.
4.1 Performance Tests Inspection shall be focused on the oil wetted

parts, including the bearings, gears, elastomer
The oil supplier shall conduct tests in accor- seals, sump oil seals, actuators, and lube/
dance with the requirements of MIL-L-23699 hydraulic pumps. GE M&I will be permitted to
and compare the results with the requirements witness any of the inspections, at the discretion
stated therein. All results, and specifically the of GE.
variations to MIL-L-23699 requirements, shall
be reviewed with GE M&I prior to initiation of
Service Evaluation Testing. Specifically, the

A-25
GEK 97310
VOLUME I
MID-TD-0000-6
July, 1996
4.3 Qualification Report Upon final review and approval of the Final
Qualification Report by GE, the candidate oil
The oil supplier, and/or operator, shall prepare will be included on the approved oils list.
and submit a Final Qualification Report to GE
M&I. The report shall include, as a minimum, Formulation changes affecting any approved
the following: performance characteristics must be reviewed
• Oil Brand Description including the com- with GE M&I for impact on qualification
plete formulation results.
• Certified physical, chemical and perfor- 4.4 Approved Lubricating Oils
mance test results
• Material Safety Data Sheets In addition to the oils listed on QPL-23699 and
• Service evaluation test history including all QPL-7808, (Qualified Products List), the fol-
significant operational and maintenance lowing lubricating oils are approved for use in
events GE M&I gas turbines and gas generators:
• Service evaluation oil sample trending
1. None at this time.
results,
• Final depot engine inspection results

A-26
GEK 97310
VOLUME I
ADDENDUM A
ADDENDUM
INDUSTRIAL GAS TURBINE MODEL
7LM2500PC101C

GEK 97310
VOLUME I
ADDENDUM A
TABLE OF CONTENTS
Paragraph Title Page
1-0 INTRODUCTION....................................................................................... A-3

2-0 REFERENCE DATA .................................................................................. A-3
3-0 INSTALLATION DRAWINGS.................................................................. A-4
4-0 EQUIPMENT DESCRIPTION ................................................................. A-4
5-0 GAS TURBINE CONTROL ...................................................................... A-4
6-0 NOX SUPPRESSION (WATER INJECTION SYSTEM)....................... A-4
7-0 INSTRUMENTATION AND SUPPLY REQUIREMENTS ................... A-8
8-0 SERVICE REQUIREMENTS ................................................................... A-11
8-1.1 Natural Gas ................................................................................................... A-11
8-1.2 Liquid Fuel.................................................................................................... A-11
8-1.3 Water Servicing And Pumping Requirements (NOX Suppression) ............. A-11
9-0 OPTIONAL HARDWARE KITS .............................................................. A-11
10-0 GAS TURBINE OPERATION .................................................................. A-11
10-1 PERFORMANCE RATINGS AND OPERATING LIMITS .................. A-12
10-1.1 Performance Ratings ..................................................................................... A-12
10-1.2 Water Scheduling Requirements During Operations (NOX Suppression) ... A-14
10-1.3 Operating Limits ........................................................................................... A-21
10-2 INITIAL OPERATION .............................................................................. A-25
10-2.1 General .......................................................................................................... A-25
10-2.2 Special Instrumentation Required for Operation .......................................... A-25
10-2.3 Special Instrumentation Required for Monitoring and Troubleshooting ...... A-25
10-2.4 Preparation .................................................................................................... A-25
10-2.5 Gas Turbine and Associated Equipment Check List..................................... A-26
10-2.6 Governor and Manual Control Check........................................................... A-26
10-2.7 Start-up and Checkout................................................................................... A-27
10-2.8 Ignition Check............................................................................................... A-28
10-2.9 Motoring........................................................................................................ A-29
10-2.10 False Start...................................................................................................... A-29
10-2.11 Governor Check ............................................................................................ A-29
10-2.12 Wet Prestart ................................................................................................... A-29
10-2.13 Manual Start and Operation .......................................................................... A-29
10-2.14 Operation to Maximum Power...................................................................... A-38
10-2.15 Automatic Operation..................................................................................... A-39
10-3 NORMAL OPERATION............................................................................ A-40
10-3.1 Interlocks....................................................................................................... A-40
10-3.2 Operation....................................................................................................... A-40
10-4 EMERGENCY OPERATION ................................................................... A-41
10-4.1 Emergency Shutdown ................................................................................... A-41
10-4.2 Post Shutdown Fire ....................................................................................... A-41

A-1
GEK 97310
VOLUME I
ADDENDUM A
Figure Title Page
1 Deleted
2 Deleted
3 Deleted
4 Deleted
5 Deleted
6 Typical Acceleration Fuel Flow Schedule When Operating on Natural Gas ........ A-6
7 Typical Acceleration Fuel Flow Schedule When Operating on Liquid Fuel......... A-7
8 Fuel Manifold Pressure Vs. Fuel Flow When Operating on Natural Gas ............. A-15
9 Fuel Manifold Pressure Vs. Fuel Flow When Operating on Natural Gas ............. A-16
10 Fuel Manifold Pressure Vs. Fuel Flow When Operating on Liquid Fuel.............. A-17
11 NOX Suppression - Total Flow Vs. Fuel Nozzle Pressure Drop........................... A-18
12 NOX Suppression - Total Flow Vs. Fuel Nozzle Pressure Drop........................... A-19
13 Transient Temperature Limits ................................................................................ A-20
LIST OF TABLES
Table Title Page
1 INSTRUMENTATION CONNECTIONS - 7LM2500PC101C ............................ A-8

2 SUPPLY CONNECTIONS - 7LM2500PC101C................................................... A-9
3 GAS TURBINE OPERATING LIMITS................................................................ A-21
4 PRESTART CHECKS ........................................................................................... A-28
5 START-UP AND OPERATION ............................................................................ A-30
6 GAS TURBINE SHUTDOWN ............................................................................. A-34
7 EMERGENCY SHUTDOWN............................................................................... A-36
8 Deleted

A-2
GEK 97310
VOLUME I
ADDENDUM A
1-0 INTRODUCTION. GAS TURBINE WEIGHTS (Cont.)
The information contained herein describes the
LM2500PC101C gas turbine basic configura- Component Wt-Lbs/(Kg)
tion and control system differences. In addi- Compressor Rear Frame 421 (191)
tion, the coverage of reference data,
instrumentation and supply connections, spe- Combustor 120 (54)
cial servicing requirements, optional hardware High Pressure Turbine Rotor 419 (190)
kits and the complete gas turbine operating High Pressure Turbine Nozzle,
instructions for the LM2500PC101C model Stage 1 68 (31)
are included.
High Pressure Nozzle, Stage 2 127 (58)
2-0 REFERENCE DATA. Turbine Mid Frame 530 (240)
Low Pressure Turbine Rotor 1095 (497)
EQUIPMENT Low Pressure Turbine Stator 601 (273)
Gas Turbine Assembly Turbine Rear Frame 1071 (486)
(General Electric Co., Cincinnati, High Speed Coupling Shaft
Ohio) Model No. 7LM2500PC101C Forward Adapter 91 (41)
Dwg. No. L24330G03 Exhaust Duct
Ring Seal 49 (22)
PERFORMANCE RATING
Ring Support 74 (34)
Refer to paragraph 10-1 Variable Stator Actuating
Mech 19 (9)
GAS TURBINE WEIGHTS Outside Piping and Bracketing 278 (126)
Component Wt-Lbs/(Kg) DRAWING LIST
The average weights of the major gas turbine
components are: Drawing No.
Gas turbine - including inlet Gas Turbine Installation
duct, centerbody, exhaust dif- Drawing L31705
fuser, and coupling nut 7396 (3355) Fuel System Flow Diagram L24354
Gas Generator 4212 (1911) Lubrication System Flow
Power Turbine 2777 (1260) Drawing L24328
Inlet Gearbox 38 (17) Electrical Diagram L24329
Transfer Gearbox 245 (111) Ignition Units L21454P02
Compressor Front Frame 517 (235) Gas Turbine Assembly
Compressor Rotor 552 (250) Drawing L24330G03
Compressor Stator, Front 307 (139)
Compressor Stator, Rear 93 (42)

A-3
GEK 97310
VOLUME I
ADDENDUM A
3-0 INSTALLATION DRAWINGS. 5-0 GAS TURBINE CONTROL.
A complete set of installation drawings have
been provided. a. The transition from natural gas to liq-
uid fuel and vice versa shall be smooth and
4-0 EQUIPMENT DESCRIPTION. shall not result in abrupt changes in gas gener-
The LM2500PC101C is a dual fuel (liquid and ator speed or temperatures. The rate of change
natural gas) nonmarinized gas turbine that from natural gas to liquid fuel or vice versa is a
incorporates a natural gas manifold, a liquid function of the operator’s control system, so
fuel manifold and 30 dual fuel nozzles. The long as the change in total fuel flow does not
gas turbine is not provided with an exhaust exceed that shown on the maximum accelera-
duct as standard equipment but an exhaust duct tion fuel flow curves. See figures 6 and 7.
inner diffuser is provided with the basic gas
turbine assembly. The LM2500PC101C is 6-0 NOX SUPPRESSION (WATER
designed to operate on 100 percent natural gas INJECTION SYSTEM).
fuel, 100 percent liquid fuel or a combination
of the two. The minimum fuel flow for each a. As an option, the 7LM2500PC101C
fuel, when operating on dual fuel, should be gas turbine can be equipped for suppression of
selected so that if one fuel is cut off, the gas oxides of nitrogen (NOX) in the gas generator
generator speed will not decrease below exhaust gases. This is accomplished by intro-
5000 RPM before the governor action restores duction of water into the liquid fuel manifold.
the gas turbine to normal operation. Should The LM2500 NOX suppression system has
the gas turbine be configured with the optional been designed to meet the requirements of the
NOX Suppression equipment, and prior to ini- U.S.E.P.A. standard for NOX emissions for
tiation of water flow for NOX Suppression, it stationary gas turbines and includes a conser-
is recommended that the gas generator be vative margin for meeting the requirements of
operating at a stabilized steady-state condition. other, possibly more restrictive, local codes
where applicable.

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VOLUME I
ADDENDUM A
Figure 1 through 5. Deleted

A-5
GEK 97310
VOLUME I
ADDENDUM A
Figure 6. Typical Acceleration Fuel Flow Schedule When Operating on Natural Gas

A-6
GEK 97310
VOLUME I
ADDENDUM A
Figure 7. Typical Acceleration Fuel Flow Schedule When Operating on Liquid Fuel

A-7
GEK 97310
VOLUME I
ADDENDUM A
7-0 INSTRUMENTATION AND SUP-
PLY REQUIREMENTS. See Tables 1 and 2.
Table 1. INSTRUMENTATION CONNECTIONS - 7LM2500PC101C
Item Nomenclature Interface
E1 Vibration pickup, Gas Generator Bell & Howell Electronics Part No. 173960
or 364450
E2 Power turbine inlet temperature MS3106-14S-9S
E3 A-sump scavenge oil temperature MS3106R12S-3S
E3A “A” sump T/C (optional equipment) MS3106R-12S-3SW except pin A iron and
pin B constantan
E4 B-sump scavenge oil temperature MS3106Rl2S-3S
E4A “B” sump T/C (optional equipment) MS3106R-12S-3SW except pin A iron and
pin B constantan
E5 C-sump scavenge oil temperature MS1306R12S-3S
E5A “C” sump T/C (optional equipment) MS3106R-12S-3SW except pin A iron and
pin B constantan
E6 Accessory gearbox scavenge oil tempera- MS3106Rl2S-3S
ture
E6A Accessory gearbox T/C (optional equip- MS3106R-12S-3SW except pin A iron and
ment) pin B constantan
E11 Oil supply temperature MS3106R12S-3S
E11A Inlet T/C (optional equipment) MS3106R-12S-3SW except pin A iron and
pin B constantan
E18 D-sump scavenge oil temperature MS3106Rl2D-3S
E18A “D” sump T/C (optional equipment) MS3106R-12S-3SW except pin A iron and
pin B constantan
E7 Gas generator speed pickup No. 1 MS3106R-10SL-4S
E13 Vibration pickup, power turbine Bell & Howell Electronics Part No. 173960
or 364450
E14 Power turbine speed pickup No. 1 MS3106-10SL-4S
A13 Power turbine inlet pressure probe AN818-6C or MS20819-6C
(optional)
A23 CDP pressure port (optional) 500-20UNJF-3B
A18 CIT sensor (part of fuel control system)
F3 Natural gas fuel manifold pressure tap MS9197-04 or AN818-4C
(optional)

A-8
GEK 97310
VOLUME I
ADDENDUM A
Table 1. INSTRUMENTATION CONNECTIONS - 7LM2500PC101C (Cont.)
Item Nomenclature Interface
F5 Fuel manifold liquid pressure tap AN818-6C or MS9197-06
L5 Lube supply pressure tap AN818-6C or MS9197-06
L7 Lube scavenge pressure tap (optional) AN818-4C or MS9197-04
Remote reading variable stator vane pro-
tractor (optional)
E10 Starter speed switch (optional) MS3106-10SL-4S
E16 Gas turbine electrical bond, left
E17 Gas turbine electrical bond, right
NOTE
For all other instrumentation connections, refer to Installation Drawings provided with
gas turbine.
.
Table 2. SUPPLY CONNECTIONS - 7LM2500PC101C
Instrumentation Interface
CAUTION
ALL LINES MUST BE FLEXIBLE ENOUGH TO ALLOW 3/4 INCH THERMAL
GROWTH OF GAS GENERATOR WITHOUT PLACING STRAIN ON LINES OR
ON GAS GENERATOR. IF EXCESSIVE FORCE IS REQUIRED TO COMPLETE A
CONNECTION, LOOSEN ALL CONNECTIONS AND CHECK/ADJUST ROUT-
ING AS REQUIRED.
F1 Natural gas supply 2 inch line from Fuel Control Unit to Gas
Generator Fuel Manifold
F2 NOX H2O Fuel Manifold Inlet liquid, mates with
AN818-12C or MS20819-12C or equivalent.
Ll Lube Oil Supply 1-1/2 inch line to Lube Pump on Gas Genera-
tor, AN818-24C or MS20819-24C
L2 Lube pump discharge 1 inch line from Lube Pump to Oil Supply Fil-
ters, AN819-16C or MS20819-16C
L4 Lube supply inlet port 1 inch line from Oil Supply Filters to Gas
Generator, AN818-16C or MS20819-16C
L3 Scavenge oil discharge 1-1/4 inch line from Gas Generator Scavenge
Pump to Oil Scavenge Filter and Cooler,
AN818-20C or MS20819-20C

A-9
GEK 97310
VOLUME I
ADDENDUM A
Table 2. SUPPLY CONNECTIONS - 7LM2500PC101C (Cont.)
Instrumentation Interface
A1 Bleed air port 8th stage Shipped with cover that must remain in place
if port is not used
A6 Starter air or gas inlet port
(optional equipment)
A7 Starter air or gas outlet port
A2 Bleed air 16th stage compressor bleed air lines if used
A4 Inlet duct seal If used - attaching hardware
A10A CDP seal leakage No. 1 If used - 2-inch line attaching hardware
A11A CDP seal leakage No. 2 If used - 2 inch line attaching hardware
A20 C sump overboard vent left bottom If used - 2 inch line attaching hardware
A21 C sump overboard vent right If used - 2 inch line attaching hardware
bottom
A22 C sump overboard vent right top If used - 2 inch line attaching hardware
A12 Air/Oil Separator 3 inch line from air/oil separator to atmo-
spheric vent or to exhaust duct (flame
arrestor)
D3 Oil drain, forward AN818-6C or MS20819-6C
D5 Oil drain, aft AN818-6C or MS20819-6C
S1 or Waterwash manifold 1 inch line - hot water line to waterwash man-
S1A ifold on Gas Generator Inlet Duct AN818-16C
or MS20819-16C
F3 H2O Manifold shroud drain Mate with AN818-4C or MS9197-04
NOTE
For all other supply connections, refer to Installation Drawings provided with gas
turbine.

A-10
GEK 97310
VOLUME I
ADDENDUM A
8-0 SERVICE REQUIREMENTS. ner to prevent any sudden pressure spikes
which could momentarily displace the fuel.
8-1.1 Natural Gas. Refer to applicable gas turbine performance
data and fuel nozzle flow characteristic curve
a. The required supply pressure to the for water pump size determination. Other cri-
fuel manifold on the gas turbine is 350 ± 5 psig teria, such as calculated gas generator water
(2415 ± 35 kPa). flow required to meet the requirement of the
applicable EPA standard or other local codes,
b. The temperature of the gas must be in corresponding fuel flow and the gas generator
the range of -65° to +150°F (-54 to +60°C). If internal cycle pressure level may be obtained
the temperature is not repeatable on a day-to- from the tabular performance data sheets.
day basis it will be necessary to change the
starting fuel adjustment to adjust the supply 9-0 OPTIONAL HARDWARE KITS -
pressure to the engine to maintain a constant LM2500PC101C.
Btu-per-cubic-foot supply. Once started, the
engine will accept variations in supply temper- Refer to Volume II, WP 001 00 for a detailed
ature of ±20°F (±11°C). The maximum fuel list of optional kits available for this particular
flow required is 13,400 pph (6078 kg/h) with a gas turbine model.
lower heating value of 19,000 Btu/lb.
10-0 GAS TURBINE OPERATION.
8-1.2 Liquid Fuel.
a. These instructions contain the detailed
a. The required supply pressure to the gas turbine operating procedures and limits
fuel manifold on the gas turbine is 390 ± 5 psig recommended by the General Electric Com-
(2691 ± 35 kPa). pany for the 7LM2500PC101C Gas Turbine.
b. The fuel temperature supplied to the b. The instructions are intended to pro-
gas turbine shall be a minimum of 20°F vide operating personnel with the information
(-6.7°C) above the wax point of the fuel and a required to operate the gas turbine. They per-
maximum of 150°F (66°C). The fuel shall be tain to routine and emergency conditions and
filtered to 20 microns absolute. The maximum procedures. When a fault exists, refer to Chap-
fuel flow required is 13,000 pph with a lower ter 4 entitled TROUBLESHOOTING.
heating value of 18,400 Btu/lb.
c. It is possible that these instructions
8-1.3 Water Servicing And Pumping may not provide for every possible variation in
Requirements (NOX Suppression). equipment or contingency to be met in connec-
tion with the operation of the gas turbine.
a. The maximum allowable water deliv- Refer requests for additional information to the
ery pressure at the manifold connection shall General Electric Company; Marine and Indus-
not exceed 1200 psig (8280 kpa). The temper- trial Engine Division; Cincinnati, Ohio 45215.
ature of the water supplied to the manifold
shall not exceed 180°F (82°C) and shall be
free of pressure pulsations in the 0 to 300 Hz
range. The water must be controlled in a man-

A-11
GEK 97310
VOLUME I
ADDENDUM A
10-1.1 Performance Ratings.
WARNING
IF A QUESTIONABLE CONDITION a. The rated performance of the
EXISTS, DO NOT OPERATE THE 7LM2500PC101C gas turbine in the new and
GAS TURBINE UNTIL A THOR- clean condition as compared to gas turbine
OUGH INVESTIGATION HAS performance with water injection is as follows:
BEEN MADE. DO NOT REPEAT
HOT STARTS, COMPRESSOR NOTE
STALLS, OR OTHER RECOGNIZED
PROBLEMS WITHOUT PRIOR The use of water injection to control
THOROUGH INVESTIGATION. NOX emissions results in a change in
FAILURE TO DO SO CAN RESULT gas turbine performance. Unless spe-
IN UNDUE STRESS BEING cifically agreed to in the applicable
IMPOSED ON GAS TURBINE COM- contract documents, all performance
PONENTS, WITH IMMEDIATE OR guarantees are based upon “dry” opera-
SUBSEQUENT DESTRUCTIVE tion with no water injection.
AND INJURY TO PERSONNEL.
Normal With NOX
NOTE (Dry) Suppression
The S. I. units shown in this chapter are Brake 27,500 27,500
direct mathematical conversions and Horsepower
may be rounded off in most instances Inlet Air 59°F 59°F
at the users discretion. Examples of Temperature (15°C) (15°C)
units that may be rounded off are those
utilized for temperatures, torque val- Inlet Losses 0”H2O 0”H2O
ues, pressures, etc. Examples where Exhaust Back
S. I. units may not be rounded off are Pressure 0”H2O 0”H2O
those utilized for drop checks, rigging Relative Humidity 60% 60%
adjustments, runouts, etc.
Altitude 0 Ft. 0 Ft.
10-1 PERFORMANCE RATINGS AND Compressor Bleed 0 Lbs/Sec 0 Lbs/Sec
OPERATING LIMITS. Accessory 0 0
Horsepower
NOTE Extraction
Ratings published in this manual apply Power Turbine 3600 RPM 3600 RPM
to the gas turbine. The driven unit rat- Speed
ings/limits may be lower in some cases Heat Rate, Max
and shall take precedence over the gas - Gas 6907 BTU/ 6959 BTU/
turbine manual limits. hp-hr hp-hr
- Liquid 6958 BTU/ 7070 BTU/
hp-hr hp-hr

A-12
GEK 97310
VOLUME I
ADDENDUM A
Normal With NOX 530 pph (240 kg/h) ± 25 pph (11 kg) @
(Dry) Suppression -65°F (-54°C) Inlet Air Temperature
Power Turbine 625 pph (284 kg/h) ± 25 pph (11 kg) @

Inlet Gas Tem- 1406°F 1404°F +60°F (16°C) Inlet Air Temperature
perature - Gas (763°C) (762°C)
- Liquid 1427°F 1402°F 680 pph (308 kg/h) ± 25 pph (11 kg) @
(775°C) (761°C) +130°F (54°C) Inlet Air Temperature
Water Injection
-Gas 0 lbs/hr 1828 lbs/hr c. The minimum fuel flow for each fuel,
(829 kg/h) when operating on dual fuel, should be
selected so that if one fuel is cut off the gas
- Liquid 0 lbs/hr 3984 lbs/hr generator speed will not decrease below
Fuel Flow 5000 rpm before the governor action restores
- Gas 9996 lbs/hr 10072 lbs/hr the engine to normal operation.
(4525 kg/h) (4569 kg/h)
- Liquid 10399 lbs/hr 10567 lbs/hr d. Figures 6 and 7 define the maximum
fuel acceleration schedule for the gas genera-
NOX Emissions
tor. When operating on dual fuel, the sched-
- Gas 170 109
ule, liquid or natural gas, which gives the
(ppm at 15% O2)
lower fuel rate shall be used.
- Liquid 290 108
e. Acceleration fuel rates greater than
b. The gas turbine is designed to operate those shown will result in over-temperature
on 100% natural gas fuel, 100% liquid fuel, or and possible stall of the engine. Acceleration
on combinations of the two with a limit on nat- fuel rates lower than those shown can result in
ural gas/liquid fuel ratios of 10/90 to 90/10. “hung” starts in the below idle speed range.
The gas turbine can be started on either natural
gas or liquid fuel but not on a combination of f. Above the idle speed point, low accel-
the two. The starting fuel flows on natural gas eration fuel rates will not harm the engine and
are: will only result in slower acceleration times.
465 pph (211 kg/h) ± 25 pph (11 kg) @ g. For normal accelerations from idle to
-65°F (-54°C) Inlet Air Temperature power settings the changes should be made
more slowly to enhance the time between hot
550 pph (249 kg/h) ± 25 pph (11 kg) @ section repairs and the life of the engine; a
+60°F (16°C) Inlet Air Temperature time of 2 to 3 minutes is reasonable.
595 pph (270 kg/h) ± 25 pph (11 kg) @ h. The fuel rates shown on the curves will
+130°F (54°C) Inlet Air Temperature give starting times to 5000 rpm idle of 60 to 90
seconds and accelerations from idle to maxi-
The starting fuel flows on liquid fuel are: mum power of 15 seconds.

A-13
GEK 97310
VOLUME I
ADDENDUM A
i. The maximum deceleration fuel flow 10-1.2 Water Scheduling Requirements Dur-
rate should consist of a step fuel decrease of ing Operations (NOX Suppression).
1500 (680 kg/h) ± 10% pph followed by a rate Water flow must be scheduled as a function of
change of 1330 pph (603 kg/h) ± 10% per sec- fuel flow and must be shut off during starting
ond to idle fuel flow. Rates greater than this and acceleration to idle. Water flow should be
can cause the engine to lose fire. Normal initiated at a fuel flow of 3000 pph ± 250 pph
decelerations from maximum power to idle (1361 kg/h ± 113kg/h) on acceleration when
should be made in approximately 2 to 3 min- operating with liquid fuel and at 5300 pph ±
utes - this will enhance the time between hot 450 pph (2404 kg/h ± 204kg/h) on acceleration
section repairs and the life of the gas turbine. when operating on natural gas. Subsequently,
the water should be shut off at these points on
j. The liquid fuel system must be free of a deceleration. During initiation of water flow,
periodic or random hunting which results in the gas turbine should be operating at a stabi-
cycling of gas generator speed or temperature. lized steady-state condition. Refer to
The frequency of the fuel flow fluctuations figures 11, 12, and 13 for water/fuel ratios,
shall not be a harmonic of the natural fre- supply pressures and manifold pressure/flow
quency of the springs in the fuel nozzles. The requirements.
natural frequency of these springs is 200 Hz.
Cycling of these parameters will reduce time a. Water Purity. The water supplied to the
between hot section repairs and the life of the gas generator must meet the following mini-
gas turbine. The transition from natural gas to mum requirements:
liquid fuel and vice versa shall be smooth and
shall not result in abrupt changes in gas gener- • Sodium + Potassium + Lead + Vana-
ator speed or temperature. The rate of change, dium + Lithium + Silica = 0.1 ppm
natural gas to liquid fuel or vice versa, must be maximum.
such that the transfer time from one fuel to
another at full power shall not exceed 10 sec- • Total ionizable solids, both dissolved
onds. and undissolved shall not exceed
5 ppm maximum.
k. The actual performance of the
7LM2500PC101C gas turbine will be a func- • PH = 6.5 to 7.5.
tion of the ratio of natural gas fuel and liquid
fuel used. The time between repairs of the hot • Water solid contaminants shall not
section will also change as a function of the exceed 10 mg per gallon with a maxi-
ratio of the natural gas and liquid fuels used mum contaminant size not exceeding
with the longest times being associated with 20 microns absolute.
100% natural gas.

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GEK 97310
VOLUME I
ADDENDUM A
Figure 8. Fuel Manifold Pressure Vs. Fuel Flow When Operating on Natural Gas

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ADDENDUM A
Figure 9. Fuel Manifold Pressure Vs. Fuel Flow When Operating on Natural Gas

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ADDENDUM A
Figure 10. Fuel Manifold Pressure Vs. Fuel Flow When Operating on Liquid Fuel

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ADDENDUM A
Figure 11. NOX Suppression - Total Flow Vs. Fuel Nozzle Pressure Drop

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ADDENDUM A
Figure 12. NOX Suppression - Total Flow Vs. Fuel Nozzle Pressure Drop

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ADDENDUM A
Figure 13. Transient Temperature Limits

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GEK 97310
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ADDENDUM A
NOTE 10-1.3 Operating Limits. Refer to Table 3.
When water is injected at the flow rates
necessary to meet U.S. E.P.A. require- NOTE
ments, the maximum gas generator If any operating limit is exceeded, ver-
corrected speed limit must be reduced ify instrumentation accuracy before
to 9650 RPM. There is no change to troubleshooting or inspecting gas
9800 RPM maximum physical (uncor- generator.
rected) speed limit.
Table 3. GAS TURBINE OPERATING LIMITS
Alarm/ Normal
Type Parameter Trip Setting Operating Range Remarks
NOTE
• Continuous operation should not take place with any parameter indicating between the alarm
and trip levels. If an alarm level is not shown, the trip level is the operating limit.
• Correct lube pressures per applicable table in Chapter 5.

Lubrication Gas Turbine Alarm 8 psig ± 1 psig 20-60 psig Bypass until
System - Lube Supply (55 kPa ± 6.9 kPa) (138-413 kPa) 4500 rpm
Settings and Pressure below 8000 rpm
Operating 15 psig ± 1 psig
Ranges (103 kPa ± 6.9 kPa)
above 8000 rpm
Gas Turbine Trip 6 psig ± 1 psig 20-60 psig Bypass until
Lube Supply (41 kPa ± 6.9 kPa) (138-413 kPa) 4500 rpm
Pressure
Gas Turbine Alarm 110 psig ±10 psig 10-100 psig Scavenge
Scavenge Dis- (759 kPa ± 69 kPa) (69-690 kPa) Discharge Pres-
charge Pressure sure shall not
exceed 180 psig
(1242 kPa)
Gas Turbine Alarm 180°-220°F 140°-160°F Normal
Lube Supply (82°-104°C) (60°-71°C) Operating Range
Temperature reflects tempera-
ture expected dur-
ing operation
above idle speed

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GEK 97310
VOLUME I
ADDENDUM A
Table 3. GAS TURBINE OPERATING LIMITS (Cont.)
Alarm/ Normal
Gas Turbine Trip 330°-350°F 215°-275°F Normal

Lube Scavenge (166°-177°C) (102°-135°C) Operating Range
Temperatures - reflects tempera-
Five ture expected dur-
ing operation
Alarm 290°-310°F above idle speed
(143°-154°C)
Fuel Fuel Manifold
System Pressure
Natural Gas 20-355 psig Supply Pressure
(138-2448 kPa) as reflected at the
fuel manifold inlet
on the gas turbine
Liquid Fuel 150-900 psig Supply Pressure
(1034-6205 kPa) as reflected at the
fuel manifold inlet
on the gas turbine
Fuel Supply Temperature
Natural Gas Alarm 150°F-170°F -65° to 150°F Starting Fuel Flow
(66°-77°C) (-54° to 66°C) Adjustments may
be required to
Liquid Fuel 20°F (-7°C) compensate for
above wax point fuel temperature
of fuel to 150°F variation
(66°C)
maximum
Starting Starter Supply 40 psig Starting Pressure
System Pressure (276 kPa) Requirement
based on engine
starter torque
requirements
Application of 1200 ± 100 rpm
Fuel and
Ignition

A-22
GEK 97310
VOLUME I
ADDENDUM A
Alarm/ Normal
Application of 1700 ± 100 rpm 1700 ± 100 rpm

Fuel and Igni- for start after
tion (if purge purge cycle
cycle is used)
Starting Time to Trip 1200 ± 100 rpm Activate 20 sec-
1200 rpm onds time delay
simultaneously
with start
initiation
Failure to Trip 380°- 420°F Activate 20 sec-
Light-Off (193°-216°C) onds time delay
simultaneously
with application
of fuel and
ignition
simultaneously
with start initia-
tion. De-energize
ignition, fuel sys-
tem and starter air
supply
4500 rpm (If onds time delay
purge cycle is upon completion
used) of purge. De-ener-
gize fuel and igni-
tion systems and
starter air supply
Power Failure to Trip 380°- 420°F 0-1600°F Trip if tempera-
Turbine Light-Off (193°- 216°C) (-18°-871°C) ture does not
Inlet reach 400°F
Temperature (204°C) within
20 seconds after
fuel and ignition
are applied

A-23
GEK 97310
VOLUME I
ADDENDUM A
Alarm/ Normal
Overtemperature
Natural Gas Trip 1450°F (788°C) 1378°-1438° F Values given are
(748° -781°C) for installations
using constant
Alarm 1438°F (781°C) T5.4 controls as
Liquid Fuel Trip 1470°F (799°C) 1400°-1460°F the power limit.
(760° -793°C) Installations using
constant power
Alarm 1460°F (793°C)
control mode
should consult the
contract docu-
ments for deter-
mining alarm and
trip settings,
which are unique
to each applica-
tion, but never to
exceed 1616°F
(880°C) (alarm)
and 1625°F
(885°C)(trip)
Vibration Gas Generator Trip 7 mils ± 1 mil DA 0-3 mils DA Avoid continuous
operation over
4 mils
Alarm 4 mils ± 1 mil DA
Power Turbine Trip 10 mils ± 1 mil DA 0-6 mils DA Avoid continuous
operation over 7
mils
Speed Gas Generator Trip 9950 ± 50 rpm 0-9850 rpm
Power Turbine Trip 3960 ± 40 rpm 0-3600 rpm
Loss of Combustor Close and lock out
Flame Flame fuel shutoff valve
upon loss of flame

A-24
GEK 97310
VOLUME I
ADDENDUM A
10-2 INITIAL OPERATION. 10-2.3 Special Instrumentation Required for
Monitoring and Troubleshooting.
10-2.1 General. Initial operational period is
that period of operation immediately following Fuel manifold pressure 0-400 psi
gas turbine replacement or major maintenance sensor . . . . . . . . . . . . . (0-2760 kPa)
on the system. Compressor inlet total 10-16 psia
pressure sensor . . . . . . (69-110.4 kPa)
10-2.2 Special Instrumentation Required for
Operation. Power turbine inlet gas 0-75 psia
pressure . . . . . . . . . . . . (0-517.5 kPa)
Fuel supply pressure . . . . 0-400 psig
Gas generator speed (0-2760 kPa)
sensor . . . . . . . . . . . . . . 0-10,000 rpm
Fuel supply 0-250°F
Lube oil scavenge temperature . . . . . . . . . (-17.8 - 121.1°C)
temperature sensors
Gas turbine inlet air 0-150°F
(A-, B-, C-, D-sumps 0-400°F
temperature . . . . . . . . . (-17.8 - 65.6°C)
and transfer gearbox) . . (-17.8 to 205°C)
Remote reading variable
Lube oil supply tempera- 0-400°F
vane indicator . . . . . . . -5° to +45°
ture sensor . . . . . . . . . . (-17.8 to 205°C)
Starter air supply pressure 0-50 psig
Vibration indicators 0-3 in/sec or
(optional). . . . . . . . . . . (0-345 kPa)
gas generator . . . . . . . . 0-10 mil DA
0-3 in/sec or 10-2.4 Preparation. The gas turbine and asso-
power turbine . . . . . . . . 0-10 mil DA ciated systems must be inspected and checked
Power turbine speed out for proper installation and operation before
sensor . . . . . . . . . . . . . . 0-5000 rpm normal operation can commence.
Power turbine inlet gas 0-2000°F
temperature (T5.4) . . . . (-17.8 to 1093°C)
Lube oil supply 0-100 psig
pressure . . . . . . . . . . . . (0-690 kPa)
pressure . . . . . . . . . . . . (0-690 kPa)
Compressor discharge 0-300 psig
pressure . . . . . . . . . . . . (0-2070 kPa)

A-25
GEK 97310
VOLUME I
ADDENDUM A
10-2.5 Gas Turbine and Associated Equip- p. T5.4 thermocouple system
ment Check List. Complete the following
check list. functioning properly _______
q. Ignition system operative _______
a. Gas Turbine Assembly S/N _______
r. Compressor inlet total pres-
b. Mounting base secured to sure probe aligned properly
foundation _______ and free of damage _______
c. Intake air and exhaust gas s. Variable stator system secure _______
ducts in place and secured _______
t. Required checks and inspec-
d. Gas turbine and exhaust duct tions specified in packager’s
support mounts and links in manual for gas turbine control
place and secure _______ have been performed _______
e. All service connections made
10-2.6 Governor and Manual Control Check.
and secure _______
Refer to packager’s manual.
f. All lines have been flushed per
packager’s manual _______
g. All instrumentation connec-
tions made and secure _______
h. All accessories are secure per
i. Gas turbine assembly free of
loose objects and all lines/
electrical leads connected _______
j. Gas turbine inlet air area free
of foreign objects. Inlet screen
secure _______
k. Gas turbine compressor rear
frame leakage ports, struts 7
and 10, are open (not capped) _______
l. Starter is serviced per pack-
ager’s manual _______
m. Lube oil storage tank serviced
to full level _______
n. Lube oil supply valves open _______
o. All filters are serviced per

A-26
GEK 97310
VOLUME I
ADDENDUM A
10-2.7 Start-up and Checkout. • ALLOW THE GAS TURBINE TO
COOL DOWN. AVOID CON-
WARNING
WEAR THERMALLY INSU-
WHEN ENTERING THE GAS TUR- LATED GLOVES AS
BINE ENCLOSURE, THE FOLLOW- NECESSARY.
ING REQUIREMENTS SHALL BE
MET: • EAR PROTECTION SHALL BE
• THE GAS TURBINE SHALL BE OPERATING.
SHUT DOWN.
• DO NOT REMAIN IN THE
• ENCLOSURE ENTRY DURING ENCLOSURE OR IN THE
ENGINE OPERATION IS PRO- PLANE OF ROTATION OF THE
HIBITED IN GENERAL. IF STARTER WHEN STARTING OR
ENTRY SHOULD BE MOTORING THE GAS
REQUIRED DURING ENGINE TURBINE.
OPERATION, CONTACT GE
FIELD SERVICE FOR A REPRE- a. When entering enclosure wear proper
SENTATIVE WHO IS TRAINED ear protection.
TO ENTER THE ENCLOSURE
UNDER SUCH CONDITIONS. b. Perform prestart checks per Table 4.
c. Perform ignition checkout per
• THE FIRE EXTINGUISHING paragraph 10-2.8.
d. Perform motoring procedure per
INACTIVE ACCORDING TO
paragraph 10-2.9.
THE CUSTOMER’S
PROCEDURES. e. Perform false start per paragraph
10-2.10.
• SECONDARY AIR TO THE f. Perform governor check per paragraph
ENCLOSURE SHALL BE SHUT 10-2.11.
OFF. HIGH SECONDARY AIR-
FLOW MAY PREVENT OPEN- g. Perform a wet prestart per paragraph
ING OR CLOSING THE 10-2.12.
ENCLOSURE DOOR. h. Perform a manual start and operate per
paragraph 10-2.13.
• THE ENCLOSURE DOOR
SHALL BE KEPT OPEN. IF THE i. Operate to maximum power per
GAS TURBINE IS OPERATING, paragraph 10-2.14.
AN OBSERVER SHALL BE STA- j. Check automatic operation per
TIONED AT THE ENCLOSURE paragraph 10-2.15.
DOOR AND CONFINED SPACE
BE FOLLOWED.

A-27
GEK 97310
VOLUME I
ADDENDUM A
Table 4. PRESTART CHECKS
Item Requirement
Maintenance requirements and discrepancies Cleared
Fire Control Operative
Fuel valves Closed
Ignition Off
Ventilation inlet air (secondary cooling air) Off-air temp below 70°F (21°C)
Ventilation exit air 180°F (82°C) max
Oil tank level Full
Lube oil supply valves Open
Lube oil temperature 140°F to 160°F (60° to 71.1°C)
Bleed air valve (if used) Closed
Water wash supply Closed
Fuel supply - natural gas:
pressure 350 ± 5 psig (2413 ± 35 kPa)
temperature -65°F to 150°F (-54° to 66°C)
flow 13,400 pph (6078 kg/h) max
- liquid fuel:
temperature 150°F (66°C) max
flow 13,000 pph max
10-2.8 Ignition Check. a. To clear combustor of any residual

fuel, motor gas turbine for one minute; allow
gas turbine to coast down.
WARNING
• ASSURE POWER TO IGNITION b. Disconnect number one ignition exciter
SYSTEMS ARE OFF WHEN DIS- input lead at exciter. Temporarily secure input
CONNECTING AND CONNECT-
ING IGNITION EXCITER INPUT c. Turn on electrical power to the ignition
LEAD. TAG SWITCH OUT OF system (No. 2 ignition exciter energized). An
SERVICE TO PRECLUDE INAD- audible report (approximately two sparks per
VERTENT ACTIVATION. second) should be heard when the No. 2 spark
igniter fires.
• ASSURE FUEL VALVES ARE
CLOSED THROUGHOUT THIS d. Turn off electrical power to the ignition
PROCEDURE. system. Reconnect input lead to exciter and

A-28
GEK 97310
VOLUME I
ADDENDUM A
e. Repeat steps b, c and d, disconnecting b. Gas generator should go through nor-
the No. 2 exciter. mal start cycle and then abort because of lack
of flame.
f. If an audible report is not heard on No.
1 and/or No. 2 igniters, check out the system to 10-2.11 Governor Check. Check governor
isolate the problem, and take appropriate cor- system per packager’s manual.
rective action.
10-2.12 Wet Prestart. Perform wet prestart as
10-2.9 Motoring. After all preliminary checks follows:
have been completed and lines flushed, gas
generator can be motored as follows: a. With ignition lead disconnected, but
with either manual liquid or gas valve open
a. Make ignition, liquid fuel and natural- and governing system operating, make auto-
gas supply systems inoperative as follows: matic start of gas generator per packager’s
manual.
(1) Disconnect power supply to igni-
tion units. b. Gas generator should accelerate to
light-off speed (1100 to 1300 rpm). Fuel valve
(2) Close liquid fuel and natural-gas should open and fuel manifold pressure should
manual shutoff valves to fuel control unit. be approximately 3 psig (20.7 kPa). Adjust
b. Depress MOTORING pushbutton. Gas fuel supply if required. Start will then abort
generator will start to rotate. If it does not, because of lack of flame.
refer to packager’s manual for supply pressure c. Allow gas generator to coast to a stop.
to starter. Motor it to purge any remaining natural gas
c. Hold MOTORING pushbutton closed from the gas turbine or drain liquid fuel from
until gas generator speed stabilizes, and check manifold if liquid fuel was used in the wet pre-
for oil pressure. If there is no indication of oil start. Purge fuel nozzles of liquid fuel with
pressure, release MOTORING pushbutton; natural gas or compressed air at 200 psid
while gas generator is coasting down, loosen (1380 kPa) maximum. Remain on starter for
oil fittings at lube pump to bleed air from sys- 60 seconds to purge fuel from gas turbine.
tem. Starter should motor gas generator to 10-2.13 Manual Start and Operation. Per-
minimum of 2200 RPM. form manual start per packager’s manual with
d. Repeat motoring and bleeding proce- fuel system normal and with ignition lead con-
dure until an indication of oil pressure appears. nected. Refer to Table 5.
10-2.10 False Start. Perform false start as NOTE

follows:
Power turbine, except in a new installa-
a. With ignition leads disconnected and tion, will be rotating when gas genera-
manual liquid fuel and natural gas valves tor idle speed is attained.
closed, make automatic start of gas turbine per
packager’s manual.

A-29
GEK 97310
VOLUME I
ADDENDUM A
Table 5. START-UP AND OPERATION
Step Corrective Action For

No. Procedure Normal Results Abnormal Results
1. Assure that prestart checks are com- Automatic shutdown at
pleted per Table 4. 1450° F (788°C) for natural
gas or 1470°F (799°C) for
liquid fuel. Refer to Table 3
CAUTION
• IF T5.4 RAPIDLY APPROACHES OR EXCEEDS 1438°F (781°C) FOR NATU-
RAL GAS OR 1460°F (793°C) FOR LIQUID FUEL, ABORT START.
• THE GAS TURBINE IS DESIGNED TO OPERATE ON 100% NATURAL GAS

FUEL, 100% LIQUID FUEL, OR ON A COMBINATION OF THE TWO. THE
GAS TURBINE CAN BE STARTED ON EITHER NATURAL GAS FUEL OR
LIQUID FUEL BUT NOT ON A COMBINATION OF THE TWO. WHEN OPER-
ATING ON BOTH FUELS, NEITHER THE NATURAL GAS OR LIQUID FUEL
FLOW SHOULD BE LESS THAN THE IDLE FUEL FLOW; I.E., IF OPERAT-
ING ON BOTH FUELS, THE MINIMUM FLOW TO THE GAS TURBINE WILL
BE LIQUID FUEL IDLE FLOW PLUS NATURAL GAS IDLE FLOW.
• WHEN OPERATING ON 100% LIQUID FUEL OR A RATIO OF LIQUID AND
NATURAL GAS, IT IS NECESSARY TO DRAIN THE LIQUID FUEL MANI-
FOLD WHEN THE GAS TURBINE IS SHUT DOWN. THE MAXIMUM TEM-
PERATURE OF THE FUEL WILL BE 200°F (94°C). REFER TO OPERATOR’S
MANUAL FOR PROCEDURE.
NOTE
• A start may be aborted at any time by closing the fuel valve, allowing the gas generator to
motor for 60 seconds, then closing the starter shutoff valve.
• When switching from liquid fuel burning to 100% natural gas burning, it is necessary to
purge and cool the liquid portion of the fuel nozzles. Either natural gas or compressed air
may be used to purge the fuel nozzles. Refer to the operator’s manual.
2. Open starter shutoff valve Gas generator Close valve
rotation
3. Start cooling air (if off)
4. At 1100 to 1300 rpm NGG
a. Ignition on

A-30
GEK 97310
VOLUME I
ADDENDUM A
Table 5. START-UP AND OPERATION (Cont.)

b. Natural gas fuel valve-open Fuel manifold pres-
Liquid fuel valve-closed sure Approx 3 psig
or (21 kPa) (natural gas)
Natural gas fuel valve-closed 90-150 psig
Liquid fuel valve-open (621-1035 kPa)
(Liquid fuel)
c. Note time to light-off 20 seconds maximum Abort start-automatic
[T5.4 above 400°F (204°C)] shutdown
5. Note time to 4500 ± 200 rpm 90 seconds maximum Troubleshoot system and
take corrective action if rpm
stops accelerating or if it
takes longer than 90 sec-
onds to reach 4300 rpm
6. At 4300 to 4500 rpm NGG
a. Starter shutoff valve closes auto- Valve closed Close fuel valve and allow
matically gas generator to motor for
60 sec; then shut off the
starter
b. Switch ignition off
c. Check oil pressure Indication Recheck at idle
7. Note time to 5000 rpm NGG
8. At idle, check the following:
a. Oil pressure See applicable figure Shutdown if below 6 psig
in Chapter 5 (41 kPa)
b. Fuel manifold pressure: Troubleshoot system and
take corrective action.
Natural gas Approx 25 psig See figures 8 or 9
(173 kPa)
Liquid fuel Approx 150 psig
(1035 kPa)
c. NGG 5000 rpm ± 250 rpm Adjust

A-31
GEK 97310
VOLUME I
ADDENDUM A

d. Maximum NGG with power tur- 7000 rpm NGG maxi- Shut down and investigate/
bine seizure (thermal seizure) mum for 30 seconds correct cause per paragraph
(for early model gas 10-2.13
turbines that have
tighter LPT blade tip
clearances, do not
exceed 6000 rpm
NGG and 30 seconds
of gas turbine opera-
tion without power
turbine rotation)
e. T5.4 1000°F (538°C) Emergency shutdown
maximum Table 7
f. NPT (unloaded) 1600-1900 rpm
g. Gas generator vibration 0 to 3 mils DA Alarm above 4 mils. Auto-
matic normal shutdown if
above 7 mils. Trouble-
shoot and take corrective
action
h. Power turbine vibration 0 to 6 mils DA Alarm above 7 mils. Auto-
action
i. Compressor inlet Approximately equal Troubleshoot sensing and
temperature (T2) to outside air temper- indicating system. Correct
ature as required
j. Check for fuel or oil leaks No leaks allowed Correct as required
9. Set desired power setting. Observe (Natural gas) 1438°F Correct as required. Refer
T5.4 during transient operation (781°C) maximum to transient temperature
(Liquid fuel) 1460°F limits contained in figure 13
(793°C) maximum

A-32
GEK 97310
VOLUME I
ADDENDUM A

10. After stabilizing at a new power set-
ting, read and record the following:
a. T5.4 (Natural gas) *
1378°-1438°F
(748°-781°C)
(Liquid fuel)
1400°-1460°F
(760° -793°C)
b. NGG 9850 rpm maximum *
c. NPT 3600 rpm maximum *
d. Oil pressure See applicable table Emergency or automatic
and figures in shutdown if 5 psig (34 kPa)
Chapter 5 out of limits
e. Scavenge oil temperature 215°F to 275°F Automatic shutdown if
(102° to 135°C) above 340°F (171°C)
f. Gas generator vibration 3 mils maximum *
4 mils (Alarm) Troubleshoot Emergency or
7 mils (Trip) automatic shutdown
g. Power turbine vibration 7 mils maximum *
(Alarm)
10 mils maximum Emergency or automatic
(Trip) shutdown
h. Fuel manifold inlet pressure:
Natural gas 25-320 psig **
(173-2208 kPa)
Liquid fuel 150-900 psig **
(1035-6210 kPa)
i. Fuel inlet temperature:
Natural gas -65° to 150°F **
(-54° to 66°C)
Liquid fuel 20°F (11°C) above **
wax point of fuel
minimum, to 150°F
(66°C) maximum

A-33
GEK 97310
VOLUME I
ADDENDUM A

j. Scavenge oil filter ∆P Refer to packager’s
manual
k. Lube oil supply filter ∆P Refer to packager’s
manual
l. T2 Approximately equal **
to outside air temper-
ature
m. Stator vane angle See applicable Correct as required per
figure in WP 118 00 WP 118 00
* Reduce power to stay within limits. If reducing power does not bring parameters within limits,
shut down.
**If all other parameters are normal, correct discrepancy at next opportunity.
Table 6. GAS TURBINE SHUTDOWN
Step Corrective Action for

1. Set gas turbine at idle power Gas generator decelerates Emergency shutdown
(unloaded)
2. After stabilizing for 3 min-
utes, read and record the
following:
a. Oil pressure See applicable figure in Automatic normal shut-
Chapter 5 down if below 8 psig
(55 kPa)
b. Fuel manifold pressure:
Natural gas Approximately 25 psig
(173 kPa). See figures 8
and 9
Liquid fuel Approximately 150 psig
(1035 kPa). See figure 10

A-34
GEK 97310
VOLUME I
ADDENDUM A
Table 6. GAS TURBINE SHUTDOWN (Cont.)

c. NGG 4950-5050 rpm Adjust
d. T5.4 1000°F (538°C) maximum Troubleshoot and take cor-

rective action
e. NPT (unloaded) 1600-1900 rpm
f. Gas generator vibration 3 mils maximum Alarm above 4 mils. Auto-

above 7 mils. Troubleshoot
and take corrective action
g. Power turbine 6 mils maximum Alarm above 7 mils.
vibration Automatic normal shut-
down if above 10 mils.
Troubleshoot and take
corrective action
h. Fuel inlet temperature:
Natural gas -65°F to +150°F
(-54° to +66°C)
Liquid fuel 20°F (-7°C) above wax
point of fuel minimum to
150°F (66°C) maximum
i. Scavenge oil filter ∆P Refer to packager’s manual
j. Lube oil supply Refer to packager’s manual
filter ∆P
3. After stabilizing at idle for 5 T5.4 drops below 400°F Shut off fuel supply
minutes, close fuel valves (204°C) NGG and NPT
decelerate and stop
4. Observe T5.4 for 3 minutes 700°F (371°C) Motor gas turbine and shut
after shutdown off fuel supply. Continue
motoring until temperature
decreases

A-35
GEK 97310
VOLUME I
ADDENDUM A
Table 7. EMERGENCY SHUTDOWN
CAUTION
ASSURE FREEDOM OF ROTATION OF GAS TURBINE AFTER AN EMERGENCY
SHUTDOWN FROM HIGH POWER SETTINGS. SEIZURE OF GAS TURBINE ROTOR
MAY OCCUR DUE TO TIGHT CLEARANCES. NORMALLY THE ROTOR WILL
FREE ITSELF AFTER A COOLING PERIOD OF 3 TO 4 HOURS. CHECK FOR FREE-
DOM OF ROTATION BY TURNING ROTOR BY HAND.
1. Conditions permitting, decelerate gas tur- T5.4 drops below Manually shut off fuel
bine to idle and close fuel valves 400°F (204°C) and supply
NGG and NPT
decelerate
2. Observe T5.4 for 3 minutes after shutdown 700°F (371°C) max Motor gas turbine. Con-
tinue motoring until tem-
perature decreases
3. If an emergency shutdown from a high
power setting (T5.4) greater than 1150°F
(621°C) has occurred, and a “hot restart”
is required, proceed as follows:
a. If the fault detection and sequencing
system can be cleared and the gas tur-
bine can be restarted within 1 minute
following coastdown of the HPC
rotor, acceptable restarts can be made
using the normal starting procedure.
b. If a “hot restart” is to be performed
between 1 minute and 2 hours follow-
ing the emergency shutdown, motor
the gas turbine at 2000-2500 rpm NGG
for 5 minutes. At the end of the 5
minute motoring/purge cycle, per-
form normal restart and accelerate to
idle. Acceleration to the desired
power setting can then be
accomplished.
c. After 2 hours following coastdown of
the HPC rotor, restart can be made

A-36
GEK 97310
VOLUME I
ADDENDUM A
Table 8. Deleted

A-37
GEK 97310
VOLUME I
ADDENDUM A
CAUTION (2) Immediately after the gas turbine
stops rotating, re-start and stabilize at idle
DO NOT EXCEED 7000 RPM NGG speed (4950±50 rpm) for 30 seconds.
AND 30 SECONDS OF GAS TUR-
BINE OPERATION WITHOUT (3) Repeat steps (1) and (2) for two
POWER TURBINE ROTATION. additional start-up and shutdown cycles.
FOR EARLY MODEL GAS TUR-
BINES THAT HAVE TIGHTER LPT (4) If the power turbine does not
BLADE TIP CLEARANCES, DO rotate after accomplishing substeps (1) through
NOT EXCEED 6000 RPM NGG AND (3), shut down the gas turbine.
30 SECONDS OF GAS TURBINE
OPERATION WITHOUT POWER (5) Immediately after gas turbine
TURBINE ROTATION. rotation stops, re-start and accelerate to
7000 rpm NGG maximum and stabilize for 30
a. The power turbine must rotate by the seconds. If the power turbine still does not
time the gas generator speed reaches 7000 rpm rotate, shut down and investigate/correct the
NGG. If power turbine speed indication is not cause. During the investigation for the cause
obtained and it is determined that a “thermal of a thermally seized rotor, inspect the LPT
seizure” of the power turbine has occurred, blades in stages 4, 5 and 6 for shingling and
proceed as follows: unlatching. If blades have become unlatched,
they may be relatched. LPT blades that have
NOTE encountered shingling may be bent, thereby
Thermal seizure of the power turbine necessitating replacement of the power
rotor can occur when a hot gas turbine turbine.
is shut down and is most likely to occur
within 30 to 40 minutes following gas 10-2.14 Operation to Maximum Power.
turbine operation. Thermal seizure is
the condition where the power turbine CAUTION
rotor is prevented from rotating by hard MANUAL OPERATION MAY
contact between LPT blades and ELIMINATE CERTAIN PROTEC-
shrouds, interstage seals and other TIVE CIRCUITS. OPERATING
internal interference. This condition is LIMITS SHALL NOT BE
the result of unequal cooling rates of EXCEEDED.
the various power turbine components.
The possibility of thermal seizures can a. Slowly increase manual control setting
be reduced by operating the gas turbine (refer to packager’s manual) to increase gas
at idle power for at least five minutes generator speed. After each 500 rpm increase,
prior to shutdown to achieve proper log all instrument readings, paying particular
cooling of the power turbine. attention to variable stator vane position and
vibration. If variable stator system is not
(1) Shutdown gas turbine. within limits, adjust it per
work package 118 00. If vibrations are not
within limits, consult the local General Elec-
tric Company representative.
A-38
GEK 97310
VOLUME I
ADDENDUM A
b. Operate gas turbine up to rated power, 10-2.15 Automatic Operation.
if possible, but do not exceed exhaust gas tem- Check automatic operation per packager’s
perature (T5. 4) limit. Hold at this power set- manual.
ting until all temperatures stabilize. If
governing system is unstable, adjust per pack- a. Accelerate to idle.
ager’s manual.
b. Accelerate to rated power.
c. Log all instrument readings once they
stabilize. Refer to Table 5, step 10. c. Log all instrument readings.
d. Reduce gas generator speed to idle. d. Decelerate to idle.

After stabilizing for three minutes, record all
instrument readings. Refer to Table 6, step 2. e. Check for fuel or lube oil leaks.
e. Check fail-safe section of control sys- f. After a total of five minutes at idle,
tem per packager’s manual. shut down gas turbine.
f. After gas turbine has been stabilized at g. Check lube oil and fuel filters and
idle for five minutes. make normal shut-down. strainers; clean or replace as necessary.
Refer to Table 6, steps 3 and 4.
h. Correct any leaks observed.
i. Remove all temporary instrumentation.
j. Check gas turbine and mounting sys-

tem for loose parts; tighten as necessary.

A-39
GEK 97310
VOLUME I
ADDENDUM A
10-3 NORMAL OPERATION. GAS TURBINE IS OPERATING,
AN OBSERVER SHALL BE STA-
10-3.1 Interlocks. Refer to packager’s man- TIONED AT THE ENCLOSURE
ual for description of interlocks which affect DOOR AND CONFINED SPACE
gas turbine operation. ENTRY PROCEDURES SHALL
BE FOLLOWED.
10-3.2 Operation.
WARNING
MET:

ENGINE OPERATION IS PRO- ENCLOSURE OR IN THE PLANE
HIBITED IN GENERAL. IF OF ROTATION OF THE STARTER
ENTRY SHOULD BE WHEN STARTING OR MOTOR-
REQUIRED DURING ENGINE ING THE GAS TURBINE.
FIELD SERVICE FOR A REPRE- a. When entering enclosure at or below
SENTATIVE WHO IS TRAINED idle speed, wear proper ear protection.
UNDER SUCH CONDITIONS. b. Start and operate the gas turbine per
Table 5. Do not exceed operating limits of
• THE FIRE EXTINGUISHING Table 3.
INACTIVE ACCORDING TO c. Shut down the gas turbine per Table 6.
THE CUSTOMER’S
PROCEDURES. NOTE
During normal shut down with NOX
suppression being used, closure of the
ENCLOSURE SHALL BE SHUT
fuel valve should be delayed after
water is shut off to allow purging of
FLOW MAY PREVENT OPEN-
water from the fuel manifold.
ING OR CLOSING THE
ENCLOSURE DOOR.
d. Emergency shut down the gas turbine
per Table 7.
SHALL BE KEPT OPEN. IF THE

A-40
GEK 97310
VOLUME I
ADDENDUM A
e. Refer to paragraph 5-3.30 and 5-3.31, 10-4 EMERGENCY OPERATION.
for lube correction factors and lube supply
pressure characteristics. (See tables V-21A, 10-4.1 Emergency Shutdown.
V-21B, V-21E, and V-21F, and figures 5-32A,
5-32B, 5-32E, 5-32F, 5-32J, 5-32L, 5-32N, a. In an emergency, the gas generator may
and 5-32Q.) be shut down from any power setting by clos-
ing the gas and/or liquid fuel valve. However,
f. Idle lube oil pressure is 29 psig this should only be done in an emergency,
(200.1 kPa) maximum after five minutes since rapid shutdown will decrease life of gas
stabilization. generator.
g. The corrected operating pressure of the b. Emergency shutdown shall be made

lube oil shall be per applicable table in Chapter per Table 7.
5 at standard conditions of 9000 RPM gas gen-
erator speed and 150°F (65.6°C) lube pump c. If an emergency shutdown must be ini-
discharge temperature. Oil pressure measured tiated while operating with NOX suppression
at conditions other than standard shall be cor- on-line, the water and fuel valves can be shut
rected to standard conditions using applicable off simultaneously. Action must be taken to
table in Chapter 5. purge the water from the fuel manifold at the
earliest opportunity and prior to the next
h. Prior to initiation of water flow for startup.
NOX suppression, it is recommended that the
gas generator be operating at a stabilized 10-4.2 Post Shutdown Fire.
steady-state condition.
a. During a normal shutdown, exhaust
NOTE gas temperature should decrease. If during
Refer to figures 6 through 10 for fuel time gas generator is coasting to stop, tempera-
system requirements when operating ture increases instead of decreasing, it indi-
on natural gas, liquid fuel or a combi- cates that combustion is still taking place
nation of the two. Refer to figures 11 because of a leaking fuel valve. (A slight tem-
and 12 when operating with NOX perature increase after rotation stops is nor-
suppression. mal.) Make certain fuel is shut off, and motor
the gas generator. This will blow out the fire.
As soon as temperature decreases to normal,
discontinue motoring.

A-41/(42 Blank)
GEK 97310
VOLUME I
ADDENDUM B
ADDENDUM
7LM2500PC102

GEK 97310
VOLUME I
ADDENDUM B
TABLE OF CONTENTS
1-0 INTRODUCTION....................................................................................... B-3

2-0 REFERENCE DATA .................................................................................. B-3
3-0 INSTALLATION DRAWINGS.................................................................. B-4
4-0 EQUIPMENT DESCRIPTION ................................................................. B-4
5-0 INSTRUMENTATION AND SUPPLY REQUIREMENTS ................... B-4
5-1 SERVICE REQUIREMENTS ................................................................... B-4
5-1.1 Liquid Fuel.................................................................................................... B-4
6-0 OPTIONAL HARDWARE KITS .............................................................. B-7
7-0 GAS TURBINE OPERATION .................................................................. B-7
7-1 PERFORMANCE RATINGS AND OPERATING LIMITS .................. B-8
7-1.1 Performance Ratings ..................................................................................... B-8
7-1.2 Operating Limits ........................................................................................... B-13
7-2 INITIAL OPERATION .............................................................................. B-13
7-2.1 General .......................................................................................................... B-13
7-2.2 Special Instrumentation Required for Operation .......................................... B-13
7-2.3 Special Instrumentation Required for Monitoring and Troubleshooting ...... B-13
7-2.4 Preparation .................................................................................................... B-13
7-2.5 Gas Turbine and Associated Equipment Check List..................................... B-18
7-2.6 Governor and Manual Control Check........................................................... B-18
7-2.7 Start-up and Checkout................................................................................... B-19
7-2.8 Ignition Check............................................................................................... B-20
7-2.9 Motoring........................................................................................................ B-21
7-2.10 False Start...................................................................................................... B-21
7-2.11 Governor Check ............................................................................................ B-21
7-2.12 Wet Prestart ................................................................................................... B-21
7-2.13 Manual Start .................................................................................................. B-22
7-2.14 Operation to Maximum Power...................................................................... B-22
7-2.15 Automatic Operation..................................................................................... B-27
7-3 NORMAL OPERATION............................................................................ B-27
7-3.1 General .......................................................................................................... B-27
7-3.2 Interlocks....................................................................................................... B-27
7-3.3 Operation....................................................................................................... B-28
7-4 EMERGENCY OPERATION ................................................................... B-30
7-4.1 Emergency Shutdown ................................................................................... B-30
7-4.2 Post Shutdown Fire ....................................................................................... B-30

B-1
GEK 97310
VOLUME I
ADDENDUM B
Figure Title Page
1 Transient Temperature Limits ....................................................................... B-10

2 Deleted
3 Deleted
4 Deleted
5 Deleted
6 Deleted
7 Acceleration Fuel Flow Schedule ................................................................. B-12
8 Fuel Manifold Pressure ................................................................................. B-33
LIST OF TABLES
Table Title Page
1 INSTRUMENTATION CONNECTIONS-7LM2500PC102........................ B-4

2 SUPPLY CONNECTIONS-7LM2500PC102............................................... B-6
3 GAS TURBINE OPERATING LIMITS....................................................... B-14
4 PRESTART CHECKS .................................................................................. B-20
5 START-UP AND OPERATION.................................................................... B-23
6 GAS TURBINE SHUTDOWN .................................................................... B-29
7 EMERGENCY SHUTDOWN...................................................................... B-31
8 Deleted

B-2
GEK 97310
VOLUME I
ADDENDUM B
1-0 INTRODUCTION. GAS TURBINE WEIGHTS - Continued
LM2500PC102 model gas turbine basic con- Component Wt-Lbs/(Kg)
figuration and control system differences. In Compressor Stator, Rear 93 (42)
addition, the coverage of reference data, Compressor Rear Frame 421 (191)
instrumentation and supply connections, spe-
cial servicing requirements, optional hardware Combustor 120 (54)
kits and the complete gas turbine operating High Pressure Turbine Rotor 419 (190)
instructions for the LM2500PC102 model are High Pressure Turbine Nozzle 68 (31)
included. Stage 1
2-0 REFERENCE DATA. High Pressure Turbine Nozzle 127 (58)
Stage 2
EQUIPMENT Turbine Mid Frame 530 (240)
Gas Turbine Assembly
Low Pressure Turbine Stator 601 (273)
(General Electric Co.,
Cincinnati, Ohio) Turbine Rear Frame 1071 (486)
Model No. 7LM2500PC102 High Speed Coupling Shaft 91 (41)
Dwg. No. L24140G04 Forward Adapter
Exhaust Duct Assembly 2741 (1243)
PERFORMANCE RATING
Exhaust Duct 1565 (710)
Refer to paragraph 7-1. Outer Cone 410 (186)
Inner Deflector 255 (116)
GAS TURBINE WEIGHTS Ring Seal 49 (22)
The average weights of the major engine Ring Support 74 (34)
components are: Insulation 269 (122)
Component Wt-Lbs/(Kg)
Cover, Insulation 62 (28)
Gas turbine, including inlet Variable Stator Actuating 19 (8.6)
duct, centerbody, exhaust Mech
diffuser, and coupling nut 7396 (3355)
Outside Piping and Bracketing 278 (126)
Exhaust duct without exhaust
diffuser 2313 (1049)
DRAWING LIST
Gas Generator 4212 (1911)
Drawing No.
Power Turbine 2777 (1260)
Inlet Gearbox 38 (17) Gas Turbine Installation Drawing L31705
Transfer Gearbox 245 (111) Fuel System Flow Diagram L25208
Compressor Front Frame 517 (235) Lubrication System Flow Diagram L24328
Compressor Rotor 552 (250) Electrical Diagram L24329
Compressor Stator, Front 307 (139) Gas Turbine Assembly Drawing L24140G04

B-3
GEK 97310
VOLUME I
ADDENDUM B
3-0 INSTALLATION DRAWINGS. 5-1 SERVICE REQUIREMENTS.
been provided. 5-1.1 Liquid Fuel.
4-0 EQUIPMENT DESCRIPTION. a. The required supply pressure to the

The LM2500PC102 is a liquid fueled, non- fuel manifold on the gas turbine is
marinized industrial gas turbine and is fur- 150-900 psig (1035-6210 kPa).
nished with an exhaust duct with an inner dif-
fuser as standard equipment. b. The fuel temperature supplied to the
gas turbine shall be a minimum of 20°F (11°C)
5-0 INSTRUMENTATION AND SUP- above the wax point of the fuel and a maxi-
PLY REQUIREMENTS. mum of 150°F (66°C). The fuel shall be
See tables 1 and 2. filtered to 20 microns absolute.
Table 1. INSTRUMENTATION CONNECTIONS-7LM2500PC102

Item Nomenclature Mates with:
El Vibration pickup, Gas Generator Bell & Howell Electronics Part No.
173960 or 364450
E3 A-sump scavenge oil temperature RTD MS3106R-12S-3S
E3A A-sump scavenge oil temperature T/C (Alt) MS3106R-12S-3SW
E4 B-sump scavenge oil temperature RTD MS3106R-12S-3S
E4A B-sump scavenge oil temperature T/C (Alt) MS3106R-12S-3SW
E5 C-sump scavenge oil temperature RTD MS3106R-12S-3S
E5A C-sump scavenge oil temperature T/C (Alt) MS3106R-12S-3SW
E6 Accessory gearbox scavenge oil temperature MS3106R-12S-3S
RTD
E6A Accessory gearbox scavenge oil temperature MS3106R-12S-3SW
T/C (Alt)
E11 Oil supply temperature RTD MS3106R-12S-3S
E11A Oil supply temperature T/C (Alt) MS3106R-12S-3SW
E18 D-sump scavenge oil temperature RTD MS3106R-12S-3S
E18A D-sump scavenge oil temperature T/C (Alt) MS3106R-12S-3SW

B-4
GEK 97310
VOLUME I
ADDENDUM B
Table 1. INSTRUMENTATION CONNECTIONS-7LM2500PC102 - Continued
E13 Vibration pickup, power turbine Bell & Howell Electronics Part No.
173960 or 364450
A13 Power turbine inlet pressure probe 3/8 inch line to pressure manifold on
turbine mid frame AN818-4C or
MS9179-04
A23 CDP pressure tap 0.500-20UNJF-3B
A18 CIT sensor pad (part of fuel control system)
F5 Liquid fuel manifold pressure tap No. 1 3/8 inch line AN818-6C or
MS20819-6C
L5 Lube supply pressure tap 3/8 inch line AN818-6C or
MS20819-6C
L7 Lube scavenge pressure tap 1/4 inch line AN818-4C or
MS20819-4C
-- Remote reading variable stator vane
protractor (optional)
NOTE
gas turbine.

B-5
GEK 97310
VOLUME I
ADDENDUM B
Table 2. SUPPLY CONNECTIONS-7LM2500PC102
CAUTION
ALL LINES MUST BE FLEXIBLE ENOUGH TO ALLOW 3/4 INCH (19 MM) THER-
MAL GROWTH OF GAS GENERATOR WITHOUT PLACING STRAIN ON LINES
OR ON GAS GENERATOR. IF EXCESSIVE FORCE IS REQUIRED TO COMPLETE
A CONNECTION, LOOSEN CONNECTION AND CHECK/ADJUST ROUTING AS
REQUIRED.
F2 Liquid fuel supply 0.750 inch line from fuel control unit to the gas generator
liquid fuel manifold AN818-12C or MS20819-12C
F4 Liquid fuel manifold shroud 1/2 inch line to fuel manifold shroud AN818-8C or
drain MS20819-8C
L1 Oil Supply 1-1/2 inch line to Lube Pump on Gas Generator
AN818-24C or MS20819-24C
L2 Lube pump discharge 1 inch line from Lube Pump to Oil Supply Filters
AN818-16C or MS20819-16C
L4 Lube supply inlet port 1 inch line from Oil Supply Filters to Gas Generator
AN818-16C or MS20819-16C
L3 Scavenge oil discharge 1-1/4 inch line from Gas Generator Scavenge Pump to
Oil Scavenge Filter and Cooler AN818-20C or
MS20819-20C
A2 Bleed air - 16th stage 16th stage compressor bleed air lines (if used) 1.92 inch
ID
A3 Exhaust duct extension
A4 Inlet duct seal (if used)
A10 CDP seal leakage No. 1 (if used) 2-inch line
A12 Air/Oil Separator Discharge 3 inch line from air/oil separator to atmospheric vent or
Port to exhaust duct (flame arrestor)
A16 Air/Oil Separator optional
air inlet port on exhaust duct
D1 Exhaust drain, forward 1 inch line to drain under exhaust duct MS33649-16
D2 Exhaust drain, aft 1 inch line to drain under exhaust duct MS33649-16

B-6
GEK 97310
VOLUME I
ADDENDUM B
Table 2. SUPPLY CONNECTIONS-7LM2500PC102 - Continued

D3 Oil drain, forward 3/8 inch line to drain manifold under transfer gearbox
AN818-6C or MS20819-6C
D5 Oil drain, aft 3/8 inch line to drain manifold under TMF AN818-6C or
MS20819-6C
S1 Waterwash manifold 1 inch line - hot water line to waterwash manifold on
Gas Generator Inlet Duct AN818-16C or MS20819-16C
NOTE
For all other supply connections, refer to Installation Drawings provided with gas turbine.
6-0 OPTIONAL HARDWARE KITS - procedures. When a fault exists, refer to

LM2500PC102. chapter 4, TROUBLESHOOTING.
a. Refer to Volume II, WP 001 00 for
may not provide for every possible variation in
detailed list of optional kits available for this
equipment or contingency to be met in connec-
particular gas turbine model.
7-0 GAS TURBINE OPERATION. Refer requests for additional information to the
General Electric Company; Marine and Indus-
NOTE trial Engine Division, Cincinnati, Ohio 45215.
The S.I. units shown in this chapter are
direct mathematical conversions and WARNING
may be rounded off in most instances IF A QUESTIONABLE CONDITION
at the user’s discretion. Examples of EXISTS, DO NOT OPERATE THE
units that may be rounded off are those GAS TURBINE UNTIL A THOR-
utilized for temperatures, torque val- OUGH INVESTIGATION HAS
ues, pressures, etc. Examples where BEEN MADE. DO NOT REPEAT
S.I. units may not be rounded off are HOT STARTS, COMPRESSOR
those utilized for drop checks, rigging STALLS, OR OTHER RECOGNIZED
adjustments, runouts, etc. PROBLEMS WITHOUT PRIOR
THOROUGH INVESTIGATION.
FAILURE TO DO SO CAN RESULT
gas turbine operating procedures and limits
IN UNDUE STRESS BEING
recommended by the General Electric Com-
IMPOSED ON GAS TURBINE COM-
pany for the 7LM2500PC102 Gas Generator.
PONENTS, WITH IMMEDIATE OR
b. The instructions are intended to pro- SUBSEQUENT DESTRUCTIVE
vide operating personnel with the information FAILURE OF THE GAS TURBINE
required to operate the gas turbine. They per- AND INJURY TO PERSONNEL.
tain to routine and emergency conditions and

B-7
GEK 97310
VOLUME I
ADDENDUM B
7-1 PERFORMANCE RATINGS AND Fuel, Liquid per GE
OPERATING LIMITS. Specification MID-TD-
NOTE 0000-2
Ratings published in this manual apply b. The gas turbine is configured to oper-
to the gas turbine. The driven unit rat- ate on 100% liquid fuel. The starting fuel
ings/ limits may be lower in some cases flows for liquid fuel are:
and shall take precedence over the gas
turbine manual limits.
530 pph (240 kg/h) ± 25 pph (11 kg/h)
7-1.1 Performance Ratings. at -65°F (-54°C) Inlet Air Temperature
a. The rating of the 7LM2500PC102 gas
turbine in the new and clean condition and 625 pph (284 kg/h) ± 25 pph (11 kg/h)
operating on 100 percent liquid fuel in accor- at +60°F (16°C) Inlet Air Temperature
dance with MID-TD-0000-2 fuel specification
is as follows: 680 pph (308 kg/h) ± 25 pph (11 kg/h)
Brake Horsepower 27,500 BHP at +130°F (54°C) Inlet Air
(Continuous) Temperature
Brake Horsepower 30,000 BHP c. Figure 7 defines the maximum liquid
(maximum) fuel acceleration fuel schedule for the gas
Inlet Air Temperature 59°F (15°C) generator.
Altitude Sea Level
d. The tolerance on the fuel schedules is
Inlet Losses 0 inch H2O
+4 percent of point. The schedule is plotted
Exhaust Back Pressure 0 inch H2O against compressor discharge pressure.
Relative Humidity 0%
Fuel Lower Heating Value 18, 400 Btu/lb those shown will result in over-temperature
Compressor Bleed 0 and possible stall of the gas turbine. Accelera-
Accessory Horsepower 0 tion fuel rates lower than those shown can
Extraction result in “hung” starts in the below idle speed
range.
Power Turbine Speed 3600 RPM
Heat Rate, Average 6946 Btu/hp/hr f. Above the idle speed point, low accel-
(Continuous) eration fuel rates will not harm the gas turbine
Heat Rate, Average 6926 Btu/hp/hr and will only result in slower acceleration
(Maximum) times.
Power Turbine Inlet Gas 1430°F (777°C)
Temperature (Average) at 27,500 BHP g. The fuel rates shown on the curve will
1503°F (817°C) give starting times to 5000 rpm idle of 60 to 90
at 30,000 BHP seconds and accelerations from idle to
maximum power of 15 seconds.

B-8
GEK 97310
VOLUME I
ADDENDUM B
h. For normal accelerations from idle to rate at any other fuel flow shall be the above
power settings, the changes should be made jump and rate multiplied by the square root of
more slowly to enhance the time between hot the ratio of fuel flow to the basepoint fuel flow.
section repairs and the life of the gas turbine. Normal decelerations from maximum power to
A time of 2 to 3 minutes is reasonable. idle should be made in approximately 2 to 3
minutes. This will enhance the time between
i. The maximum deceleration fuel flow hot section repairs and the life of the gas
rate should consist of a step fuel decrease of turbine.
1500 pph (680 kg/h) ±10 percent followed by a
rate change of 1330 pph (603 kg/h) ±10 per- j. The liquid fuel system must be free of
cent per second at a basepoint fuel flow of periodic or random hunting which result in
10,000 pph (4536 kg/h). Fuel flow jump or cycling of gas generator speed or temperature.
The frequency of the fuel flow fluctuations
shall not be a harmonic of the natural fre-
quency of the springs in the fuel nozzles. The
Cycling of these parameters will reduce time
between hot section repairs and the life of the
gas turbine.

B-9
GEK 97310
VOLUME I
ADDENDUM B

B-10
GEK 97310
VOLUME I
ADDENDUM B

B-11
GEK 97310
VOLUME I
ADDENDUM B
Figure 7. Acceleration Fuel Flow Schedule

B-12
GEK 97310
VOLUME I
ADDENDUM B
7-1.2 Operating Limits. Refer to table 3. 7-2.3 Special Instrumentation Required for
Monitoring and Troubleshooting:
NOTE
Fuel manifold pressure 0-1200 psi
If any operating limit is exceeded, ver- sensor - Liquid fuel (0-8280 kPa)
ify instrumentation accuracy before
troubleshooting or inspecting gas Compressor inlet total 10-16 psia
generator. pressure (69-110 kPa)
Fuel supply pressure 0-1200 psig
7-2 INITIAL OPERATION. Liquid fuel (0-8280 kPa)
Fuel supply temperature 0-250°F
7-2.1 General. Initial operational period is Liquid fuel (-18 to 121°C)
that period of operation immediately following
gas turbine replacement or major maintenance
temperature (-18 to 66°C)
on the system.
Remote reading variable -5° to +45°
7-2.2 Special Instrumentation Required for vane indicator
Operation. Starter air supply pressure 0-50 psig
(optional) (0-345 kPa)
Gas Generator speed sensor 0-10,000 rpm
Lube oil scavenge tempera- 0-400°F 7-2.4 Preparation. The gas turbine and asso-
ture sensor (A-, B-, C-, (-18 to 204°C) ciated systems must be inspected and checked
D-sumps and transfer out for proper installation and operation before
gearbox) normal operation can commence.
Lube oil supply temperature 0-400°F
sensor (-18 to 204°C)
Vibration indicators
gas generator 0-10 mil DA
power turbine 0-10 mil DA
Power turbine speed sensor 0-5000 rpm
temperature (T5.4) (-18 to 1093°C)
Lube oil supply pressure 0-100 psig
(0-690 kPa)
Lube oil scavenge pressure 0-100 psig
(0-690 kPa)
pressure (0-2070 kPa)

B-13
GEK 97310
VOLUME I
ADDENDUM B
Alarm/ Normal
NOTE
• Continuous operation should not take place with any parameter indicating between the
alarm and trip levels. If an alarm level is not shown, the trip level is the operating limit.
• Correct lube pressure per applicable table in Chapter 5.
Lubrication Gas Turbine Alarm 8 psig ± 1 psig 20 - 60 psig Bypass until
System - Lube Pump (55 kPa ± 6.9 kPa) (138 - 413 kPa) 4500 rpm
Settings and Discharge below 8000 rpm
Operating Pressure 15 psig ± 1 psig
above 8000 rpm
Trip 6 psig ± 1 psig 20 - 60 psig Bypass until
(41 kPa ± 6.9 kPa) (138 - 413 kPa) 4500 rpm
Gas Turbine Alarm 110 psig ± 10 psig 10 - 100 psig Scavenge Discharge
Scavenge (759 kPa ± 69 kPa) (69 - 690 kPa) Pressure shall not
Discharge exceed
Pressure 180 psig (1242 kPa)
Gas Turbine Alarm 180° - 220ºF 140° - 160°F Normal Operating
Lube Pump (82° - 104°C) (60° - 71°C) Range reflects
Discharge temperature
Temperature expected during
operation above idle
speed
Gas Turbine Trip 330° - 350°F 215° - 275°F Normal Operating
Lube (166° - 177°C) (102° - 135°C) Range reflects
Scavenge temperature
Temperatures expected during
- Five operation above idle
speed
Alarm 290° - 310°F
(143° - 154°C)
Fuel System Fuel Manifold 150 - 900 psig Supply Pressure as
(Liquid Pressure (1034 - reflected at the fuel
Fuel) 6205 kPa) manifold inlet on the
gas turbine

B-14
GEK 97310
VOLUME I
ADDENDUM B
Table 3. GAS TURBINE OPERATING LIMITS - Continued
Alarm/ Normal
Fuel Supply 20°F (-7°C) Starting Fuel Flow

Temperature above wax point Adjustments may be
of fuel to 150°F required to compen-
(66°C) sate for fuel temper-
maximum ature variation
System Pressure (276 kPa) Requirement based
on engine starter
torque requirements
Application 1200 ± 100 rpm
of Fuel and
Ignition
Application 1700 ± 100 rpm 1700 ± 100 rpm for
of Fuel and start after purge
Ignition (If cycle
purge cycle is
used)
Starting Time Trip 1200 ± 100 rpm Activate 20 seconds
to 1200 rpm time delay simulta-
neously with start
initiation
Failure to Trip 380° - 420°F Activate 20 seconds
Light-Off (193° - 216°C) time delay simulta-
neously with appli-
cation of fuel and
ignition
neously with start
initiation. De-ener-
gize ignition, fuel
system and starter
air supply

B-15
GEK 97310
VOLUME I
ADDENDUM B
Alarm/ Normal
to 4500 rpm time delay upon
(If purge completion of purge.
cycle is used) De-energize fuel and
ignition systems and
starter air supply
Power Failure to Trip 380° - 420°F 0-1600°F Trip if temperature
Turbine Inlet Light-Off (193° - 216°C) (-18 - 871°C) does not reach 400°F
(T5.4) (204°C) within
Temperature 20 seconds after fuel
(Gas and ignition are
Generator applied
Exhaust)
Overtemperature:
Liquid Fuel Trip 1470°F (799°C) 1400° - 1460°F Values given are for
(760° - 793°C) installations using
constant T5.4 control
as the power limit.
Installations using
constant power con-
trol mode should
consult the contract
documents for deter-
mining alarm and
trip settings, which
are unique to each
application, but
never to exceed
1616°F (880°C)
(alarm) and 1625°F
(885°C) (trip)
Vibration Gas Trip 7 mils ± 1 mil DA 0-3 mils DA Avoid continuous
Generator operation above 4
mils

B-16
GEK 97310
VOLUME I
ADDENDUM B
Alarm/ Normal
Power Trip 10 mils ± 1 mil DA 0 - 6 mils DA Avoid continuous

Turbine operation above 7
mils
Speed Gas Trip 9950 ± 50 rpm 0 - 9850 rpm
Generator
Power Trip 3960 ± 40 rpm 0 - 3600 rpm
Turbine
upon loss of flame

B-17
GEK 97310
VOLUME I
ADDENDUM B
7-2.5 Gas Turbine and Associated Equip- p. T5.4 thermocouple system
checklist. functioning properly _______
r. Compressor inlet total pres-
b. Mounting base secured to sure probe aligned properly
foundation _______ and free of damage _______
c. Intake air and exhaust gas s. Variable stator system secure _______
d. Gas turbine and exhaust duct tions specified in Packager’s
support mounts and links in manual for gas turbine control
place and secure _______ have been performed _______
and secure _______
Refer to Packager’s manual.
Packager’s manual _______
secure _______
l. Starter is serviced per Pack-
m. Lube oil storage tank serviced
n. Lube oil supply valves open _______

B-18
GEK 97310
VOLUME I
ADDENDUM B
WARNING
SHUT DOWN.
TO ENTER THE ENCLOSURE b. Perform prestart checks per table 4.
• THE FIRE EXTINGUISHING

THE CUSTOMER’S
PROCEDURES.

ING OR CLOSING THE
ENCLOSURE DOOR.

GAS TURBINE IS OPERATING,
TIONED AT THE ENCLOSURE
BE FOLLOWED.

B-19
GEK 97310
VOLUME I
ADDENDUM B

Item Requirement
Maintenance requirements Cleared
and discrepancies
Fuel Valves Closed
Ignition Off
Oil tank level Full
Lube oil temperature 140-160°F
(60-71°C)
Fuel supply - Liquid fuel
pressure 150-900 psig (1035- 6210 kPa)
temperature 150°F
(66°C) max
c. Perform ignition checkout per j. Check automatic operation per

paragraph 7-2.8. paragraph 7-2.15.
d. Perform motoring procedure per 7-2.8 Ignition Check.

paragraph 7-2.9.
WARNING
e. Perform false start per
paragraph 7-2.10. • ASSURE POWER TO IGNITION
SYSTEMS IS OFF WHEN DIS-
f. Perform governor check per CONNECTING AND CONNECT-
paragraph 7-2.11. ING IGNITION EXCITER INPUT
LEAD. TAG SWITCH OUT OF
g. Perform a wet prestart per SERVICE TO PRECLUDE INAD-
paragraph 7-2.12. VERTENT ACTIVATION.
h. Perform a manual start and operate per
CLOSED THROUGHOUT THIS
paragraph 7-2.13.
PROCEDURE.
i. Operate to maximum power per a. To clear combustor of any residual
paragraph 7-2.14. fuel, motor gas turbine for one minute; allow

B-20
GEK 97310
VOLUME I
ADDENDUM B
b. Disconnect number one ignition exciter tem. Starter should motor gas generator to
input lead at exciter. Temporarily secure input minimum of 2200 RPM.
d. Repeat motoring and bleeding proce-
c. Turn on electrical power to the ignition dure until an indication of oil pressure appears.
audible report (approximately two sparks per 7-2.10 False Start. Perform false start as
second) should be heard when the No. 2 spark follows:
igniter fires.
a. With power supply to ignition unit dis-
d. Turn off electrical power to the ignition connected and manual fuel shutoff valve
system. Reconnect input lead to exciter and closed, make automatic start of gas turbine per
safetywire connector. operator’s manual.
the No. 2 exciter. b. Gas generator should go through nor-
mal start cycle and then abort because of lack
f. If an audible report is not heard on of flame.
tem to isolate the problem, and take appropri- 7-2.11 Governor Check. Check governor sys-
ate corrective action. tem per packager’s manual.
7-2.9 Motoring. After all preliminary
checks have been completed and lines flushed, follows:
gas generator can be motored as follows:
a. Make ignition and liquid fuel supply
connected, with the liquid fuel manual shutoff
systems inoperative as follows:
valve open, and the governing system operat-
(1) Disconnect power supply to igni- ing, make an automatic start of the gas turbine
tion unit. per the operator’s manual.
(2) Close liquid fuel manual shutoff b. Gas generator should accelerate and
valve to fuel control unit. stabilize at a speed dependent on starter inlet
pressure level. Start will then abort because of
b. Depress MOTORING pushbutton. Gas lack of ignition.
generator will start to rotate. If it does not,
refer to packager’s manual for supply pressure c. Allow gas generator to coast to a stop.
to starter. Purge fuel nozzles of liquid fuel with com-
pressed air at 200 psid (1380 kPa) maximum.
c. Hold MOTORING pushbutton closed After wet prestart, drain liquid fuel from fuel
until gas generator speed stabilizes, and check manifold, then motor gas generator on starter
for oil pressure. If there is no indication of oil for 60 seconds to purge fuel from gas turbine.
pressure, release MOTORING pushbutton;
while gas generator is coasting down, loosen
oil fittings at lube pump to bleed air from sys-

B-21
GEK 97310
VOLUME I
ADDENDUM B
7-2.13 Manual Start. Perform manual start (1) Shutdown gas turbine.
with ignition lead connected and fuel system
normal. (2) Immediately after the gas turbine
CAUTION speed (4950 ± 50 rpm) for 30 seconds.
DO NOT EXCEED 7000 RPM NGG (3) Repeat steps (1) and (2) for two
AND 30 SECONDS OF GAS TUR- additional start-up and shutdown cycles.
BINE OPERATION WITHOUT
POWER TURBINE ROTATION. (4) If the power turbine does not
FOR EARLY MODEL GAS TUR- rotate after accomplishing substeps (1) through
BINES THAT HAVE TIGHTER LPT (3), shut down the gas turbine.
BLADE TIP CLEARANCES, DO
NOT EXCEED 6000 RPM NGG AND (5) Immediately after gas turbine
30 SECONDS OF GAS TURBINE rotation stops, re-start and accelerate to 7000
OPERATION WITHOUT POWER rpm NGG maximum and stabilize for 30 sec-
TURBINE ROTATION. onds. If the power turbine still does not rotate,
shut down and investigate/correct the cause.
a. The power turbine must rotate by the
time the gas generator speed reaches 7000 rpm During the investigation for the cause of a
NGG. If power turbine speed indication is not thermally seized rotor, inspect the LPT blades
obtained and it is determined that a “thermal in stages 4, 5 and 6 for shingling and unlatch-
seizure” of the power turbine has occurred, ing. If blades have become unlatched, they
proceed as follows: may be relatched. LPT blades that have
encountered shingling may be bent, thereby
NOTE necessitating replacement of the power
• Power turbine, except in a new installa- turbine.
tion, will be rotating when gas generator
7-2.14 Operation to Maximum Power.
idle speed is attained.
• Thermal seizure of the power turbine CAUTION
rotor can occur when a hot gas turbine is
shut down and is most likely to occur MANUAL OPERATION MAY ELIMI-
within 30 to 40 minutes following gas NATE CERTAIN PROTECTIVE CIR-
turbine operation. Thermal seizure is the CUITS. OPERATING LIMITS SHALL
condition where the power turbine rotor NOT BE EXCEEDED.
is prevented from rotating by hard con-
a. Slowly increase manual control setting
tact between LPT blades and shrouds,
(refer to packager’s manual) to increase gas
interstage seals and other internal inter-
generator speed. After each 500 rpm increase,
ference. This condition is the result of
log all instrument readings, paying particular
unequal cooling rates of the various
attention to variable stator vane position and
power turbine components. The possibil-
ity of thermal seizures can be reduced by
within limits, adjust it per WP 118 00. If
operating the gas turbine at idle power
vibrations are not within limits, consult the
for at least five minutes prior to shut-
local General Electric Company
down to achieve proper cooling of the
representative.
power turbine.
B-22
GEK 97310
VOLUME I
ADDENDUM B
b. Operate gas turbine up to rated power, c. Log all instrument readings once they
if possible, but do not exceed exhaust gas tem- stabilize. Refer to table 5, step 9.
perature (T5.4) limit. Hold at this power setting
until all temperatures stabilize. If governing
system is unstable, adjust per packager’s
manual.

1. Assure that prestart checks are

completed per table 4
CAUTION
• IF T5.4 RAPIDLY APPROACHES OR EXCEEDS 1450°F
(788°C) FOR LIQUID FUEL, ABORT START.
• THE GAS TURBINE IS DESIGNED TO OPERATE ON
100% LIQUID FUEL.
• WHEN OPERATING ON 100% LIQUID FUEL IT IS
NECESSARY TO DRAIN THE LIQUID FUEL MANI-
FOLD WHEN THE GAS TURBINE IS SHUT DOWN.
THE MAXIMUM TEMPERATURE OF THE FUEL WILL
BE 200°F (93°C). REFER TO OPERATOR’S MANUAL
FOR PROCEDURE.
NOTE
A start may be aborted at any time by closing the fuel valve, allowing
the gas generator to motor for 60 seconds, then closing the starter
shutoff valve.
rotation

B-23
GEK 97310
VOLUME I
ADDENDUM B
Table 5. START-UP AND OPERATION - Continued

3. At 1100 to 1300 rpm NGG
a. Ignition on
b. Liquid fuel valve-open Fuel manifold
pressure 90-150 psig
(621-1035 kPa)
(Liquid fuel)
c. Note time to light-off 20 seconds max Abort start-automatic
4. Note time to 4500 ± 200 rpm 90 seconds Troubleshoot system and

maximum take corrective action if
gas turbine stops acceler-
ating or if it takes longer
than 90 seconds to reach
4300 rpm
5. At 4300 to 4500 rpm NGG
a. Starter shutoff valve closes Valve closed Close fuel valve and allow
automatically gas generator to motor for
60 sec., then shut off the
starter

a. Oil pressure See applicable Alarm at 6 psig (41 kPa).
figures in Chapter 5 Shut down if below 6 psig
(41 kPa)
b. Fuel manifold pressure Approximately 150 Troubleshoot system and
Liquid fuel psig (1035 kPa) take corrective action. See
figure 8

B-24
GEK 97310
VOLUME I
ADDENDUM B

d. T5.4 1000°F (538°C) max Emergency shutdown
e. NPT 1600-1900 rpm
f. Gas generator vibration 0 to 3 mils DA Alarm above 4 mils, auto-

action
g. Power turbine vibration 0 to 6 mils DA Alarm above 7 mils, auto-
action
h. Compressor inlet Approximately equal Troubleshoot sensing and
temperature (T2) to outside air indicating system. Cor-
temperature rect as required
i. Check for fuel or oil leaks None allowed Correct as necessary
8. Set desired power setting. 1450°F (788°C) - Ref. Note 1
Observe T5.4 during transient Liquid Trip
operation
9. After stabilizing at a new power
setting, read and record the
following:
a. T5.4 1450°F (788°C) max
b. NGG 9400 rpm max

(corrected)
c. NPT 3600 rpm max
d. Oil pressure See applicable table Emergency shutdown if

and figure in below 6 psig (41 kPa)
Chapter 5
e. Scavenge oil temperature 215-300°F Ref. Note 1. Automatic
(102-149°C) shutdown if above 340°F
(171°C)

B-25
GEK 97310
VOLUME I
ADDENDUM B

f. Gas generator vibration 3 mils maximum Ref. Note 1.
4 mils Alarm Emergency shutdown
7 mils Trip
g. Power turbine vibration 6 mils maximum Ref. Note 1.
7 mils Alarm Emergency shutdown
10 mils Trip
h. Fuel manifold inlet 150-900 psig Ref. Note 2
pressure - Liquid fuel (1035-6210 kPa)
i. Fuel inlet temperature - 20°F (11°C) above Ref. Note 2

Liquid fuel wax point of fuel
minimum to +150°F
(66°C) maximum
manual
manual
l. T2 Approximately equal Ref. Note 2
to outside air
temperature
m. VSV schedule See applicable figure Correct as required per
in WP 118 00 WP 118 00
Note 1 Reduce power to stay within limits. If reducing power does not bring parameters
within limits, shut down.
Note 2 If all other parameters are normal, correct discrepancy at next opportunity.

B-26
GEK 97310
VOLUME I
ADDENDUM B
d. Reduce gas generator speed to idle.
instrument readings. Refer to table 6, step 2.
e. Check fail-safe section of control sys-

tem per packager’s manual.
f. After gas turbine has been stabilized at

idle for five minutes, make normal shut-down.
Refer to table 6, steps 3 and 4.
7-2.15 Automatic Operation. Check auto-

matic operation per packager’s manual.
a. Accelerate to idle.
c. Log all instrument readings.
d. Decelerate to idle.
e. Check for fuel or lube oil leaks.
f. After a total of five minutes at idle,
shut down gas turbine.
g. Check lube oil and fuel filters and

strainers; clean or replace as necessary.

7-3 NORMAL OPERATION.
7-3.1 General. Normal operation is the rou-

tine operation of an installed gas turbine. For
directions in the use of manual or automatic
operation for normal operation, refer to pack-
ager’s manual.
7-3.2 Interlocks. Refer to packager’s

manual.

B-27
GEK 97310
VOLUME I
ADDENDUM B
7-3.3 Operation. • ALLOW THE GAS TURBINE TO
WARNING
SHUT DOWN.
ENGINE OPERATION IS PRO- PLANE OF ROTATION OF
HIBITED IN GENERAL. IF THE STARTER WHEN
ENTRY SHOULD BE STARTING OR MOTORING
REQUIRED DURING ENGINE THE GAS TURBINE.
TO ENTER THE ENCLOSURE b. Start and operate the gas turbine per
UNDER SUCH CONDITIONS. table 5. Do not exceed operating limits of
table 3.
c. Shutdown the gas turbine per table 6.
INACTIVE ACCORDING TO d. Emergency shut down the gas turbine
THE CUSTOMER’S per table 7.
PROCEDURES. e. Refer to paragraph 5-3.30 and 5-3.31,
• SECONDARY AIR TO THE pressure characteristics. (See tables
ENCLOSURE SHALL BE SHUT V-21A, V-21B, V-21E, and V-21F, and figures
OFF. HIGH SECONDARY AIR- 5-32A, 5-32B, 5-32E, 5-32F, 5-32J, 5-32K,
FLOW MAY PREVENT OPEN- 5-32N, and 5-32Q.)
ING OR CLOSING THE
ENCLOSURE DOOR.

BE FOLLOWED.

B-28
GEK 97310
VOLUME I
ADDENDUM B

1. Set gas turbine at idle Gas generator decelerates Emergency shutdown

power
following:
a. Oil pressure See applicable table and Automatic normal shut-
figure in Chapter 5 down if below 8 psig
(55.2 kPa)
b. Fuel manifold pressure Approximately 150 psig
Liquid fuel (1035 kPa). See figure 8
d. T5.4 Approximately 800°F Troubleshoot system and

(427°C) take corrective action
f. Gas generator vibration 3 mils max Alarm above 4 mils, auto-

action
g. Power turbine 6 mils max Alarm above 7 mils, auto-
vibration matic normal shutdown if
action
h. Fuel inlet temperature 20°F (11°C) above wax of
Liquid fuel fuel minimum to 150°F
(66°C) maximum
j. Lube oil supply filter Refer to packager’s manual
∆P

B-29
GEK 97310
VOLUME I
ADDENDUM B
Table 6. GAS TURBINE SHUTDOWN - Continued

3. After stabilizing at idle for T5.4 drops below 400°F Shut off fuel supply
5 minutes, close fuel (204°C). NGG and NPT
valves decelerate and stop
4. Observe T5.4 for 700°F (371°C) max Motor gas turbine and shut
3 minutes after shutdown off fuel supply. Continue
decreases
7-4 EMERGENCY OPERATION. 7-4.2 Post Shutdown Fire.
7-4.1 Emergency Shutdown. a. During a normal shutdown, exhaust

gas temperature should decrease. If during
a. In an emergency, the gas generator may time gas generator is coasting to stop, tempera-
be shut down from any power setting by clos- ture increases instead of decreases, it indicates
ing the fuel valve. However, this should only that combustion is still taking place. (A slight
be done in an emergency, since rapid shutdown temperature increase after rotation stops is nor-
will decrease life of gas generator. mal.) Make certain fuel is shut off, and motor
b. Emergency shut-down shall be made As soon as temperature decreases to normal,
per table 7. discontinue motoring.

B-30
GEK 97310
VOLUME I
ADDENDUM B
CAUTION
1. Conditions permitting, decelerate gas tur- T5.4 drops below 400°F Manually shut off
bine to idle and close fuel valves (204°C) and NGG and fuel supply
NPT decelerate
2. Observe T5.4 for 3 minutes after 700°F (371°C) max Motor gas turbine.
shutdown Continue motoring
until temperature
decreases
power setting (T5.4) greater than
1150°F (621°C) has occurred, and a “hot
restart” is required, proceed as follows:
following coastdown of the HPC rotor,
acceptable restarts can be made using
the normal starting procedure.
between 1 minute and 2 hours following
the emergency shutdown, motor the gas
turbine at
2000-2500 rpm NGG for 5 minutes. At
the end of the 5 minute motoring/purge
cycle, perform normal restart and accel-
erate to idle. Acceleration to the desired
power setting can then be accomplished.
the HPC rotor, restart can be made using

B-31
GEK 97310
VOLUME I
ADDENDUM B
Table 8. Deleted

B-32
GEK 97310
VOLUME I
ADDENDUM B
Figure 8. Fuel Manifold Pressure

B-33/(B-34 Blank )
GEK 97310
VOLUME I
ADDENDUM C
ADDENDUM
7LM2500PC103

GEK 97310
VOLUME I
ADDENDUM C
TABLE OF CONTENTS
1-0 INTRODUCTION....................................................................................... C-3

2-0 REFERENCE DATA .................................................................................. C-3
3-0 INSTALLATION DRAWINGS.................................................................. C-4
4-0 EQUIPMENT DESCRIPTION ................................................................. C-4
5-0 INSTRUMENTATION AND SUPPLY REQUIREMENTS ................... C-4
6-0 SERVICE REQUIREMENTS ................................................................... C-4
6-1.1 Liquid Fuel.................................................................................................... C-4
7-0 OPTIONAL HARDWARE KITS - 7LM2500PC103 ............................... C-7
8-0 GAS TURBINE OPERATION .................................................................. C-7
8-1 PERFORMANCE RATINGS AND OPERATING LIMITS .................. C-7
8-1.1 Performance Ratings. .................................................................................... C-8
8-1.2 Operating Limits ........................................................................................... C-12
8-2 INITIAL OPERATION .............................................................................. C-12
8-2.1 General .......................................................................................................... C-12
8-2.2 Special Instrumentation Required for Operation .......................................... C-12
....................................................................................................................... C-13
8-2.4 Preparation .................................................................................................... C-17
8-2.5 Gas Turbine and Associated Equipment Checklist ....................................... C-17
8-2.6 Governor and Manual Control Check........................................................... C-18
8-2.7 Start-up and Checkout................................................................................... C-18
8-2.8 Ignition Check............................................................................................... C-20
8-2.9 Motoring........................................................................................................ C-20
8-2.10 False Start...................................................................................................... C-20
8-2.11 Wet Prestart ................................................................................................... C-20
8-2.12 Manual Start .................................................................................................. C-21
8-2.13 Operation to Maximum Power...................................................................... C-22
8-2.14 Automatic Operation..................................................................................... C-22
8-3 NORMAL OPERATION............................................................................ C-22
8-3.1 General .......................................................................................................... C-22
8-3.2 Interlocks....................................................................................................... C-22
8-3.3 Operation....................................................................................................... C-26
8-4 EMERGENCY OPERATION ................................................................... C-27
8-4.1 Emergency Shutdown ................................................................................... C-27
8-4.2 Post Shutdown Fire ....................................................................................... C-27

C-1
GEK 97310
VOLUME I
ADDENDUM C
Figure Title Page
1 Transient Temperature Limits ................................................................................ C-9

2 Deleted
3 Deleted
4 Deleted
5 Deleted
6 Acceleration Fuel Flow Schedule .......................................................................... C-11
7 Deleted
8 Fuel Manifold Pressure .......................................................................................... C-28
LIST OF TABLES
Table Title Page
1 INSTRUMENTATION CONNECTIONS - 7LM2500PC103............................... C-5

2 SUPPLY CONNECTIONS - 7LM2500PC103...................................................... C-6
3 GAS TURBINE OPERATING LIMITS................................................................ C-13
4 PRESTART CHECKS ........................................................................................... C-19
5 START-UP AND OPERATION ............................................................................ C-23
6 GAS TURBINE SHUTDOWN ............................................................................. C-29
7 EMERGENCY SHUTDOWN............................................................................... C-30
8 DELETED

C-2
GEK 97310
VOLUME I
ADDENDUM C
1-0 INTRODUCTION. Component Wt-Lbs/(Kg)
7LM2500PC103 model gas turbine basic con- Compressor Rear Frame 421(191)
figuration and control system differences. In Combustor 120(54)
addition, the coverage of reference data, High Pressure Turbine Rotor 419(190)
instrumentation and supply connections, spe- High Pressure Turbine Nozzle 68(31)
cial servicing requirements, optional hardware Stage 1
kits and the complete gas turbine operating
High Pressure Turbine Nozzle 127(58)
instructions for the 7LM2500PC103 model are
Stage 2
included.
Turbine Mid Frame 530(240)
2-0 REFERENCE DATA. Low Pressure Turbine Rotor 1095(497)
Low Pressure Turbine Stator 601(273)
EQUIPMENT Turbine Rear Frame 1071(486)
Gas Turbine Assembly High Speed Coupling Shaft 91(41)
(General Electric Co., Cincinnati, Ohio) Forward Adapter
Model No. 7LM2500PC103 Exhaust Duct Assembly 2741(1243)
Drawing No. L24140G01
Exhaust Duct 1565(710)
PERFORMANCE RATING Outer Cone 410(186)
Refer to paragraph 8-1.1. Inner Diffuser 255(116)
Ring Seal 49(22)
GAS TURBINE WEIGHTS Ring Support 74(34)
Insulation 269(122)
The average weights of the major engine com-
ponents are: Cover, Insulation 62(28)
Variable Stator Actuating 19(8.6)
Component Wt-Lbs/(Kg) Mech
Gas turbine, including inlet 7396(3355) Outside Piping and Bracketing 278(126)
duct, centerbody, exhaust
diffuser, and coupling nut DRAWING LIST
Exhaust duct without exhaust 2313(1049)
diffuser Drawing No.
Gas Generator 4212(1911) Gas Turbine Installation L31705
Power Turbine 2777(1260) Drawing
Inlet Gearbox 38(17) Fuel System Flow Diagram L25208
Transfer Gearbox 245(111) Lubrication System Flow L24328
Compressor Front Frame 517(235) Diagram
Compressor Rotor 552(250) Electrical Diagram L24329
Compressor Stator, Front 307(139) Gas Turbine Assembly L24140G01
Compressor Stator, Rear 93(42) Drawing

C-3
GEK 97310
VOLUME I
ADDENDUM C
3-0 INSTALLATION DRAWINGS. 5-0 INSTRUMENTATION AND SUP-
A complete set of installation drawings have PLY REQUIREMENTS. See tables 1 and 2.
been provided.
6-0 SERVICE REQUIREMENTS.
4-0 EQUIPMENT DESCRIPTION.
The 7LM2500PC103 gas turbine is a liquid 6-1.1 Liquid Fuel.
fueled, marinized gas turbine. The gas turbine
is equipped with 30 fuel nozzles and is a. The required pressure to the fuel mani-
designed to operate only with liquid fuel. It has fold on the gas turbine is 150-900 psig
both an exhaust duct and an exhaust duct inner (1035-6210 kPa).
diffuser as standard equipment.
b. The fuel temperature supplied to the
gas turbine shall be a minimum of 20ºF (-7ºC)
above the wax point of the fuel and a maxi-
mum of 150ºF (66ºC). The fuel shall be fil-
tered to 20 microns absolute.

C-4
GEK 97310
VOLUME I
ADDENDUM C
.
Table 1. INSTRUMENTATION CONNECTIONS - 7LM2500PC103

or 364450
E4 B-sump scavenge oil temperature MS3106R12S-3S
E6 Accessory gearbox scavenge oil temperature MS3106R12S-3S
E18 D-sump scavenge oil temperature MS3106R12S-3S
E7 Gas generator speed pickup No. 1 MS3106R10SL-4S
or 364450
A9 Compressor inlet total pressure probe 3/8 inch line to probe on top of compressor
(optional) front frame MS33656-6
A13 Power turbine inlet pressure probe 3/8 inch line to pressure manifold on tur-
(optional) bine mid frame AN818-6C or MS20819-6C
A23 CDP pressure port (optional) .500-20UNJF-3B
F5 Liquid fuel manifold pressure tap (Optional) 3/8 inch line AN818-6C or MS20819-6C
L5 Lube supply pressure tap 3/8 inch line AN818-6C or MS20819-6C
L7 Lube scavenge pressure tap (optional) 1/4 inch line AN818-4C or MS20819-4C
-- Remote reading variable stator vane protractor (optional)
NOTE
For all other instrumentation connections, refer to Installation Drawings
provided with gas turbine.

C-5
GEK 97310
VOLUME I
ADDENDUM C
Table 2. SUPPLY CONNECTIONS - 7LM2500PC103
CAUTION
ALL LINES MUST BE FLEXIBLE ENOUGH TO ALLOW 3/4 INCH (19 MM)
THERMAL GROWTH OF GAS GENERATOR, WITHOUT PLACING
STRAIN ON THE LINES OR GAS GENERATOR.
F2 Liquid fuel supply 3/4 inch line from fuel control unit to the gas generator
liquid fuel manifold AN818-12C or MS20819-12C
F4 Liquid fuel manifold shroud 1/2 inch line to fuel manifold shroud AN818-8C or
drain MS20819-8C
AN818-24C or MS20819-24C
AN818-16C or MS20819-16C
AN818-16C or MS20819-16C
MS20819-20C
A2 Bleed air 16th stage compressor bleed air lines if used 1.92 inch
ID
A4 Inlet duct seal (if required)
A10 CDP seal leakage No. 1 (if required) 2-inch line
A12 Air/Oil Separator 3 inch line from air/oil separator to atmospheric vent or
A16 Discharge to exhaust duct (flame arrestor)
D1 Exhaust drain, forward 1 inch line to drain under exhaust duct MS33649-16
D2 Exhaust drain, aft 1 inch line to drain under exhaust duct MS33649-16
D3 Oil drain, forward 3/8 inch line to drain manifold under transfer
gearbox AN818-6C or MS20819-6C
D5 Oil drain, aft 3/8 inch line to drain manifold under TMF AN818-6C
or MS20819-6C
Gas Generator Inlet Duct AN818-16C or
MS20819-16C
NOTE
For all other supply connections, refer to Installation Drawings provided
with gas turbine.

C-6
GEK 97310
VOLUME I
ADDENDUM C
7-0 OPTIONAL HARDWARE KITS -
7LM2500PC103. WARNING
IF A QUESTIONABLE CONDITION
a. Refer to Volume II, WP 001 00 for a
GAS TURBINE UNTIL A THOR-
OUGH INVESTIGATION HAS
HOT STARTS, COMPRESSOR
PROBLEMS WITHOUT PRIOR
FAILURE TO INVESTIGATE
pany for the 7LM2500PC103 Gas Turbine.
THOROUGHLY, AND CORRECT
AS NECESSARY, CAN RESULT IN
b. The instructions are intended to pro-
UNDUE STRESS BEING IMPOSED
vide operating personnel with the information
ON GAS TURBINE COMPONENTS,
required to operate the gas turbine. They per-
WITH IMMEDIATE OR SUBSE-
QUENT DESTRUCTIVE FAILURE
procedures. When a fault exists, refer to
OF THE GAS TURBINE AND
Chapter IV, TROUBLESHOOTING.
INJURY TO PERSONNEL A
RESULT.
8-1 PERFORMANCE RATINGS AND
OPERATING LIMITS.
tion with operation of the gas turbine. Refer
requests for additional information to The
NOTE
General Electric Company, Marine and Indus-
trial Engine Division, Cincinnati, Ohio 45215. Ratings published in this manual apply
to the gas turbine. The driven unit rat-
NOTE ings/limits may be lower, in some
cases, and shall take precedence over
the gas turbine manual limits.
direct mathematical conversions and
may be rounded off in most instances
at the users discretion. Examples of
utilized for temperatures, torque val-
ues, pressures, etc. Examples where
S. I. units may not be rounded off are
those utilized for drop checks, rigging

C-7
GEK 97310
VOLUME I
ADDENDUM C
8-1.1 Performance Ratings. c. Figure 6 defines the maximum liquid
fuel acceleration fuel schedule for the gas
a. The rating of the 7LM2500PC103 gas
generator.
turbine in new and clean condition operating
on 100% liquid fuel, in accordance with d. The tolerance on the fuel schedules is
MID-TD-0000-2 fuel specification, is as +4% of point. The schedule is plotted against
follows: compressor discharge pressure.
Brake Horsepower 27,500
those shown will result in over-temperature
(continuous)
and possible stall of the gas turbine. Accelera-
Inlet Air Temperature 59ºF (15ºC) tion fuel rates lower than those shown can
Altitude Sea Level result in "hung" starts in the below idle speed
Inlet Losses 0 inch H2O range.
Exhaust Back Pressure 0 inch H2O f. Above the idle speed point, low accel-
Relative Humidity 0% eration fuel rates will not harm the gas turbine
and will only result in slower acceleration
Fuel Lower Heating Value 18,400 BTU/lb
times.
Compressor Bleed 0
Accessory Horsepower 0 g. The fuel rates shown on the curve will
Extraction give starting times to 5000 rpm idle of 60 to 90
Power Turbine Speed 3600 RPM seconds and accelerations from idle to maxi-
mum power of 15 seconds.
Heat Rate, Average 6946 BTU/
(continuous) hp-hr h. For normal accelerations from idle to
Power Turbine Inlet Gas 1430ºF power settings, the changes should be made
Temperature (Average) (777ºC) more slowly to enhance the time between hot
at 27,500 BHP section repairs and the life of the gas turbine.
1503ºF A time of 2 to 3 minutes is reasonable.
(817ºC)
at 30,000 BHP i. The maximum deceleration fuel flow
Fuel, Liquid per GE Speci- rate should consist of a step fuel decrease of
fication MID-TD-0000-2 1500 pph (680 kg/h) ± 10% followed by a rate
change of 1330 pph (603 kg/h) ± 10% per sec-
b. The starting fuel flows for liquid fuel ond at a basepoint fuel flow of 10, 000 pph
are: (4536 kg/h). Fuel flow jump or rate at any
other fuel flow shall be the above jump and
530 pph (240 kg/h) ± 25 pph (11 kg) @ -65ºF rate multiplied by the square root of the ratio
(-54ºC) Inlet Air Temperature of fuel flow to the basepoint fuel flow. Normal
decelerations from maximum power to idle
625 pph (284 kg/h) ± 25 pph (11 kg) @ +60ºF should be made in approximately 2 to 3 min-
(16ºC) Inlet Air Temperature utes. This will enhance the time between hot
section repairs and the life of the gas turbine.
680 pph (308 kg/h) ± 25 pph (11 kg) @ +130ºF
(54ºC) Inlet Air Temperature
C-8
GEK 97310
VOLUME I
ADDENDUM C

C-9
GEK 97310
VOLUME I
ADDENDUM C
Figures 2 through 5. Deleted

C-10
GEK 97310
VOLUME I
ADDENDUM C

C-11
GEK 97310
VOLUME I
ADDENDUM C
j. The liquid fuel system must be free of 8-2.2 Special Instrumentation Required for
periodic or random hunting which result in Operation:
cycling of gas generator speed or temperature.
The frequency of the fuel flow fluctuations Gas Generator speed sensor . . 0-10,000
shall not be a harmonic of the natural fre- RPM
Lube oil scavenge temperature 0-400ºF
sensor (A-, B-, C-, (-18 to
D-sumps and transfer gear- 205ºC)
box)
engine.
Lube oil supply temperature . . 0-400ºF
8-1.2 Operating Limits. Refer to Table 3. sensor (-18 to
205ºC)
NOTE Vibration indicators
If any operating limit is exceeded, ver- gas generator . . . . . . . . . . . . . 0-10 mil DA
ify instrumentation accuracy before power turbine . . . . . . . . . . . . 0-10 mil DA
troubleshooting or inspecting gas Power turbine speed sensor. . . 0-5000 RPM
generator.
Power turbine inlet gas . . . . . . 0-2000ºF
8-2 INITIAL OPERATION. temperature (T5.4) (-18 to
1093ºC)
8-2.1 General. Initial operational period is Lube oil supply pressure . . . . . 0-100 psig
that period of operation immediately following (0-690 kPa)
gas turbine replacement, or major maintenance
on the system.

C-12
GEK 97310
VOLUME I
ADDENDUM C
Alarm/ Normal
NOTE
• Continuous operation should not take place with any parameter
indicating between the alarm and trip levels. If an alarm level is
not shown, the trip level is the operating limit.
System - Lube Pump (55 kPa ± (138 - 413 kPa) 4500 rpm
Settings and Discharge 6.9 kPa) below
Operating Pressure 8000 rpm
Ranges 15 psig ± 1 psig
(103 kPa ±
6.9 kPa) above
8000 rpm
Trip 6 psig ± 1 psig 20-60 psig Bypass until
(41 kPa + (138-413 kPa) 4500 rpm
6.9 kPa)
Gas Turbine Alarm 110 psig ± 10 - 100 psig Scavenge
Scavenge 10 psig (759 kPa (69 - 690 kPa) Discharge
Discharge ± 69 kPa) Pressure shall not
Pressure exceed 180 psig
(1242 kPa)
Gas Turbine Alarm 180º - 220ºF 140º - 160ºF Normal Operating
Lube Pump (82º - 104ºC) (60º - 71ºC) Range reflects tem-
Discharge perature expected
Temperature during operation
above idle speed
Gas Turbine Trip 330º - 350ºF 215º - 275ºF Normal Operating
Lube Scav- (166º - 177ºC) (102º - 135ºC) Range reflects tem-
enge Temper- perature expected
atures - Five during operation
above idle speed
Alarm 290º - 310ºF
(143º - 154ºC)

C-13
GEK 97310
VOLUME I
ADDENDUM C
Table 3. GAS TURBINE OPERATING LIMITS - (Cont.)
Alarm/ Normal
Fuel System Fuel 150 - 900 psig Supply Pressure as
(Liquid Fuel) Manifold (1034 - 6205 reflected at the fuel
Pressure kPa) manifold inlet on
the gas turbine
Fuel Supply 20º to 150ºF Starting Fuel Flow
Temperature (-7 to 66ºC) Adjustments may
be required to
compensate for
fuel temperature
variation
Starting Starter Sup- 40 psig Starting Pressure
System ply Pressure (276 kPa) Requirement based
on engine starter
torque
requirements
of Fuel and
Ignition
Ignition (If cycle
purge cycle is
used)
Starting Time Trip 1200 ± 100 rpm Activate 20 sec-
to 1200 rpm onds time delay
simultaneously
with start
initiation
Failure to Trip 380º - 420ºF Activate 20 sec-
Light-Off (193º - 216ºC) onds time delay
simultaneously
with application of
fuel and ignition

C-14
GEK 97310
VOLUME I
ADDENDUM C
Alarm/ Normal
simultaneously
with start initiation.
De-energize igni-
tion, fuel system
and starter air
supply
(If purge upon completion of
cycle is used) purge. De-energize
fuel and ignition
systems and starter
air supply
Power Tur- Failure to Trip 380º - 420ºF 0 - 1600ºF Trip if temperature
bine Inlet Light-Off (193º - 216ºC) (-7 - 871ºC) does not reach
(T5.4) 400ºF (205ºC)
Temperature within 20 seconds
(Gas Genera- after fuel and igni-
tor Exhaust) tion are applied
(Liquid Fuel)

C-15
GEK 97310
VOLUME I
ADDENDUM C
Alarm/ Normal
Overtempera-
ture:
Trip 1470ºF (799ºC) 1400º - 1460ºF Values given are
(760º - 793ºC) for installations
using constant T5.4
Alarm 1460ºF (793ºC) control as the
power limit.
Installations using
constant power
control mode
should consult the
contract docu-
ments for deter-
mining alarm and
are unique to each
application, but
never to exceed
1616ºF (880ºC)
(alarm) and 1625ºF
(885ºC) (trip)
Vibration Gas Trip 7 mils ± 1 mil 0-3 mils DA Avoid continuous
Generator DA operation above 4
mils
Alarm 4 mils ± 1 mil
DA
Power Trip 10 mils ± 1 mil 0 - 6 mils DA Avoid continuous
Turbine DA operation above 7
mils
DA
Generator
Turbine
upon loss of flame

C-16
GEK 97310
VOLUME I
ADDENDUM C
8-2.3 Special Instrumentation Required for e. Gas turbine and exhaust duct _______
Monitoring and Troubleshooting: support mounts and links in
place and secure
Fuel manifold pressure . . . . . . 0-1200 psi f. All service connections made _______
sensor - Liquid fuel (0-8280 kPa) and secure
Compressor inlet total . . . . . . 10-16 psia
g. All lines flushed, per _______
pressure sensor (69-110 kPa)
packager’s manual
Power turbine inlet gas. . . . . . 0-75 psia
pressure (0-517 kPa) h. All instrumentation connections _______
made and secure
Compressor discharge . . . . . . 0-300 psig
pressure (0-2070 kPa) i. All accessories secured, per _______
packager’s manual
Fuel supply pressure - . . . . . . 0-1200 psig
Liquid fuel (0-8280 kPa) j. Gas turbine assembly free of _______
Fuel supply temperature - . . . 0-250ºF loose objects, and all lines/
Liquid fuel (-18 to electrical leads connected
121ºC) k. Gas turbine inlet air area free _______
Gas turbine inlet air . . . . . . . . 0-150ºF of foreign objects. Inlet
temperature (-18 to 66ºC) screen secure
Lube oil scavenge pressure . . 0-100 psig l. Gas turbine compressor rear _______
(0-690 kPa) frame leakage ports, struts 7
Remote reading variable . . . . -5º to +45º and 10, open (not capped)
vane indicator m. Starter serviced, per _______
Starter air supply pressure . . . 0-50 psig packager’s manual
(optional) (0-345 kPa) n. Lube oil storage tank serviced _______
to full level
8-2.4 Preparation. The gas turbine and asso- o. Lube oil supply valves open _______
ciated systems must be inspected and checked
out for proper installation and operation before p. All filters serviced, per _______
normal operation can commence. packager’s manual
q. Fire alarm/extinguish system _______
8-2.5 Gas Turbine and Associated Equip- ON and operative
ment Checklist. Complete the following r. T5.4 thermocouple system _______
checklist. functioning properly
a. Gas Turbine Assembly S/N _______ s. Ignition system operative _______

b. Mounting base secured to _______ t. Compressor inlet total pressure _______
foundation probe aligned properly and
free of damage
c. Intake air and exhaust gas _______
ducts in place and secured u. Variable stator system secure _______
d. Bonding straps in place and _______ v. Required checks and inspections _______
secure specified in packager’s manual
for gas turbine control have been
performed

C-17
GEK 97310
VOLUME I
ADDENDUM C
8-2.6 Governor and Manual Control Check. ENTRY PROCEDURES SHALL
Refer to packager’s manual. BE FOLLOWED.
WARNING
MET:
SHUT DOWN.
a. When entering enclosure wear proper
ear protection.
SENTATIVE WHO IS TRAINED
TO ENTER THE ENCLOSURE b. Perform prestart checks per Table 4.
c. Perform ignition checkout per para-
• THE FIRE EXTINGUISHING graph 8-2.8.
INACTIVE ACCORDING TO d. Perform motoring procedure per para-
THE CUSTOMER’S graph 8-2.9.
PROCEDURES.
e. Perform false start per paragraph
• SECONDARY AIR TO THE 8-2.10.
f. Perform governor check per packager’s
manual.
ING OR CLOSING THE g. Perform a wet prestart per paragraph
ENCLOSURE DOOR. 8-2.11.
• THE ENCLOSURE DOOR h. Perform a manual start and operate per
SHALL BE KEPT OPEN. IF THE paragraph 8-2.12.
AN OBSERVER SHALL BE STA- i. Operate to maximum power per para-
TIONED AT THE ENCLOSURE graph 8-2.13.
DOOR AND CONFINED SPACE j. Check automatic operation per para-
graph 8-2.14.

C-18
GEK 97310
VOLUME I
ADDENDUM C

Item Requirement
Fire control Operative
Fuel Valves Closed
Ignition Off
Ventilation Inlet air (secondary cooling air) Off-air temp. below 70ºF (21ºC)
Ventilation exit air 180ºF (82ºC) max.
Oil tank level Full
Lube oil temperature 140-160ºF (60-71ºC)
Bleed air valve Closed
pressure 150-900 psig (1035- 6205 kPa)
temperature 150ºF (66ºC) max
flow 12,000 pph
(5443 kg/h) max

C-19
GEK 97310
VOLUME I
ADDENDUM C
8-2.8 Ignition Check. a. Make ignition and liquid fuel supply
WARNING (1) Disconnect power supply to igni-

tion unit.
• ASSURE POWER TO IGNITION
(2) Close liquid fuel manual shutoff
valve to fuel control unit.
ING IGNITION EXCITER INPUT b. Depress MOTORING pushbutton. Gas
LEADS. TAG SWITCH OUT OF generator will start to rotate. If it does not,
SERVICE TO PRECLUDE INAD- refer to packager’s manual for supply pressure
VERTENT ACTIVATION. to starter.
c. Hold MOTORING pushbutton closed
until gas generator speed stabilizes, and check
for oil pressure. If there is no indication of oil
PROCEDURE.
a. To clear combustor of any residual while gas generator is coasting down, loosen
fuel, motor gas turbine for one minute; allow oil fittings at lube pump to bleed air from sys-
gas turbine to coast down. tem. Starter should motor gas generator to
minimum of 2200 RPM.
input lead at exciter. Temporarily secure input d. Repeat motoring and bleeding proce-
lead away from the exciter. dure until an indication of oil pressure appears.
8-2.10 False Start. Perform false start as
follows:
audible report (approximately two sparks per
second) should be heard when the No. 2 spark
igniter fires.
connected and manual fuel shutoff valve
d. Turn off electrical power to the ignition closed, make automatic start of gas turbine per
system. Reconnect input lead to exciter and operator’s manual.
b. Gas generator should go through nor-
the No. 2 exciter.
of flame.
f. If an audible report is not heard from
No. 1 and/or No. 2 igniters, check out the sys- 8-2.11 Wet Prestart. Perform wet prestart as
tem to isolate the problem, and take appropri- follows:
8-2.9 Motoring. After all preliminary checks connected, with the liquid fuel manual shutoff
have been completed and lines flushed, gas valve open, and the governing system operat-
generator can be motored as follows: ing, make an automatic start of the gas turbine
per the operator’s manual.

C-20
GEK 97310
VOLUME I
ADDENDUM C
b. Gas generator should accelerate and NOTE
stabilize at a speed dependent on starter inlet Thermal seizure of the power turbine
pressure level. Start will then abort because of rotor can occur when a hot gas turbine
lack of ignition. is shut down and is most likely to occur
within 30 to 40 minutes following gas
c. Allow gas generator to coast to a stop. turbine operation. Thermal seizure is
Purge fuel nozzles of liquid fuel with com- the condition where the power turbine
pressed air at 200 psid (1380 kPa d) maximum. rotor is prevented from rotating by hard
After wet prestart, drain liquid fuel from fuel contact between LPT blades and
manifold. Then motor gas generator on starter shrouds, interstage seals and other
for 60 seconds to purge fuel from gas turbine. internal interference. This condition is
the result of unequal cooling rates of
8-2.12 Manual Start. Perform manual start the various power turbine components.
with ignition lead connected and fuel system The possibility of thermal seizures can
normal, per Table 5. be reduced by operating the gas turbine
at idle power for at least five minutes
NOTE prior to shutdown to achieve proper
Power turbine, except in a new installa- cooling of the power turbine.
tion, will be rotating when gas genera-
tor idle speed is attained. (1) Shutdown gas turbine.
(2) Immediately after the gas turbine
CAUTION
stops rotating, restart and stabilize at idle
DO NOT EXCEED 7000 RPM NGG speed (4950 + 50 rpm) for 30 seconds.
AND 30 SECONDS OF GAS TUR- (3) Repeat steps (1) and (2) for two
BINE OPERATION WITHOUT additional start-up and shutdown cycles.
POWER TURBINE ROTATION.
FOR EARLY MODEL GAS TUR- (4) If the power turbine does not
BINES THAT HAVE TIGHTER LPT rotate after accomplishing substeps (1) through
BLADE TIP CLEARANCES, DO (3), shut down the gas turbine.
NOT EXCEED 6000 RPM NGG AND
30 SECONDS OF GAS TURBINE (5) Immediately after gas turbine
OPERATION WITHOUT POWER rotation stops, restart and accelerate to
TURBINE ROTATION. 7000 rpm NGG maximum and stabilize for
30 seconds. If the power turbine still does not
a. The power turbine must rotate by the rotate, shut down and investigate/correct the
time the gas generator speed reaches 7000 rpm cause. During the investigation for the cause of
NGG. If power turbine speed indication is not a thermally seized rotor, inspect the LPT
obtained and it is determined that a "thermal blades in stages 4, 5 and 6 for shingling and
seizure" of the power turbine has occurred, unlatching. If blades have become unlatched,
proceed as follows: they may be relatched. LPT blades that have
encountered shingling may be bent thereby
necessitating replacement of the power
turbine.

C-21
GEK 97310
VOLUME I
ADDENDUM C
8-2.13 Operation to Maximum Power. 8-2.14 Automatic Operation. Check automatic
operation per packager’s manual.
CAUTION
MANUAL OPERATION MAY
ELIMINATE CERTAIN PROTEC- b. Accelerate to rated power.
TIVE CIRCUITS. OPERATING LIM- c. Log all instrument readings.
ITS SHALL NOT BE EXCEEDED.
a. Slowly increase manual control setting e. Check for fuel or lube oil leaks.
generator speed. After each 500 RPM increase, f. After a total of five minutes at idle,
log all instrument readings, paying particular shut down gas turbine.
attention to variable stator vane position and g. Check lube oil and fuel filters and
vibration. If variable stator system is not strainers; clean or replace as necessary.
within limits, adjust it per WP 118 00 or
WP 119 00. If vibrations are not within limits, h. Correct any leaks observed.
consult the local General Electric Company i. Remove all temporary instrumentation.
representative.
b. Operate gas turbine up to rated power,
if possible, but do not exceed exhaust gas tem-
perature (T5.4) limit (see Table 3). Hold at this
power setting until all temperatures stabilize. 8-3.1 General. Normal operation is the rou-
If governing system is unstable, adjust per tine operation of an installed gas turbine. For
packager’s manual. directions in the use of manual or automatic
operation for normal operation, refer to pack-
c. Log all instrument readings once they ager’s manual.
stabilize. Refer to Table 5, step 10.
8-3.2 Interlocks. Refer to paragraph 2-11.9
d. Reduce gas generator speed to idle. for description of interlocks which affect gas
After stabilizing for three minutes, record all turbine operation.
instrument readings. Refer to Table 6, step 2.


C-22
GEK 97310
VOLUME I
ADDENDUM C
1. Assure that prestart checks
are completed per Table 4
CAUTION
• IF T5.4 RAPIDLY APPROACHES OR EXCEEDS 1450ºF
(788ºC) FOR LIQUID FUEL, ABORT START.
100% LIQUID FUEL.
• WHEN OPERATING ON 100% LIQUID FUEL IT IS NEC-
ESSARY TO DRAIN THE LIQUID FUEL MANIFOLD
WHEN THE GAS TURBINE IS SHUT DOWN. THE MAX-
IMUM TEMPERATURE OF THE FUEL WILL BE 200ºF
(93ºC). REFER TO OPERATOR’S MANUAL FOR
PROCEDURE.
NOTE
A start may be aborted at any time by closing the fuel valve, allowing
the gas generator to motor for 60 seconds, then closing the starter
shutoff valve.
2. Open starter shutoff valve Gas generator rotation Close valve
4. At 1100 to 1300 RPM NGG
a. Ignition on
b. Liquid fuel valve-open Fuel manifold pressure
90-150 psig
(621-1035 kPa)
(Liquid fuel)
c. Note time to light-off 20 seconds max Abort start-automatic
[T5.4 above 400ºF (205ºC)] shutdown
5. Note time to 4500 ± 200 Troubleshoot system and
RPM take corrective action if
RPM stops increasing, or
if it takes longer than 90
seconds to reach 4300
RPM (see figure 6)

C-23
GEK 97310
VOLUME I
ADDENDUM C
Table 5. START-UP AND OPERATION - (Cont.)
6. At 4300 to 4500 RPM NGG
a. Starter shutoff valve Valve closed
closes automatically
7. Note time to 5000 RPM
NGG
8. At idle, check the
following:
a. Oil Pressure See applicable figures in Alarm at 6 psig (41 kPa).
Chapter 5 Shut down if below 6
psig (41 kPa)
b. Fuel manifold pressure Approximately 150 psig Troubleshoot system and
Liquid fuel (1035 kPa) take corrective action.
See figure 8
c. NGG 5000 ± 50 RPM Adjust
d. T5.4 1000ºF (538ºC) max Emergency shutdown
e. NPT (unloaded) 1600-1900 RPM
f. Gas generator vibration 0 to 3 mils DA Alarm above 4 mils.
Automatic normal shut-
corrective action
g. Power turbine vibration 0 to 6 mils DA Alarm above 7 mils.
corrective action
h. Compressor inlet Approximately equal to Normal shutdown
temperature (T2) outside air temperature
i. Check for fuel and oil
leaks

C-24
GEK 97310
VOLUME I
ADDENDUM C
9. Set desired power setting. 1450ºF (788ºC) - Liquid Ref. Note 1
Observe T5.4 during tran- Trip
sient operation
10. After stabilizing at a new
power setting, read and
record the following:
a. T5.4 1450ºF (788ºC) max
b. NGG 9400 RPM max (corrected)
c. NPT 3600 RPM max
d. Oil Pressure See applicable table and Emergency shutdown if
figure in Chapter 5 below 6 psig (41 kPa)
e. Scavenge oil 215-300ºF (102-149ºC) Ref. Note 1. Automatic
temperature shutdown if above 340ºF
(171ºC)
4 mils alarm Emergency shutdown
7 mils trip
g. Power turbine vibration 6 mils maximum Ref. Note 1.
7 mils alarm Emergency shutdown
10 mils trip
h. Fuel manifold inlet pres- 150-900 psig Ref. Note 2
sure-Liquid fuel (1035-6205 kPa)
i. Fuel inlet temperature - 20ºF (11ºC) minimum Ref. Note 2
Liquid fuel above wax point of fuel to
+ 150ºF (66ºC) maximum
j. Scavenge oil filter ∆P Refer to packager’s manual
k. Lube oil supply filter ∆P Refer to packager’s manual
l. T2 Approximately equal to Ref. Note 2
outside air temperature
m. VSV schedule See applicable Figure in Correct as required per
WP 118 00 WP 118 00
NOTE 1 Reduce power to stay within limits. If reducing power does not bring parameters
NOTE 2 If all other parameters are normal, correct discrepancy at next opportunity.

C-25
GEK 97310
VOLUME I
ADDENDUM C
WARNING WEAR THERMALLY INSU-
LATED GLOVES AS
WHEN ENTERING THE GAS TUR-
NECESSARY.
BINE ENCLOSURE, THE FOLLOW-
MET:
OPERATING.
• THE GAS TURBINE SHALL BE
SHUT DOWN.
ENCLOSURE OR IN THE
• ENCLOSURE ENTRY DURING
PLANE OF ROTATION OF THE
ENGINE OPERATION IS PRO-
STARTER WHEN STARTING OR
HIBITED IN GENERAL. IF
MOTORING THE GAS
ENTRY SHOULD BE
TURBINE.
REQUIRED DURING ENGINE
OPERATION, CONTACT GE a. When entering enclosure at or below
FIELD SERVICE FOR A REPRE- idle speed, wear proper ear protection.
b. Start and operate the gas turbine per
Table 3.
• THE FIRE EXTINGUISHING c. Shut down the gas turbine per Table 6.
per Table 7.
THE CUSTOMER’S
PROCEDURES. e. Refer to paragraph 5-3.30 and 5-3.31,
• SECONDARY AIR TO THE pressure characteristics. (See tables V-21A, V-
ENCLOSURE SHALL BE SHUT 21B, V-21E, and V-21F, and figures 5-32A,
OFF. HIGH SECONDARY AIR- 5-32B, 5-32E, 5-32F, 5-32J, 5-32L, 5-32N,
FLOW MAY PREVENT OPEN- and 5-32Q.)
ING OR CLOSING THE
ENCLOSURE DOOR.

BE FOLLOWED.

C-26
GEK 97310
VOLUME I
ADDENDUM C

a. In an emergency, the gas generator may time gas generator is coasting to stop, tempera-
ing the fuel valve. However, this should only that combustion is still taking place. (A slight
be done in an emergency, since rapid shutdown temperature increase after rotation stops is nor-
will decrease life of gas generator. mal.) Make certain fuel is shut off, and motor
b. Emergency shut-down shall be made As soon as temperature decreases to normal,
per Table 7. discontinue motoring.
Figure 7. Deleted

C-27
GEK 97310
VOLUME I
ADDENDUM C

C-28
GEK 97310
VOLUME I
ADDENDUM C
power
following:
(41 kPa)
- Liquid fuel (1035 kPa). See figure 8
c. NGG 4900-5000 RPM Adjust
d. T5.4 Approximately 800ºF Troubleshoot system and
(427ºC) take corrective action
f. Gas generator vibration 3 mils max Alarm above 4 mils.
corrective action
g. Power turbine vibration 6 mils max Alarm above 7 mils.
corrective action
h. Fuel inlet temperature 20ºF (-7ºC) minimum
Liquid fuel above wax point of fuel to
150ºF (66ºC) maximum
∆P
3. After stabilizing at idle for T5.4 drops below 400ºF Shut off fuel supply
5 minutes, close fuel valves (205ºC). NGG and NPT
decelerate and stop
4. Observe T5.4 for 3 minutes 700ºF (371ºC) max Motor gas turbine and
after shutdown shut off fuel supply.
Continue motoring until
temperature decreases

C-29
GEK 97310
VOLUME I
ADDENDUM C

CAUTION
ASSURE FREEDOM OF ROTATION OF GAS TURBINE AFTER AN EMER-
GENCY SHUTDOWN FROM HIGH POWER SETTINGS. SEIZURE OF GAS TUR-
BINE ROTOR MAY OCCUR DUE TO TIGHT CLEARANCES. NORMALLY THE
ROTOR WILL FREE ITSELF AFTER A COOLING PERIOD OF 3 TO 4 HOURS.
CHECK FOR FREEDOM OF ROTATION BY TURNING ROTOR BY HAND.
1. Conditions permitting, T5.4 drops below 400ºF Manually shut off fuel
decelerate gas turbine to (204ºC) and NGG and NPT supply
idle and close fuel valves decelerate
2. Observe T5.4 for 3 minutes 700ºF (371ºC) max Motor gas turbine. Con-
after shutdown tinue motoring until
3. If an emergency shutdown
from a high power setting
(T5.4) greater than 1150ºF
(621ºC) has occurred, and a
“hot restart” is required,
proceed as follows:
a. If the fault detection
and sequencing system
can be cleared and the
gas turbine can be
restarted within 1
minute following coast-
down of the HPC rotor,
acceptable restarts can
be made using the nor-
mal starting procedure.

C-30
GEK 97310
VOLUME I
ADDENDUM C
Table 7. EMERGENCY SHUTDOWN - (Cont.)

b. If a “hot restart” is to be
performed between 1
minute and 2 hours fol-
lowing the emergency
shutdown, motor the
gas turbine at
2000-2500 rpm NGG for
5 minutes. At the end
of the 5 minute motor-
ing/purge cycle, per-
form normal restart and
accelerate to idle.
Acceleration to the
desired power setting
can then be
accomplished.
c. After 2 hours follow-
ing coastdown of the
HPC rotor, restart can
be made using the nor-
mal starting procedure.

C-31
GEK 97310
VOLUME I
ADDENDUM C
Table 8. Deleted

C-32
GEK 97310
VOLUME I
ADDENDUM D
ADDENDUM
7LM2500PC103B

GEK 97310
VOLUME I
ADDENDUM D
TABLE OF CONTENTS
1-0 INTRODUCTION....................................................................................... D-3

2-0 REFERENCE DATA .................................................................................. D-3
3-0 INSTALLATION DRAWINGS.................................................................. D-4
4-0 EQUIPMENT DESCRIPTION ................................................................. D-4
5-0 INSTRUMENTATION AND SUPPLY REQUIREMENTS ................... D-4
6-0 SERVICE REQUIREMENTS ................................................................... D-4
6-1.1 Liquid Fuel.................................................................................................... D-4
7-0 OPTIONAL HARDWARE KITS- 7LM2500PC103B ............................. D-4
8-0 GAS TURBINE OPERATION .................................................................. D-7
8-1 Performance Ratings And Operating Limits................................................. D-7
8-1.1 Performance Ratings ..................................................................................... D-8
8-1.2 Operating Limits ........................................................................................... D-12
8-2 INITIAL OPERATION .............................................................................. D-12
8-2.1 General .......................................................................................................... D-12
8-2.2 Special Instrumentation Required For Operation ......................................... D-12
8-2.3 Special Instrumentation Required For Monitoring And Troubleshooting .... D-12
8-2.4 Preparation .................................................................................................... D-13
8-2.5 Gas Turbine And Associated Equipment Checklist...................................... D-13
8-2.6 Governor And Manual Control Check.......................................................... D-18
8-2.7 Start-up And Checkout.................................................................................. D-18
8-2.8 Ignition Check............................................................................................... D-20
8-2.9 Motoring........................................................................................................ D-20
8-2.10 False Start...................................................................................................... D-20
8-2.11 Wet Prestart ................................................................................................... D-21
8-2.12 Manual Start .................................................................................................. D-21
8-2.13 Operating To Maximum Power..................................................................... D-22
8-2.14 Automatic Operation..................................................................................... D-22
8-3 NORMAL OPERATION............................................................................ D-33
8-3.1 General .......................................................................................................... D-33
8-3.2 Interlocks....................................................................................................... D-33
8-3.3 Operation....................................................................................................... D-33
8-4 EMERGENCY OPERATION ................................................................... D-34
8-4.1 Emergency Shutdown ................................................................................... D-34
8-4.2 Post Shutdown Fire ....................................................................................... D-34

D-1
GEK 97310
VOLUME I
ADDENDUM D
Figure Title Page
1 Transient Temperature Limits ....................................................................... D-9

2 Deleted
3 Deleted
4 Deleted
5 Deleted
6 Acceleration Fuel Flow Schedule ................................................................. D-11
7 Deleted
8 Fuel Manifold Pressure ................................................................................. D-28
LIST OF TABLES
Table Title Page
1 INSTRUMENTATION CONNECTIONS - 7LM2500PC103B ................... D-4

2 SUPPLY CONNECTIONS - 7LM2500PC103B .......................................... D-5
3 GAS TURBINE OPERATING LIMITS....................................................... D-14
4 PRESTART CHECKS .................................................................................. D-19
5 START-UP OPERATION ............................................................................. D-24
6 GAS TURBINE SHUTDOWN .................................................................... D-29
7 EMERGENCY SHUTDOWN...................................................................... D-31
8 DELETED

D-2
GEK 97310
VOLUME I
ADDENDUM D
7LM2500PC103B model gas turbine basic Combustor 120(54)
configuration and control system differences. High Pressure Turbine Rotor 419(190)
In addition, the coverage of reference data, High Pressure Turbine Nozzle
cial servicing requirements, optional hardware Stage 1 68(31)
kits and the complete gas turbine operating High Pressure Turbine Nozzle
instructions for the 7LM2500PC103B model Stage 2 127(58)
are included.
2-0 REFERENCE DATA. Low Pressure Turbine Rotor 1095(497)
EQUIPMENT
Turbine Rear Frame 1071(486)
(General Electric Co., Cincinnati, Ohio) High Speed Coupling Shaft
Model No. 7LM2500PC103B Forward Adapter 91(41)
Drawing No. L24140G02 Outer Cone 410(186)
PERFORMANCE RATING Inner Diffuser 255(116)
Refer to paragraph 8-1.1. Ring Seal 49(22)
Ring Support 74(34)
GAS TURBINE WEIGHTS
Insulation 269(122)
Cover, Insulation 69(31)
ponents are:
Variable Stator Actuating
Component Wt-Lbs/(Kg) Mech 19(8.6)
Outside Piping and Bracketing 278(126)
Gas turbine, including inlet
duct, centerbody, exhaust dif-
DRAWING LIST
fuser, and coupling nut 7396(3355)
Exhaust duct without exhaust Drawing No.
diffuser 2313(1049)
Gas generator 4212(1911) Gas Turbine Installation
Drawing
Power Turbine 2777(1260) (7LM2500PC103B) L31705
Inlet Gearbox 38(17)
Fuel System Flow Diagram L25208
Transfer Gearbox 245(111)
Compressor Front Frame 517(235) Lubrication System Flow
Diagram L24328
Compressor Rotor 552(250)
Compressor Stator, Front 307(139) Electrical Diagram L24329
Compressor Stator, Rear 93(42) Gas Turbine Assembly
Compressor Rear Frame 421(191) Drawing L24140G02

D-3
GEK 97310
VOLUME I
ADDENDUM D
been provided. 6-1.1 Liquid Fuel.
4-0 EQUIPMENT DESCRIPTION. a. The required pressure to the fuel mani-

The 7LM2500PC103B gas generator is a liq- fold on the gas turbine is 150-900 psig (1035-
uid fuel marinized gas turbine. It is equipped 6210 kpa).
with 30 fuel nozzles and is designed to operate
only on liquid fuel. It has an exhaust inner dif- b. The fuel temperature supplied to the
fuser as standard equipment. gas turbine shall be a minimum of 20°F (-7° C)
above the wax point of the fuel and a maxi-
5-0 INSTRUMENTATION AND SUP- mum of 150°F (66°C). The fuel shall be fil-
PLY REQUIREMENTS. See tables 1 and 2. tered to 20 microns absolute.
7-0 OPTIONAL HARDWARE KITS-

7LM2500PC103B.

Table 1. INSTRUMENTATION CONNECTIONS - 7LM2500PC103B

E1 Vibration pickup, Gas Generator Bell & Howell Electronics Part No. 173960 or
364450
E3 A-sump scavenge oil temperature MS3106R-12S-3S
E4 B-sump scavenge oil temperature MS3106R-12S-3S
E5 C-sump scavenge oil temperature MS3106R-12S-3S
E6 Accessory gearbox scavenge oil MS3106R-12S-3S
temperature
E11 Oil supply temperature MS3106R-12S-3S
E18 D-sump scavenge oil temperature MS3106R-12S-3S
E13 Vibration pickup, power turbine Bell & Howell Electronics Part No. 173960 or
364450
E14 Power turbine speed Pickup No. 1 MS3106-10SL-4S
E15 Power turbine speed Pickup No. 2 MS3106-10SL-4S

D-4
GEK 97310
VOLUME I
ADDENDUM D
Table 1. INSTRUMENTATION CONNECTIONS - 7LM2500PC103B - (Cont.)
A13 Power turbine inlet pressure probe 3/8 inch line to pressure manifold on turbine
(optional) mid-frame AN818-6C or MS20819-6C
F5 Liquid fuel manifold pressure tap 3/8 inch line AN818-6C or MS20819-6C
(optional)
NOTE
gas turbine.
Table 2. SUPPLY CONNECTIONS - 7LM2500PC103B

CAUTION
MAL GROWTH OF GAS GENERATOR WITHOUT PLACING STRAIN ON THE
LINES OR GAS GENERATOR.
F2 Liquid fuel supply 3/4 inch line from fuel control unit to the gas
generator liquid manifold AN818-12C or
MS20819-12C
F4 Liquid fuel manifold shroud drain 1/2 inch line to fuel manifold shroud
AN818-8C or MS20819-8C
L1 Oil Supply 1-1/2 inch line to Lube Pump on Gas Genera-
tor AN818-24C or MS20819-24C
L2 Lube pump discharge 1 inch line from Lube Pump to Oil Supply
Filters AN818-16C of MS20819-16C

D-5
GEK 97310
VOLUME I
ADDENDUM D
Table 2. SUPPLY CONNECTIONS - 7LM2500PC103B - (Cont.)
Generator AN818-16C or MS20819-16C
Pump to Oil Scavenge Filter and Cooler
AN818-20C or MS20819-20C
1.92 inch ID
A16 Discharge spheric or to exhaust duct (flame arrestor)
D1 Exhaust drain, forward 1 inch line to drain under exhaust duct
MS33649-16
D2 Exhaust drain, aft 1 inch line to drain under exhaust duct
MS33649-16
D5 Oil drain, aft 3/8 inch line to drain manifold under TMF
AN818-6C or MS20819-6C
S1 Waterwash manifold 1 inch line - hot water line to waterwash
manifold on Gas Generator Inlet Duct
AN818-16C or MS20819-16C
NOTE
turbine.

D-6
GEK 97310
VOLUME I
ADDENDUM D
8-0 GAS TURBINE OPERATION. WARNING
a. These instructions contain the detailed IF A QUESTIONABLE CONDITION
gas turbine operating procedures and limits EXISTS, DO NOT OPERATE THE
recommended by the General Electric Com- GAS TURBINE UNTIL A THOR-
pany for the 7LM2500PC103B Gas Turbine. OUGH INVESTIGATION HAS
b. The instructions are intended to pro- HOT STARTS, COMPRESSOR
vide operating personnel with the information STALLS, OR OTHER RECOGNIZED
required to operate the gas turbine. They per- PROBLEMS WITHOUT PRIOR
tain to routine and emergency conditions and THOROUGH INVESTIGATION.
procedures. When a fault exists, refer to Chap- FAILURE TO INVESTIGATE
ter IV, TROUBLESHOOTING. THOROUGHLY, AND CORRECT
AS NECESSARY, CAN RESULT IN
c. It is possible that these instructions UNDUE STRESS BEING IMPOSED
may not provide for every possible variation in ON GAS TURBINE COMPONENTS,
equipment or contingency to be met in connec- WITH IMMEDIATE OR SUBSE-
tion with operation of the gas turbine. Refer QUENT DESTRUCTIVE FAILURE
requests for additional information to The OF THE GAS TURBINE AND
General Electric Company, Marine and Indus- INJURY TO PERSONNEL A
trial Projects Department, Cincinnati, Ohio RESULT.
42515.
NOTE OPERATING LIMITS.
The S. I. units shown in this chapter are
direct mathematical conversions and NOTE
may be rounded off in most instances Ratings published in this manual apply
at the users discretion. Examples of to the gas turbine. The driven unit rat-
units that may be rounded off are those ings/limits may be lower in some cases
utilized for temperatures, torque val- cases, and shall take precedence over
ues, pressures, etc. Examples where the gas turbine manual limits.

D-7
GEK 97310
VOLUME I
ADDENDUM D
8-1.1 Performance Ratings. c. Figure 6 defines the maximum liquid
fuel acceleration fuel schedule for the gas gen-
a. The rating of the 7LM2500PC103B
erator.
gas turbines in the new and clean condition
and operating on 100% liquid fuel, in accor- d. The tolerance on the fuel schedules is
dance with MID-TD-0000-2 fuel specification, +4 percent of point. The schedule is plotted
is as follows: against compressor discharge pressure.
Brake Horsepower 27,500
(Continuous)
Inlet Air Temperature 59°F (15°C) tion fuel rates lower than those shown can
Altitude Sea Level result in “hung” starts in the below idle speed
Inlet Losses 0 inch H2O range.
Exhaust Back Pressure 0 inch H2O f. Above the idle speed point, low accel-
eration fuel rates will not harm the gas turbine
Fuel Lower Heating Value 18, 400 Btu/lb times.
Compressor Bleed 0
g. The fuel rates shown on the curve will
Accessory Horsepower 0 give starting times to 5000 rpm idle of 60 to 90
Extraction seconds and accelerations from idle to maxi-
Power Turbine Speed 3600 RPM mum power of 15 seconds.
Heat Rate, Average 6946 Btu/Hp/Hr h. For normal accelerations from idle to
(Continuous) power settings, the changes should be made
Power Turbine Inlet Gas 1430°F(777°C) more slowly to enhance the time between hot
Temperature (Average) at 27,500 BHP section repairs and the life of the gas turbine.
1503°F(817°C) A time of 2 to 3 minutes is reasonable.
at 30,000 BHP
i. The maximum deceleration fuel flow
Fuel, Liquid per GE Speci- rate should consist of a step fuel decrease of
fication MID-TD-0000-2 1500 pph (680 kg/h) ± 10 percent followed by
a rate change of 1330 pph (603 kg/h) ± 10 per-
b. The gas turbine must be started on 100 cent per second at a basepoint fuel flow of
percent liquid fuel. The starting fuel flows for 10,000 pph (4536 kg/h). Fuel flow jump or rate
liquid fuel are: at any other fuel flow shall be the above jump
530 pph (240 kg/h) ± 25 pph (11 kg) at -65°F rate multiplied by the square root of the ratio
(-54°C) Inlet Air Temperature of fuel flow to the basepoint fuel flow. Normal
625 pph (284 kg/h) ± 25 pph (11 kg) at +60°F
should be made in approximately 2 to 3 min-
(16°C) Inlet Air Temperature
utes. This will enhance the time between hot
680 pph (308 kg/h) ± 25 pph (11 kg) at +130°F section repairs and the life of the gas turbine.
(54°C) Inlet Air Temperature

D-8
GEK 97310
VOLUME I
ADDENDUM D

D-9
GEK 97310
VOLUME I
ADDENDUM D

D-10
GEK 97310
VOLUME I
ADDENDUM D

D-11
GEK 97310
VOLUME I
ADDENDUM D
j. The liquid fuel system must be free of Power turbine inlet gas 0-2000°F
periodic or random hunting which result in temperature (T5.4) (-18 to
cycling of gas generator speed or temperature. 1093°C)
shall not be a harmonic of the natural fre-
(0-690 kPa)
natural frequency of these springs is 200 Hz. 8-2.3 Special Instrumentation Required For
Cycling of these parameters will reduce time Monitoring And Troubleshooting:
gas turbine. Fuel manifold pressure 0-1200 psi
8-1.2 Operating Limits. Refer to Table 3. sensor - Liquid fuel (0-8280 kPa)
NOTE Compressor inlet total 10-16 psia
If any operating limit is exceeded, ver-
Power turbine inlet gas 0-75 psia
troubleshooting or inspecting gas gen-
erator. Compressor discharge 0-300 psig
8-2 INITIAL OPERATION. Fuel supply pressure - 0-1200 psig
8-2.1 General. Initial operational period is Liquid fuel (0-8280 kPa)
that period of operation immediately following Fuel supply temperature - 0-250°F
gas turbine replacement, or major maintenance Liquid fuel (-18 to 121°C)
on the system. Gas turbine inlet air 0-150°F
8-2.2 Special Instrumentation Required For temperature (-18 to 66°C)
Operation: Lube oil scavenge pressure 0-100 psig
(0-690 kPa)
Gas Generator speed sensor 0-10,000 RPM Remote reading variable -5° to +45°
Lube oil scavenge tempera- 0-400°F vane indicator
ture sensor (A-, B-, C-, D- (-18 to 204°C) Starter air supply pressure 0-50 psig
sumps and transfer gear- (optional) (0-345 kPa)
box)
Vibration indicator
power turbine 0-10 mil DA
Power turbine speed sensor 0-5000 RPM

D-12
GEK 97310
VOLUME I
ADDENDUM D
8-2.4 Preparation. The gas turbine and asso- l. Gas turbine compressor _________
ciated systems must be inspected and checked rear frame leakage ports,
out for proper installation and operation before struts 7 and 10, open (not
normal operation can commence. capped)
8-2.5 Gas Turbine And Associated Equip- m. Starter serviced per Pack- _________
ment Checklist. Complete the following ager’s manual
checklist.
n. Lube oil storage tank ser- _________
viced to full level
a. Gas Turbine Assembly _________
S/N o. Lube oil supply valves _________
open
b. Mounting base secured to _________
foundation p. All filters serviced per _________
packager’s manual
c. Intake air and exhaust gas _________
ducts in place and secured q. Fire alarm/extinguish sys- _________
tem ON and operative
d. Bonding straps in place _________
and secure r. T5. 4 thermocouple sys- _________
tem functioning properly
e. Gas turbine and exhaust _________
duct support mounts and s. Ignition system operative _________
links in place and secure
t. Compressor inlet total _________
f. All service connections _________ pressure probe aligned
made and secure properly and free of dam-
age
g. All lines flushed, per _________
Packager’s manual u. Variable stator system _________
secure
h. All instrumentation con- _________
nections made and secure v. Required checks and _________
inspections specified in
i. All accessories secured, _________ packager’s manual for gas
per Packager’s manual turbine control have been
j. Gas turbine assembly free _________ performed
of loose objects and all
lines/electrical leads con-
nected
k. Gas turbine inlet air area _________
free of foreign objects.
Inlet screen secure

D-13
GEK 97310
VOLUME I
ADDENDUM D
Normal
Alarm Operating
Type Parameter /Trip Setting Range Remarks
NOTE

Lubrication Gas Turbine Alarm 8 psig ± 1 psig 20 - 60 psig Bypass until 4500
System - Lube Pump (55 kPa ± 6.9 (138 - 413 rpm
Settings and Discharge kPa) below kPa)
(103 kPa ± 6.9
kPa) above 8000
rpm
Trip 6 psig ± 1 psig 20 - 60 psig Bypass until 4500
(41 kPa ± 6.9 (138 - 413 rpm
kPa) kPa)
Gas Turbine Alarm 110 psig ± 10 10 - 100 psig Scavenge Dis-
Scavenge psig (759 kPa ± (69 - 690 kPa) charge Pressure
Discharge 69 kPa) shall not exceed
Pressure 180 psig (1242
kPa)
Gas Turbine Alarm 180° - 220°F 140° - 160°F Normal Operat-
Lube Pump (82° - 105°C) (60° - 71°C) ing Range reflects
operation above
idle speed
Gas Turbine Trip 330° - 350°F 215° - 275°F Normal Operat-
Lube Scav- (166° - 177°C) (102° - 135°C) ing Range reflects
enge Temper- temperature
atures - Five expected during
operation above
idle speed
Alarm 290° - 310°F
(143° - 155°C)

D-14
GEK 97310
VOLUME I
ADDENDUM D
Normal
Alarm Operating
Fuel System Fuel Mani- 150-900 psig Supply Pressure
(Liquid) fold Pressure (1034-6205 as reflected at the
kPa) fuel manifold inlet
on the gas turbine
Fuel Supply 20° to 150°F Starting Fuel Flow
Temperature (-7° to 66°C) Adjustments may
be required to
compensate for
fuel temperature
variation
System ply Pressure (276 kPa) Requirement
based on engine
starter torque
requirements
of Fuel and
Ignition
Application 1700 ± 100 rpm 1700 ± 100 rpm
of Fuel and for start after
Ignition (If purge cycle
purge cycle is
used)
simultaneously
with start initia-
tion
Failure to Trip 380° - 420°F Activate 20 sec-
Light-Off (194° - 216°C) onds time delay
simultaneously
with application
of fuel and igni-
tion

D-15
GEK 97310
VOLUME I
ADDENDUM D
Normal
Alarm Operating
simultaneously
with start initia-
tion. De-energize
ignition, fuel sys-
tem and starter air
supply
(If purge upon completion
cycle is used) of purge. De-ener-
gize fuel and igni-
tion systems and
starter air supply
Power Tur- Failure to Trip 380°- 420°F 0 - 1600°F Trip if tempera-
bine Inlet Light-Off (194° - 216ºC) (0 - 871ºC) ture does not
(T5.4) Tem- reach 400°F
perature (204°C) within 20
(Gas Genera- seconds after fuel
tor Exhaust) and ignition are
(Liquid Fuel) applied
Overtemper-
ature:

D-16
GEK 97310
VOLUME I
ADDENDUM D
Normal
Alarm Operating
Liquid Fuel Trip 1470°F (799°C) 1400° -1460°F Values given are
(760° - 793°C) for installations
Alarm 1460°F (793°C) using constant
T5.4 control as the
power limit.
Installations using
constant power
control mode
should consult the
contract docu-
ments for deter-
mining alarm and
trip settings,
which are unique
to each applica-
tion, but never to
exceed 1616°F
(880°C) (alarm)
and 1625°F
(885°C) (trip)
Vibration Gas Genera- Trip 7 mils ± 1 mil 0-3 mils DA Avoid continuous
tor DA operation above 4
mils
DA
Power Tur- Trip 10 mils ± 1 mil 0 - 6 mils DA Avoid continuous
bine DA operation above 7
mils
DA
Speed Gas Genera- Trip 9950 ± 50 rpm 0 - 9850 rpm
tor
Power Tur- Trip 3960 ± 40 rpm 0 - 3600 rpm
bine
upon loss of flame

D-17
GEK 97310
VOLUME I
ADDENDUM D
8-2.6 Governor And Manual Control Check. • ALLOW THE GAS TURBINE TO
Refer to packager’s manual. COOL DOWN. AVOID CON-
8-2.7 Start-up And Checkout. WEAR THERMALLY INSU-
LATED GLOVES AS
WARNING NECESSARY.
WHEN ENTERING THE GAS TUR- • EAR PROTECTION SHALL BE
BINE ENCLOSURE, THE FOLLOW- WORN IF GAS TURBINE IS
ING REQUIREMENTS SHALL BE OPERATING.
MET:
• THE GAS TURBINE SHALL BE ENCLOSURE OR IN THE
SHUT DOWN. PLANE OF ROTATION OF THE
MOTORING THE GAS
TURBINE.
ENTRY SHOULD BE
a. When entering enclosure at or below
idle speed, wear proper ear protection.
FIELD SERVICE FOR A REPRE- b. Perform prestart checks per Table 4.
TO ENTER THE ENCLOSURE c. Perform ignition checkout per para-
UNDER SUCH CONDITIONS. graph 8-2.8.
SYSTEM SHALL BE MADE d. Perform motoring procedure per para-
INACTIVE ACCORDING TO graph 8-2.9.
THE CUSTOMER’S
e. Perform false start per paragraph
PROCEDURES.
8-2-10.
ENCLOSURE SHALL BE SHUT f. Perform governor check per packer’s
OFF. HIGH SECONDARY AIR- manual.
ING OR CLOSING THE g. Perform a wet prestart per
ENCLOSURE DOOR. paragraph 8-2.11.

AN OBSERVER SHALL BE STA- i. Operate to maximum power per para-
TIONED AT THE ENCLOSURE graph 8-2.13.
ENTRY PROCEDURES SHALL j. Check automatic operation per para-
BE FOLLOWED. graph 8-2.14.

D-18
GEK 97310
VOLUME I
ADDENDUM D
.

Item Requirement
Fuel Valves Closed
Ignition Off
Ventilation Inlet air (secondary cooling air) Off-air temp. below 70°F (21° C)
Ventilation exit air 180ºF (82ºC) max.
Oil tank level Full
Lube oil temperature 140-160ºF
(60-71ºC)
pressure 150-900 psig
(1035 - 6205 kPa)
flow 12,000 pph
(5443 kg/h) max

D-19
GEK 97310
VOLUME I
ADDENDUM D
8-2.8 Ignition Check. 8-2.9 Motoring. After all preliminary checks
generator can be motored as follows:
WARNING
• ASSURE POWER TO IGNITION a. Make ignition and liquid fuel supply
SYSTEMS IS OFF WHEN DIS- systems inoperative as follows:
ING IGNITION EXCITER INPUT (1) Disconnect power supply to igni-
LEAD. TAG SWITCH OUT OF tion unit.
SERVICE TO PRECLUDE INAD-
VERTENT ACTIVATION. (2) Close liquid fuel manual shutoff
CLOSED THROUGHOUT THIS b. Depress MOTORING pushbutton. Gas
PROCEDURE. generator will start to rotate. If it does not,
refer to packager’s manual for supply pressure
a. To clear combustor of any residual to starter.
gas turbine to coast down. c. Hold MOTORING pushbutton closed
b. Disconnect number one ignition exciter for oil pressure. If there is no indication of oil
input lead at exciter. Temporarily secure input pressure, release MOTORING pushbutton;
lead away from exciter. while gas generator is coasting down, loosen
c. Turn on electrical power to the ignition tem. Starter should motor gas generator to
system (No. 2 ignition exciter energized). An minimum of 2200 RPM.
second) should be heard when the No. 2 spark d. Repeat motoring and bleeding proce-
igniter fires. dure until an indication of oil pressure appears.
d. Turn off electrical power to the ignition 8-2.10 False Start. Perform false start as fol-
system. Reconnect input lead to exciter and lows:
e. Repeat steps b, c, and d, disconnecting connected and manual fuel shutoff valve
the No. 2 exciter. closed, make automatic start of gas turbine, per
operator’s manual.
No. 1 and/or No. 2 igniters, check out the sys- b. Gas generator should go through nor-
tem to isolate the problem, and take appropri- mal start cycle and then abort because of lack
ate corrective action. of flame.

D-20
GEK 97310
VOLUME I
ADDENDUM D
8-2.11 Wet Prestart. Perform wet prestart as a. The power turbine must rotate by the
follows: time the gas generator speed reaches 7000 rpm
NGG. If power turbine speed indication is not
a. With supply to ignition unit discon- obtained and it is determined that a “thermal
nected, with the liquid fuel manual shutoff seizure” of the power turbine has occurred,
valve open, and the governing system operat- proceed as follows:
ing, make an automatic start of the gas turbine
per the operator’s manual. NOTE
Thermal seizure of the power turbine
b. Gas generator should accelerate and
rotor can occur when a hot gas turbine
stabilize at a speed dependent on starter inlet
lack of ignition.
the condition where the power turbine
c. Allow gas generator to coast to a stop.
rotor is prevented from rotating by hard
Purge fuel nozzles of liquid fuel with com-
contact between LPT blades and
pressed air at 200 psid (1380 kPa) maximum.
shrouds, interstage seals and other
After wet prestart, drain liquid fuel from fuel
internal interference. This condition is
manifold. Then motor gas generator on starter
for 60 seconds to purge fuel from gas turbine.
8-2.12 Manual Start. Perform manual start The possibility of thermal seizures can
with ignition lead connected and fuel system be reduced by operating the gas turbine
normal, per table 5. at idle power for at least five minutes
prior to shutdown to achieve proper
NOTE cooling of the power turbine.
• Power turbine, except in a new installa-
(1) Shutdown gas turbine.
tion, will be rotating when gas generator
idle speed is attained.
CAUTION
speed (4950 + 50 rpm) for 30 seconds.
DO NOT EXCEED 7000 RPM NGG
OPERATION WITHOUT POWER
TURBINE ROTATION.

D-21
GEK 97310
VOLUME I
ADDENDUM D
(5) Immediately after gas turbine b. Operate gas turbine up to rated power,
rotation stops, re-start and accelerate to 7000 if possible, but do not exceed exhaust gas tem-
rpm NGG maximum and stabilize for 30 sec- perature (T5.4) limit. (See table 3.) Hold at this
onds. If the power turbine still does not rotate, power setting until all temperatures stabilize.
shut down and investigate/correct the cause. If governing system is unstable, adjust per
During the investigation for the cause of a packager’s manual.
thermally seized rotor, inspect the LPT blades
in stages 4, 5 and 6 for shingling and unlatch- c. Log all instrument readings once they
ing. If blades have become unlatched, they stabilize. Refer to Table 5, step 10.
may be relatched. LPT blades that have
encountered shingling may be bent thereby d. Reduce gas generator speed to idle.
necessitating replacement of the power tur- After stabilizing for three minutes, record all
bine. instrument readings. Refer to Table 6, step 2.
8-2.13 Operating To Maximum Power. e. Check fail-safe section of control sys-

CAUTION
MANUAL OPERATION MAY idle for five minutes, make normal shut-down.
ELIMINATE CERTAIN PROTEC- Refer to Table 6, steps 3 and 4.
TIVE CIRCUITS. OPERATING LIM-
ITS SHALL NOT BE EXCEEDED. 8-2.14 Automatic Operation. Check auto-
(Refer to packager’s manual.) to increase gas a. Accelerate to idle.
generator speed. After each 500 RPM increase,
within limits adjust it per WP 118 00 or 119
00. If vibrations are not within limits, consult
the local General Electric Company represen-
tative.

D-22
GEK 97310
VOLUME I
ADDENDUM D
Figure 7. Deleted

D-23
GEK 97310
VOLUME I
ADDENDUM D
Table 5. START-UP OPERATION

1. Assure that prestart

checks are completed
per Table 4
CAUTION
(788°C) FOR LIQUID FUEL, ABORT START.
100% LIQUID FUEL.
• WHEN OPERATING ON 100% LIQUID FUEL IT IS NEC-
ESSARY TO DRAIN THE LIQUID FUEL MANIFOLD
WHEN THE GAS TURBINE IS SHUT DOWN. THE
MAXIMUM TEMPERATURE OF THE FUEL WILL BE
200°F (93°C). REFER TO OPERATOR’S MANUAL FOR
PROCEDURE.
NOTE
A start may be aborted at any time by closing the fuel valve, allowing the gas generator
to motor for 60 seconds, then closing the starter shutoff valve.
2. Open starter shutoff Gas generator rotation Close valve
valve
3. Start cooling air
(if off)
4. At 1100 to 1300 RPM
NGG
a. Ignition on
b. Liquid fuel valve- Fuel manifold pressure 90-
open 150 psig (621-1035 kPa)
(Liquid fuel)
c. Note time to light- 20 seconds max Abort start-automatic
off T5.4 above shutdown
400°F (205°C)

D-24
GEK 97310
VOLUME I
ADDENDUM D
Table 5. START-UP OPERATION - (Cont.)

5. Note time to 4500 ± Troubleshoot system and take
200 RPM corrective action if RPM stops
increasing or if it takes longer
than 90 seconds to reach 4300
RPM (see figure 6)
6. At 4300 to 4500 rpm
NGG
a. Starter shutoff Valve closed

valve closes auto-
matically
7. Note time to 5000
RPM NGG
8. At idle, check the fol-

lowing:
a. Oil pressure See applicable figures in Alarm at 6 psig (41 kPa). Shut
Chapter 5 down if below 6 psig (41 kPa)
b. Fuel manifold Approximately 150 psig Troubleshoot system and take
pressure (1035 kPa) corrective action. See figure 8
Liquid fuel
c. NGG 5000 RPM ± 50 RPM Adjust
d. T5.4 1000° F (538°C) max Emergency shutdown
f. Gas generator 0 to 3 mils DA Alarm if above 4 mils. Auto-

above 7 mils. Troubleshoot and
take corrective action

D-25
GEK 97310
VOLUME I
ADDENDUM D

g. Power turbine 0 to 6 mils DA Alarm if above 7 mils. Auto-
h. Compressor inlet Approximately equal to Normal shutdown
temperature (T2) outside air temperature
i. Check for fuel and

oil leaks
9. Set desired power set- 1450ºF (788ºC) - Liquid Ref. Note 1
ting. Observe T5.4 Trip
during transient oper-
ation
10. After stabilizIng at a
new power setting,
read and record the
following:
a. T5.4 1450ºF (788ºC) max
b. NPT 9400 RPM max (corrected)
c. NPT 3600 RPM max
d. Oil pressure See applicable table and Emergency shutdown if below

figure in Chapter 5 6 psig (41 kPa)
e. Scavenge oil tem- 215-300ºF (102-149ºC) Ref. Note 1. Automatic shut-
perature down if above 340ºF (171ºC)
f. Gas generator 3 mils maximum Ref. Note 1.
vibration 4 mils alarm Emergency shutdown
7 mils trip
g. Power turbine 6 mils max Ref. Note 1.
vibration 7 mils alarm Emergency shutdown
10 mils trip
h. Fuel manifold 150-900 psig (1035-6205 Ref. Note 2
inlet pressure - kPa)
Liquid fuel

D-26
GEK 97310
VOLUME I
ADDENDUM D

i. Fuel inlet 20ºF (11ºC) above wax Ref. Note 2
temperature point of fuel minimum to
Liquid fuel + 150ºF (66ºC) maximum
j. Scavenge oil filter Refer to packager’s manual
∆P
k. Lube oil supply Refer to packager’s manual
filter ∆P
m. VSV Schedule See applicable figure in Correct as required per
WP 118 00 WP 118 00
NOTE 1 Reduce power to stay within limits. If reducing power does not bring parameters
NOTE 2 If all other parameters are normal, correct discrepancy at next opportunity.

D-27
GEK 97310
VOLUME I
ADDENDUM D

D-28
GEK 97310
VOLUME I
ADDENDUM D

Procedure Normal Results
No. Abnormal Results

power
2. After stabilizing for 3
minutes, read and
a. Oil pressure See applicable figure in Automatic normal shutdown if
Chapter 5 below 6 psig (41 kPa)
b. Fuel manifold Approximately 150 psig
pressure Liquid (1035 kPa). See figure 8
fuel
d. T5.4 Approximately 800ºF Troubleshoot system and take

(427ºC) corrective action
e. NPT (unloaded) 1600-1900 RPM Ref. Note 1
f. Gas generator 3 mils max Automatic normal shutdown if

vibration above 7 mils. Troubleshoot
g. Power turbine 6 mils max Automatic normal shutdown if
vibration above 10 mils. Troubleshoot
h. Fuel inlet temper- 20ºF (11ºC) above wax point
ature Liquid fuel of fuel minimum to 150ºF
(66ºC) maximum
i. Scavenge oil fil- Refer to packager’s manual
ter ∆P
j. Lube oil supply Refer to packager’s manual
filter ∆P

D-29
GEK 97310
VOLUME I
ADDENDUM D
Table 6. GAS TURBINE SHUTDOWN - (Cont.)

3. After stabilizing at T5.4 drops below 400ºF Shut off fuel supply
idle for 5 minutes, (205ºC). NGG and NPT
close fuel valves decelerate and stop
4. Observe T5.4 for 3 700ºF (371ºC) max Motor gas turbine and shut off
minutes after shut- fuel supply. Continue motoring
down until temperature decreases

D-30
GEK 97310
VOLUME I
ADDENDUM D

CAUTION
GENCY SHUTDOWN FROM HIGH POWER SETTINGS. SEIZURE OF GAS TUR-
BINE ROTOR MAY OCCUR DUE TO TIGHT CLEARANCES. NORMALLY THE
1. Conditions permit- T5.4 drops below 400º F Manually shut off fuel supply
ting, decelerate gas (204º C) and NGG and NPT
turbine to idle and decelerate
close fuel valves
2. Observe T5.4 for 3 700ºF (371ºC) max Motor gas turbine. Continue
minutes after shut- motoring until temperature
down decreases
3. If an emergency shut-
down from a high
power setting (T5.4)
greater than 1150ºF
(621ºC) has occurred,
and a “hot restart” is
required, proceed as
follows:
a. If the fault detec-
tion and sequenc-
ing system can be
cleared and the
gas turbine can be
restarted within 1
minute following
coastdown of the
HPC rotor, accept-
able restarts can
be made using the
normal starting
procedure.

D-31
GEK 97310
VOLUME I
ADDENDUM D

b. If a “hot restart” is
to be performed
between 1 minute
and 2 hours fol-
lowing the emer-
gency shutdown,
motor the gas tur-
bine at 2000-2500
rpm NGG for 5
minutes. At the
end of the 5
minute motoring/
purge cycle, per-
form normal
restart and accel-
erate to idle.
Acceleration to
the desired power
setting can then be
accomplished.
c. After 2 hours fol-
lowing coastdown
of the HPC rotor,
restart can be
made using the
normal starting
procedure.
b. Accelerate to rated power. g. Check lube oil and fuel filters and
f. After a total of five minutes at idle, tem for loose parts; tighten as necessary.

D-32
GEK 97310
VOLUME I
ADDENDUM D
8-3 NORMAL OPERATION. FLOW MAY PREVENT OPEN-
ING OR CLOSING THE
8-3.1 General. Normal operation is the rou- ENCLOSURE DOOR.
directions in the use of manual or automatic • THE ENCLOSURE DOOR
operation for normal operation, refer to pack- SHALL BE KEPT OPEN. IF THE
ager’s manual. GAS TURBINE IS OPERATING,
8-3.2 Interlocks. Refer to paragraph 2-11.9 TIONED AT THE ENCLOSURE
for description of interlocks which affect gas DOOR AND CONFINED SPACE
turbine operation. ENTRY PROCEDURES SHALL
BE FOLLOWED.
8-3.3 Operation.
WARNING
MET:

SENTATIVE WHO IS TRAINED a. When entering enclosure wear proper
TO ENTER THE ENCLOSURE ear protection.
• THE FIRE EXTINGUISHING Table 5. Do not exceed operating limits of
SYSTEM SHALL BE MADE Table 3.
THE CUSTOMER’S c. Shutdown the gas turbine per Table 6.
PROCEDURES.
• SECONDARY AIR TO THE per Table 7.

D-33
GEK 97310
VOLUME I
ADDENDUM D
e. Refer to paragraph 5-3.30 and 5-3.31,
pressure characteristics. (See tables V-21A,
5-32B, 5-32E, 5-32F, 5-32J, 5-32L, 5-32N,
and 5-32Q.)
8-4 EMERGENCY OPERATION.
8-4.1 Emergency Shutdown.
a. In an emergency, the gas generator may

be shut down from any power setting by clos-
ing the fuel valve. However, this should only
be done in an emergency, since rapid shutdown
will decrease life of gas generator.
b. Emergency shut-down shall be made

per Table 7.
8-4.2 Post Shutdown Fire. During a normal

shutdown, exhaust gas temperature should
decrease. If during time gas generator is coast-
ing to stop, temperature increases instead of
decreases, it indicates that combustion is still
taking place. (A slight temperature increase
after rotation stops is normal.) Make certain
fuel is shut off, and motor the gas generator.
This will blow out the fire. As soon as temper-
ature decreases to normal, discontinue motor-
ing.

D-34
GEK 97310
VOLUME I
ADDENDUM D
Table 8. Deleted

D-35/(D-36 Blank)
GEK 97310
VOLUME I
ADDENDUM E
ADDENDUM
7LM2500PC104

GEK 97310
VOLUME I
ADDENDUM E
TABLE OF CONTENTS
1-0 INTRODUCTION....................................................................................... E-3

2-0 REFERENCE DATA .................................................................................. E-3
3-0 INSTALLATION DRAWINGS.................................................................. E-4
4-0 EQUIPMENT DESCRIPTION ................................................................. E-4
5-0 INSTRUMENTATION AND SUPPLY REQUIREMENTS ................... E-4
6-0 SERVICE REQUIREMENTS ................................................................... E-4
6-1.1 Natural Gas ................................................................................................... E-4
7-0 OPTIONAL HARDWARE KITS, 7LM2500PC104 ................................ E-4
8-0 GAS TURBINE OPERATION .................................................................. E-7
8-1.1 Performance Ratings And Operating Limits................................................. E-7
8-1.2 Performance Ratings ..................................................................................... E-7
8-1.3 Operating Limits ........................................................................................... E-16
8-2 INITIAL OPERATION .............................................................................. E-16
8-2.1 General .......................................................................................................... E-16
8-2.2 Special Instrumentation Required for Operation .......................................... E-16
8-2.3 Special Instrumentation Required for Monitoring and Troubleshooting ...... E-16
8-2.4 Preparation .................................................................................................... E-16
8-2.5 Gas Turbine and Associated Equipment Check List..................................... E-17
8-2.6 Governor and Manual Control Check........................................................... E-18
8-2.7 Start-up and Checkout................................................................................... E-18
8-2.8 Ignition Check............................................................................................... E-19
8-2.9 Motoring........................................................................................................ E-19
8-2.10 False Start...................................................................................................... E-21
8-2.11 Governor Check ............................................................................................ E-21
8-2.12 Wet Prestart ................................................................................................... E-21
8-2.13 Manual Start and Operation. ......................................................................... E-21
8-2.14 Operation to Maximum Power...................................................................... E-22
8-2.15 Automatic Operation..................................................................................... E-22
8-3 NORMAL OPERATION............................................................................ E-28
8-3.1 General .......................................................................................................... E-28
8-3.2 Interlocks....................................................................................................... E-28
8-3.3 Operation....................................................................................................... E-28
8-4 EMERGENCY OPERATION ................................................................... E-29
8-4.1 Emergency Shutdown ................................................................................... E-29
8-4.2 Post Shutdown Fire ....................................................................................... E-29

E-1
GEK 97310
VOLUME I
ADDENDUM E
Figure Title Page
1 Transient Temperature Limits ....................................................................... E-9

2 Deleted
3 Typical Acceleration Fuel Flow Schedule .................................................... E-11
4 Deleted
5 Deleted
6 Deleted
7 Deleted
8 Deleted
9 Deleted
LIST OF TABLES
Table Title Page
1 INSTRUMENTATION CONNECTIONS-7LM2500PC104........................ E-5

2 SUPPLY CONNECTIONS-7LM2500PC104............................................... E-6
3 GAS TURBINE OPERATING LIMITS....................................................... E-12
4 PRESTART CHECKS .................................................................................. E-20
5 START-UP AND OPERATION.................................................................... E-23
6 GAS TURBINE SHUTDOWN .................................................................... E-26
7 EMERGENCY SHUTDOWN...................................................................... E-27
8 DELETED

E-2
GEK 97310
VOLUME I
ADDENDUM E
7LM2500PC104 model gas turbine basic con- Compressor Stator, Front 307(139)
figuration and control system differences. In Compressor Stator, Rear 93(42)
addition, the coverage of reference data, Compressor Rear Frame 421(191)
cial servicing requirements, optional hardware Combustor 120(54)
kits and the complete gas turbine operating High Pressure Turbine Rotor 419(190)
instructions for the 7LM2500PC104 model are High Pressure Turbine Nozzle, 68(31)
included. Stg 1
High Pressure Turbine Nozzle, 127(58)
2-0 REFERENCE DATA.
Stg 2
EQUIPMENT Turbine Mid Frame 530(240)
Low Pressure Turbine Rotor 1095(497)
Gas Turbine Assembly Low Pressure Turbine Stator 601(273)
(General Electric Co.,
Cincinnati, Ohio) Turbine Rear Frame 1071(486)
Model No. 7LM2500PC104 High Speed Coupling Shaft 91(41)
Dwg. No. L24290G01 Forward Adapter
Exhaust Duct Assembly 2741(1243)
PERFORMANCE RATING
Exhaust Duct 1565(710)
Refer to paragraph 8-1.1 Outer Cone 410(186)
Inner Deflector 255(116)
GAS TURBINE WEIGHTS Ring Seal 49(22)
The average weights of the major gas Ring Support 74(34)
turbine components are: Insulation 269(122)
Component Wt-Lbs/(Kg) Variable Stator Actuating 19(9)
Gas turbine - including inlet 7396(3355) Mech
duct, centerbody, exhaust dif- Outside Piping and Bracketing 278(126)
fuser, and coupling nut
diffuser
Gas Generator 4212(1911)
Power Turbine 2777(1260)
Compressor Front Frame 517(235)

E-3
GEK 97310
VOLUME I
ADDENDUM E
DRAWING LIST 6-0 SERVICE REQUIREMENTS.
Drawing No. 6-1.1 Natural Gas.

Gas Turbine Installation L31705 a. The required supply pressure to the
Drawing fuel manifold on the gas turbine is 350 ± 5 psig
Fuel System Flow Diagram L24327 (2413 ± 34 kPa).
Lubrication System Flow L24328
Diagram b. The temperature of the gas must be in
the range of -65° to +150°F (-54° to +66°C). If
Electrical Diagram L24329
the temperature is not repeatable on a day-to-
Ignition Units L21454P02 day basis it will be necessary to change the
Gas Turbine Assembly L24290G01 starting fuel adjustment to adjust the supply
Drawing pressure to the engine to maintain a constant
Btu-per-cubic-foot supply. Once started, the
3-0 INSTALLATION DRAWINGS. engine will accept variations in supply temper-
A complete set of installation drawings have ature of ± 20°F (±11°C). The maximum fuel
been provided. flow required is 13,400 pph (6078 kg/h) with a
The LM2500PC104 is a natural gas fueled, 7-0 OPTIONAL HARDWARE KITS,
marinized gas turbine and is furnished com- 7LM2500PC104.
plete with an exhaust duct and inner diffuser as
standard equipment. a. Refer to Volume II, WP 001 00 for a
5-0 INSTRUMENTATION AND particular gas turbine model.
SUPPLY REQUIREMENTS.
(See Tables 1 and 2).

E-4
GEK 97310
VOLUME I
ADDENDUM E
Table 1. INSTRUMENTATION CONNECTIONS-7LM2500PC104

E1 Vibration pickup, Gas Generator Bell & Howell Electronics
Part No. 173960 or 364450
E13 Vibration pickup, power turbine Bell & Howell Electronics
Part No. 173960 or 364450
A9 Compressor inlet total pressure probe MS33656-6
(optional)
A13 Power turbine inlet pressure probe (optional) AN818-6C or MS20819-6C
A23 CDP pressure port (optional) .500-20UNJF
F3 Natural gas fuel manifold pressure tap MS33656-4
(optional)
L5 Lube supply pressure tap AN818-6C or MS20819-6C
L7 Lube scavenge pressure tap (optional) AN818-4C or MS20819-4C
Remote reading variable stator vane protractor
(optional)
NOTE
gas turbine.

E-5
GEK 97310
VOLUME I
ADDENDUM E
Table 2. SUPPLY CONNECTIONS-7LM2500PC104
CAUTION
ALL LINES MUST BE FLEXIBLE ENOUGH TO ALLOW 3/4 INCH (19MM) THER-
OR ON GAS GENERATOR.
F1 Natural gas supply 2 inch line from Fuel Control Unit to Gas Turbine
Fuel Manifold
L1 Oil supply 1-1/2 inch line to Lube Pump on Gas Turbine AN818-24C or
MS20819-24C
L2 Lube pump discharge 1 inch line from Lube Pump to Oil Supply Filters AN818-16C
or MS20819-16C
L4 Lube supply inlet port 1 inch line from Oil Supply Filters to Gas Turbine AN818-16C
or MS20819-16C
L3 Scavenge oil discharge 1-1/4 inch line from Gas Turbine Scavenge Pump to Oil Scav-
enge Filter and Cooler AN818-20C or MS20819-20C
A2 Bleed air 16th stage compressor bleed air lines if used (1.92 inch ID)
A12 Air/Oil Separator 3 inch line from air/oil separator to atmospheric vent
A16 Discharge or to exhaust duct (flame arrestor)
D1 Exhaust drain, forward MS33649-16
D2 Exhaust drain, aft MS33649-16
S1 Waterwash manifold 1 inch line - hot water line to waterwash manifold on Gas Tur-
bine Inlet Duct AN818-16C or MS20819-16C
NOTE

E-6
GEK 97310
VOLUME I
ADDENDUM E
8-0 GAS TURBINE OPERATION. 8-1.1 Performance Ratings And Operating
Limits.
gas turbine operating procedures and limits NOTE
recommended by the General Electric Ratings published in this manual apply
Company for the 7LM2500PC104 Gas to the gas turbine. The driven unit rat-
Turbine. ings/ limits may be lower in some cases
b. The instructions are intended to turbine manual limits.
provide operating personnel with the informa-
tion required to operate the gas turbine. 8-1.2 Performance Ratings.
They pertain to routine and emergency condi-
tions and procedures. When a fault exists, a. The rated performance of the
refer to Volume I, Chapter IV, 7LM2500PC104 gas turbine in the new and
TROUBLESHOOTING. clean condition is as follows:
c. It is possible that these instructions • Brake Horsepower
equipment or contingency to be met in connec- - Continuous 27,500 BHP
tion with the operation of the gas turbine. - Maximum 30,000 BHP
Refer requests for additional information to the
General Electric Company; Marine and Indus- • Heat Rate, Average
trial Engine Division; Cincinnati, Ohio 45215.
- Continuous 6895 Btu/HP-Hr
WARNING - Maximum 6876 Btu/HP-Hr
IF A QUESTIONABLE CONDITION Based on the following conditions:
EXISTS DO NOT OPERATE THE
GAS TURBINE UNTIL A THOR- Inlet Air Temperature 59°F (15°C)
OUGH INVESTIGATION HAS Altitude Sea Level
BEEN MADE. DO NOT REPEAT Inlet Losses 0” H2O
STALLS, OR OTHER RECOGNIZED Exhaust Losses 0” H2O
PROBLEMS WITHOUT PRIOR Relative Humidity 0%
THOROUGH INVESTIGATION. Compressor Bleed 0
FAILURE TO DO SO CAN RESULT Accessory Power
IN UNDUE STRESS BEING Extraction 0
IMPOSED ON GAS TURBINE COM- Power Turbine Speed 3600 rpm
PONENTS, WITH IMMEDIATE OR Power Turbine Inlet Gas
SUBSEQUENT DESTRUCTIVE Temperature, Average 1408ºF
FAILURE OF THE GAS TURBINE (764ºC) at
AND INJURY TO PERSONNEL. 27,500 BHP
1481ºF
(805ºC) at
30,000 BHP

E-7
GEK 97310
VOLUME I
ADDENDUM E
b. Approximate starting fuel flow require- f. Above the idle speed point, low accel-
ments based on applying fuel and ignition at eration fuel rates will not harm the gas turbine
1200 rpm are: and will only result in slower acceleration
times.
465 pph (211 kg/h) ± 25 pph (11 kg/h)
at -65ºF (-54°C) Inlet Air g. For normal accelerations from idle to
Temperature power settings the changes should be made
550 pph (249 kg/h) ± 25 pph (11 kg/h) more slowly to enhance the time between hot
at +60ºF (16°C) Inlet Air section repairs and the life of the gas turbine; a
Temperature time of 2 to 3 minutes is reasonable.
595 pph (270 kg/h) ± 25 pph (11 kg/h)
at +130ºF (54°C) Inlet Air h. The fuel rates shown on the curve will
Temperature give starting times to 5000 rpm idle of
60 to 90 seconds and accelerations from idle to
c. Typical transient fuel flow require- maximum power of 15 seconds.
ments are shown in Acceleration Fuel Sched-
ule, figure 3. i. The maximum deceleration fuel flow
rate should consist of a step fuel decrease of
d. Deleted 1500 pph (680 hg/h) ± 10 percent followed by
a rate change of 1300 pph (603 kg/h) ± 10 per-
e. Acceleration fuel rates greater than cent per second to idle fuel flow. Rates greater
those shown will result in over-temperature than this can cause the gas turbine to lose fire.
and possible stall of the gas turbine. Accelera- Normal decelerations from maximum power to
tion fuel rates lower than those shown can idle should be made in approximately
result in “hung” starts in the below idle speed 2 to 3 minutes - this will enhance the time
range. between hot section repairs and the life of the
gas turbine.

E-8
GEK 97310
VOLUME I
ADDENDUM E

E-9
GEK 97310
VOLUME I
ADDENDUM E
Figure 2. Deleted

E-10
GEK 97310
VOLUME I
ADDENDUM E
Figure 3. Typical Acceleration Fuel Flow Schedule

E-11
GEK 97310
VOLUME I
ADDENDUM E
Normal
Alarm/ Operating
Type Parameter Trip Setting Range Remarks
NOTE
System - Lube Supply (55 kPa ± 6.9 kPa) (138 - 413 kPa) 4500 rpm
above 8000 rpm
(41 kPa ± 6.9 kPa) (138 - 413 kPa) 4500 rpm
Gas Turbine Alarm 110 psig ± 10 psig 10 - 100 psig Scavenge Dis-
Scavenge (759 kPa ± 69 kPa) (69 - 690 kPa) charge Pressure
Discharge shall not exceed
Lube Supply (82º - 104ºC) (60º - 71ºC) Range reflects tem-
Temperature perature expected
during operation
above idle speed
Lube Scav- (166º - 177ºC) (102º - 135ºC) Range reflects tem-
enge Tempera- perature expected
tures - Five during operation
above idle speed
(143º - 154ºC)
Fuel Fuel Manifold 20-355 psig Supply Pressure as
System Pressure (138-2448 kPa) reflected at the fuel
(Natural manifold inlet on the
Gas) gas turbine

E-12
GEK 97310
VOLUME I
ADDENDUM E
Normal
Alarm/ Operating
Fuel Supply Alarm 150º - 170ºF -65º to 150º F Starting Fuel Flow
Temperature (66º - 77º C) (-54 to 66ºC) Adjustments may be
required to compen-
sate for fuel temper-
ature variation
on engine starter
torque requirements
Fuel and
Ignition
Application of 1700 ± 100 rpm 1700 ± 100 rpm for
Fuel and Igni- start after purge
tion (If purge cycle
cycle is used)
neously with start
initiation
Failure to Trip 380º - 420ºF Activate 20 seconds
Light-Off (193º - 216ºC) time delay simulta-
neously with appli-
cation of fuel and
ignition
neously with start
gize ignition, fuel
system and starter
air supply

E-13
GEK 97310
VOLUME I
ADDENDUM E
Normal
Alarm/ Operating

(If purge cycle completion of purge.
is used) De-energize fuel and
starter air supply
bine Inlet Light-Off (193º - 216ºC) (0 - 871ºC) does not reach 400ºF
(T5.4) (204ºC) within
Tempera- 20 seconds after fuel
ture (Gas and ignition are
Generator applied
Exhaust)
Overtemperature:
Natural Gas Trip 1450ºF (788ºC) 1378º -1438ºF Values given are for
(748º - 781ºC) installations using
Alarm 1438ºF (781ºC)
as the power limit.
Installations using
constant power con-
trol mode should
mining alarm and
are unique to each
application, but
never to exceed
1616ºF (880ºC)
(alarm) and 1625ºF
(885ºC) (trip)
Generator operation above
4 mils

E-14
GEK 97310
VOLUME I
ADDENDUM E
Normal
Alarm/ Operating

Turbine operation above
7 mils
Generator
Turbine
Power Trip 380º
Turbine
upon loss of flame

E-15
GEK 97310
VOLUME I
ADDENDUM E
8-1.3 Operating Limits. Refer to Table 3. 8-2.3 Special Instrumentation Required for
NOTE
If any operating limit is exceeded, ver- Fuel manifold pressure . . . . . . 0-400 psi
ify instrumentation accuracy before sensor (0-2760 kPa)
troubleshooting or inspecting gas Compressor inlet total . . . . . . . 10-16 psia
generator. pressure sensor (69-110 kPa)
Power turbine inlet gas . . . . . . 0-75 psia
8-2 INITIAL OPERATION. pressure (0-517 kPa)
Compressor discharge . . . . . . . 0-300 psig
gas turbine replacement or major maintenance Fuel supply pressure . . . . . . . . 0-400 psig
on the system. (0-2760 kPa)
Fuel supply temperature . . . . . 0-250º F
8-2.2 Special Instrumentation Required for (-18 to 121ºC)
Operation. Gas turbine inlet air . . . . . . . . . 0-150ºF
temperature (-18 to 66ºC)
Gas Generator speed. . . . . . . . 0-10,000
sensor RPM Lube oil scavenge pressure . . . 0-100 psig
(0-690 kPa)
Lube oil scavenge temper- . . . 0-400ºF
ature sensors (A-, B-, (-18 to 204ºC) Remote reading variable . . . . . -5º to +45º
C-, D-sumps and transfer vane indicator
gearbox) Starter air supply pressure . . . . 0-50 psig
Lube oil supply . . . . . . . . . . . . 0- 400ºF (optional) (0-345 kPa)
temperature sensor (-18 to 204ºC)
8-2.4 Preparation. The gas turbine and asso-
gas generator . . . . . . . . . . 0-3 in/sec or
out for proper installation and operation before
0-10 mil DA
normal operation can commence.
power turbine . . . . . . . . . . . 0-3 in/sec or
0-10 mil DA
Power turbine speed sensor . . 0-5000 RPM
Power turbine inlet gas . . . . . . 0-2000ºF
temperature (T5.4) (-18 to
1093ºC)
Lube oil supply pressure. . . . . 0-100 psig
(0-690 kPa)

E-16
GEK 97310
VOLUME I
ADDENDUM E
8-2.5 Gas Turbine and Associated Equip- l. Gas turbine compressor rear
ment Check List. Complete the following frame leakage ports, struts
checklist. 7 and 10, are open (not
capped) _________
a. Gas Turbine Assembly S/N _________ m. Starter is serviced per Pack-
b. Mounting base secured to ager’s manual _________
foundation _________ n. Lube oil storage tank ser-
c. Intake air and exhaust gas viced to full level _________
ducts in place and secured _________ o. Lube oil supply valves open _________
d. Bonding straps in place and p. All filters are serviced per
secure _________ Packager’s manual _________
e. Gas turbine and exhaust q. Fire alarm/extinguish sys-
duct support mounts and tem ON and operative _________
links in place and secure _________
r. T5.4 thermocouple system
f. All service connections
made and secure _________ functioning properly _________
g. All lines have been flushed s. Ignition system operative _________
per Packager’s manual _________ t. Compressor inlet total pres-
h. All instrumentation connec- sure probe aligned properly
tions made and secure _________ and free of damage _________
i. All accessories are secure u. Variable stator system
per Packager’s manual _________ secure _________
j. Gas turbine assembly free v. Required checks and
of loose objects and all inspections specified in
lines/electrical leads Packager’s manual for gas
connected _________ turbine control have been
performed _________
k. Gas turbine inlet air area
free of foreign objects. Inlet
screen secure _________

E-17
GEK 97310
VOLUME I
ADDENDUM E
Refer to Packager’s manual. BE FOLLOWED.
WARNING
WHEN ENTERING THE GAS TUR- LATED GLOVES AS NECES-
BINE ENCLOSURE, THE FOLLOW- SARY.
SHUT DOWN.
ENTRY SHOULD BE MOTORING THE GAS TUR-
REQUIRED DURING ENGINE BINE.
paragraph 8-2.8.
THE CUSTOMER’S PROCE-
DURES.
paragraph 8-2.9.
ENCLOSURE SHALL BE SHUT e. Perform false start per
OFF. HIGH SECONDARY AIR- paragraph 8-2.10.
ING OR CLOSING THE f. Perform governor check per
• THE ENCLOSURE DOOR g. Perform a wet prestart per

AN OBSERVER SHALL BE STA- h. Perform a manual start and operate per

E-18
GEK 97310
VOLUME I
ADDENDUM E
i. Operate to maximum power per e. Repeat steps b, c, and d, disconnecting
paragraph 8-2.14. the No. 2 exciter.
j. Check automatic operation per
No.1 and/or No. 2 igniters, check out the sys-
paragraph 8-2.15.
8-2.8 Ignition Check.
checks have been completed and lines flushed,
WARNING
SYSTEMS IS OFF WHEN DIS- a. Make ignition and natural-gas supply
CONNECTING AND CONNECT- systems inoperative as follows:
VERTENT ACTIVATION. (2) Close natural-gas manual shutoff
PROCEDURE. turbine will start to rotate. If it does not, refer
to packager’s manual for supply pressure to
a. To clear combustor of any residual starter.
lead away from the exciter. while gas turbine is coasting down, loosen oil
fittings at lube pump to bleed air from system.
c. Turn on electrical power to the ignition Starter should motor gas turbine to minimum
system (No. 2 ignition exciter energized). An of 2200 RPM.
audible report (approximately two sparks per d. Repeat motoring and bleeding proce-
second) should be heard when the No. 2 spark dure until an indication of oil pressure appears.
igniter fires.


E-19
GEK 97310
VOLUME I
ADDENDUM E
Item Requirements
Fuel valves Closed
Ignition Off
Ventilation inlet air Off - air temp.
(secondary cooling air) below 70ºF
(21ºC)
Oil tank level Full
Lube oil temperature 140ºF to 160ºF
(60º to 71ºC)
Fuel supply
pressure 350 ± 5 psig
(2413 ± 34 kPa)
temperature -65 to 150ºF
(-54 to 66ºC)
flow 13,400 pph
(6078 kg ph) max

E-20
GEK 97310
VOLUME I
ADDENDUM E
8-2.10 False Start. Perform false start as CAUTION
follows:
a. With ignition leads disconnected and AND 30 SECONDS OF GAS TUR-
manual gas valve closed, make automatic start BINE OPERATION WITHOUT
of gas turbine per packager’s manual. POWER TURBINE ROTATION.
b. Gas turbine should go through normal BINES THAT HAVE TIGHTER LPT
start cycle and then abort because of lack of BLADE TIP CLEARANCES, DO
flame. NOT EXCEED 6000 RPM NGG AND
8-2.11 Governor Check. Check governor 30 SECONDS OF GAS TURBINE
system per packager’s manual. OPERATION WITHOUT POWER
TURBINE ROTATION.
a. The power turbine must rotate by the
follows:
time the gas generator speed reaches 7000 rpm
a. With ignition lead disconnected, but NGG. If power turbine speed indication is not
with manual gas valve open and governing obtained and it is determined that a “thermal
system operating, make automatic start of gas seizure” of the power turbine has occurred,
turbine per packager’s manual. proceed as follows:
b. Gas turbine should accelerate to light- NOTE
off speed (1100 to 1300 rpm). Fuel valve Power Turbine except in a new installa-
should open and fuel manifold pressure should tion will be rotating at gas generator
be approximately 3 psig (21 kPa). Adjust fuel idle speed.
supply if required. Start will then abort
because of lack of flame. NOTE
c. Allow gas turbine to coast to stop; then rotor can occur when a hot gas turbine
motor it to purge any remaining natural gas is shut down and is most likely to occur
from gas turbine. Continue to motor for within 30 to 40 minutes following gas
60 seconds to purge fuel from the gas turbine. turbine operation. Thermal seizure is
8-2.13 Manual Start and Operation. the condition where the power turbine
Perform manual start per packager’s manual rotor is prevented from rotating by hard
with fuel valve open and with ignition lead contact between LPT blades and
connected. Refer to Table 5. shrouds, interstage seals and other
The possibility of thermal seizures can
be reduced by operating the gas turbine
cooling of the power turbine.

E-21
GEK 97310
VOLUME I
ADDENDUM E
(1) Shutdown gas turbine. b. Operate gas turbine up to rated power,
(2) Immediately after the gas turbine perature (T5.4) limit. Hold at this power set-
stops rotating, re-start and stabilize at idle ting until all temperatures stabilize. If
speed (4950 ± 50 rpm) for 30 seconds. governing system is unstable, adjust per pack-
ager’s manual.
(3) Repeat steps (1) and (2) for two
additional start-up and shutdown cycles. c. Log all instrument readings once they
(4) If the power turbine does not
rotate after accomplishing substeps (1) through d. Reduce gas turbine speed to idle. After
(3), shut down the gas turbine. stabilizing for three minutes, record all instru-
ment readings. Refer to Table 6, step 2.
(5) Immediately after gas turbine
rotation stops, re-start and accelerate to e. Check fail-safe section of control sys-
7000 rpm NGG maximum and stabilize for tem per packager’s manual.
rotate, shut down and investigate/correct the f. After gas turbine has been stabilized at
cause. During the investigation for the cause idle for five minutes, make normal shut-down.
of a thermally seized rotor, inspect the LPT Refer to Table 6, steps 3 and 4.
blades in stages 4, 5 and 6 for shingling and
unlatching. If blades have become unlatched, 8-2.15 Automatic Operation. Check auto-
they may be relatched. LPT blades that have matic operation per packager’s manual.
necessitating power turbine replacement. a. Accelerate to idle.
8-2.14 Operation to Maximum Power. b. Accelerate to rated power.

CAUTION
MANUAL OPERATION MAY d. Decelerate to idle.
ELIMINATE CERTAIN PROTEC-
TIVE CIRCUITS. OPERATING LIM- e. Check for fuel or lube oil leaks.
(refer to packager’s manual) to increase gas g. Check lube oil and fuel filters and
generator speed. After each 500 RPM strainers; clean or replace as necessary.
increase, log all instrument readings, paying
particular attention to variable stator vane h. Correct any leaks observed.
position and vibration. If variable stator sys-
tem is not within limits, adjust it per work i. Remove all temporary instrumentation.
packages 118 00. If vibrations are not within
limits, consult the local General Electric Com- j. Check gas turbine and mounting sys-
pany representative. tem for loose parts; tighten as necessary.
E-22
GEK 97310
VOLUME I
ADDENDUM E

1. Assure that prestart checks Automatic shutdown (trip) at 1450ºF
are completed per Table 4 (788ºC). Refer to Table 3.
CAUTION
IF T5.4 RAPIDLY APPROACHES OR EXCEEDS 1438ºF (781ºC), ABORT
START.
NOTE
A start may be aborted at any time by closing fuel valve, allowing gas turbine
to motor for 60 seconds, then closing starter shutoff valve.
2. Open starter shutoff valve GG rotation Close valve
NOTE
If purge cycle is required, NGG in step 3 may be revised.
3. At 1100 to 1300 RPM NGG
a. Ignition on
b. Fuel valve open Fuel manifold pressure
approximately
3 psig (21 kPa)
c. Note time to lightoff 20 seconds max Abort start-automatic shutdown
(T5.4 above
400ºF/204ºC)
1200 RPM
4. Note time to 90 seconds maximum Troubleshoot system and take cor-
4500 ± 200 RPM rective action if RPM stops increas-
ing or it takes longer than 90 sec. to
reach 4300 RPM
5. At 4300 to 4700 RPM NGG
a. Starter shutoff valve, Valve closed Close fuel valve and allow gas tur-
close automatically bine to motor for 60 seconds, then
shutoff starter

E-23
GEK 97310
VOLUME I
ADDENDUM E
6. Note time to 5000 RPM NGG
a. Oil pressure See applicable figures Shutdown if below 6 psig (41 kPa)
in Chapter 5
b. NGG 5000 RPM ± 250 Adjust
RPM
c. T5.4 1000ºF (538ºC) max Emergency shutdown - Table 7
d. NPT (unloaded) 1600-1900 RPM
e. Gas generator 0 to 3 mils DA Alarm set at 4 mils. Automatic nor-
vibration mal shutdown if above 7 mils. Trou-
bleshoot and take corrective action
f. Power turbine 0 to 6 mils DA Alarm set at 7 mils. Automatic nor-
vibration mal shutdown if above 10 mils.
Troubleshoot and take corrective
action
g. Compressor inlet Approximately equal Troubleshoot sensing and indicating
temperature (T2) to outside air system. Correct as required
temperature
h. Check for fuel or oil No leaks allowed Correct as required
leaks
i. Maximum NGG with 7000 RPM NGG maxi- Shut down and investigate/correct
power turbine seizure mum for 30 seconds cause per paragraph 8-2.13
(thermal seizure) (for early model gas
turbines that have
tighter LPT blade tip
clearances, do not
exceed 6000 RPM
NGG and 30 seconds of
gas turbine operation
without power turbine
rotation)
8. Set desired power setting. 1438ºF (781ºC) max Correct as required. Refer to
Observe T5.4 during transient Chapter 5
operation

E-24
GEK 97310
VOLUME I
ADDENDUM E
a. T5.4 1438ºF (781ºC) *
b. NGG 9850 RPM max *
c. NPT 3600 RPM max *
d. Oil pressure See applicable table Emergency or automatic shutdown if
and figure in Chapter 5 5 psig (34 kPa) out of limits
e. Scavenge oil 215º to 275ºF Automatic shutdown if above 340ºF
temperature (102º to 135ºC) (171ºC)
f. Gas generator 3 mils max. *
vibration 4 mils (Alarm) Troubleshoot
7 mils (Trip) Emergency or automatic shutdown
g. Power turbine 7 mils max. (Alarm) *
vibration 10 mils max (Trip) Emergency or automatic shutdown
h. Fuel manifold 350 ± 5 psig **
pressure (2413 ± 35 kPa)
i. Fuel inlet -65 to 150ºF **
temperature (-54 to ± 66ºC)
manual
k. Lube oil supply filter Refer to packager’s
∆P manual
to outside air
temperature
m. Stator vane angle See applicable figure Correct as required per WP 118 00
in WP 118 00
* Reduce power to stay within limits. If reducing power does not bring parameters within
limits, shutdown.
** If all other parameters are normal, correct discrepancy at next opportunity.

E-25
GEK 97310
VOLUME I
ADDENDUM E

(unloaded)
following:
(55 kPa)
b. NGG 4950-5050 RPM Adjust
c. T5.4 1000ºF (538ºC) Troubleshoot and take cor-
rective action
e. Gas generator vibration 3 mils max Alarm set at 4 mils. Auto-
f. Power turbine vibration 6 mils max Alarm set at 7 mils. Auto-
g. Fuel inlet temperature -65 to 150ºF (-54 to 66ºC)
h. Scavenge oil filter ∆P Refer to packager’s manual
i. Lube oil supply filter ∆P Refer to packager’s manual
5 minutes, close fuel valves (204ºC) NGG and NPT decel-
erate and stop
4. Observe T5.4 for 3 minutes 700ºF (371ºC) Motor gas turbine and shut-
decreases

E-26
GEK 97310
VOLUME I
ADDENDUM E
CAUTION
SHUTDOWN FROM HIGH POWER SETTINGS. SEIZURE OF GAS TURBINE
ROTOR MAY OCCUR DUE TO TIGHT CLEARANCES. NORMALLY THE ROTOR
WILL FREE ITSELF AFTER A COOLING PERIOD OF 3 TO 4 HOURS. CHECK
FOR FREEDOM OF ROTATION BY TURNING ROTOR BY HAND.
1. Conditions permitting, decelerate gas T5.4 drops below 400ºF Manually shut off
turbine to idle and close fuel valves (204ºC) and NGG and fuel supply
NPT decelerate
2. Observe T5.4 for 3 minutes after 700ºF (371ºC) max Motor gas turbine.
until temperature
decreases
following coastdown of the HPC
rotor, acceptable restarts can be made
the gas turbine at 2000-2500 rpm
NGG for 5 minutes. At the end of the
5 minute motoring/purge cycle, per-
accomplished.

E-27
GEK 97310
VOLUME I
ADDENDUM E
8-3 NORMAL OPERATION. • SECONDARY AIR TO THE
8-3.1 General. Normal operation is the rou- OFF. HIGH SECONDARY AIR-
tine operation of an installed gas turbine. For FLOW MAY PREVENT OPEN-
directions in the use of manual or automatic ING OR CLOSING THE
operation for normal operation, refer to pack- ENCLOSURE DOOR.
ager’s manual.
8-3.2 Interlocks. Refer to packager’s man- SHALL BE KEPT OPEN. IF THE
ual for description of interlocks which affect GAS TURBINE IS OPERATING,
gas turbine operation. AN OBSERVER SHALL BE STA-
8-3.3 Operation. DOOR AND CONFINED SPACE
BE FOLLOWED.
WARNING
WHEN ENTERING THE GAS TUR- • ALLOW THE GAS TURBINE TO
BINE ENCLOSURE, THE FOLLOW- COOL DOWN. AVOID CON-
ING REQUIREMENTS SHALL BE TACT WITH HOT PARTS, AND
MET: WEAR THERMALLY INSU-
LATED GLOVES AS
• THE GAS TURBINE SHALL BE NECESSARY.
SHUT DOWN.
• ENCLOSURE ENTRY DURING WORN IF GAS TURBINE IS
ENGINE OPERATION IS PRO- OPERATING.
ENTRY SHOULD BE • DO NOT REMAIN IN THE
REQUIRED DURING ENGINE ENCLOSURE OR IN THE
OPERATION, CONTACT GE PLANE OF ROTATION OF THE
FIELD SERVICE FOR A REPRE- STARTER WHEN STARTING OR
SENTATIVE WHO IS TRAINED MOTORING THE GAS
TO ENTER THE ENCLOSURE TURBINE.
• THE FIRE EXTINGUISHING idle speed, wear proper ear protection.
INACTIVE ACCORDING TO b. Start and operate the gas turbine per
THE CUSTOMER’S Table 5. Do not exceed operating limits of
PROCEDURES. Table 3.

E-28
GEK 97310
VOLUME I
ADDENDUM E
c. Shut down the gas turbine per Table 6. 8-4 EMERGENCY OPERATION.
d. Emergency shut down the gas turbine 8-4.1 Emergency Shutdown.

per Table 7.
a. In an emergency, the gas turbine may
e. Refer to paragraph 5-3.30 and 5-3.31, be shut down from any power setting by clos-
for lube correction factors and lube supply ing the fuel valve. However, this should only
pressure characteristics. (See tables V-21A, be done in an emergency, since rapid shutdown
V-21B, V-21E, and V-21F, and figures 5-32A, will decrease life of gas turbine.
5-32B, 5-32E, 5-32F, 5-32J, 5-32L, 5-32N,
and 5-32Q.) b. Emergency shutdown shall be made
per Table 7.
f. Idle lube oil pressure is 29 psig
(200 kPa) maximum after five minutes 8-4.2 Post Shutdown Fire.
stabilization.
g. The corrected operating pressure of the gas temperature should decrease. If during
lube oil shall be per applicable table in time gas turbine is coasting to stop, tempera-
Chapter 5 at standard conditions of 9000 rpm ture increases instead of decreases, it indicates
gas generator speed and 150ºF (66ºC) lube that combustion is still taking place because of
pump discharge temperature. Oil pressure a leaking fuel valve. (A slight temperature
measured at conditions other than standard increase after rotation stops is normal.) Make
shall be corrected to standard conditions using certain fuel is shut off, and motor the gas tur-
applicable table in Chapter 5. bine. This will blow out the fire. As soon as
temperature decreases to normal, discontinue
motoring.

E-29
GEK 97310
VOLUME I
ADDENDUM E
Table 8. Deleted

E-30
GEK 97310
VOLUME I
ADDENDUM

E-31/(E-32 Blank)
GEK 97310
VOLUME I
ADDENDUM F
ADDENDUM
7LM2500PC104A

GEK 97310
VOLUME I
ADDENDUM F
TABLE OF CONTENTS
1-0 INTRODUCTION....................................................................................... F-3

2-0 REFERENCE DATA .................................................................................. F-3
3-0 INSTALLATION DRAWINGS.................................................................. F-4
4-0 EQUIPMENT DESCRIPTION ................................................................. F-4
5-0 GAS TURBINE CONTROL ...................................................................... F-4
5-1 NOX SUPPRESSION SYSTEM (WATER INJECTION SYSTEM) ..... F-4
6-0 INSTRUMENTATION AND SUPPLY REQUIREMENTS ................... F-4
7-0 SERVICE REQUIREMENTS ................................................................... F-12
7-1.1 Natural Gas ................................................................................................... F-12
7-1.2 Liquid Fuel.................................................................................................... F-12
7-1.3 Water Servicing and Pumping Requirements (NOX Suppression)............... F-12
8-0 OPTIONAL HARDWARE KITS - 7LM2500PC104A ............................ F-13
9-0 GAS TURBINE OPERATION .................................................................. F-13
9-1 PERFORMANCE RATINGS AND OPERATING LIMITS .................. F-13
9-1.1 Performance Ratings ..................................................................................... F-13
9-1.1A Water Scheduling Requirements During Operations (Nox Suppression) ..... F-15
9-1.2 Operating Limits ........................................................................................... F-21
9-2 INITIAL OPERATION .............................................................................. F-21
9-2.1 General .......................................................................................................... F-21
9-2.2 Special Instrumentation Required For Operation and Monitoring ............... F-22
9-2.3 Preparation .................................................................................................... F-22
9-2.4 Gas Turbine and Associated Equipment Check List..................................... F-22
9-2.5 Governor and Manual Control Check........................................................... F-28
9-2.6 Start-up and Checkout................................................................................... F-28
9-2.7 Ignition Check............................................................................................... F-29
9-2.8 Motoring........................................................................................................ F-31
9-2.9 False Start...................................................................................................... F-31
9-2.10 Governor Check ............................................................................................ F-31
9-2.11 Wet Prestart ................................................................................................... F-31
9-2.12 Manual Start and Operation .......................................................................... F-31
9-2.13 Operation to Maximum Power...................................................................... F-38
9-2.14 Automatic Operation..................................................................................... F-38
9-3 NORMAL OPERATION............................................................................ F-38
9-3.1 General .......................................................................................................... F-38
9-3.2 Interlocks....................................................................................................... F-38
9-3.3 Operation....................................................................................................... F-41
9-4 EMERGENCY OPERATION ................................................................... F-43
9-4.1 Emergency Shutdown ................................................................................... F-43
9-4.2 Post Shutdown Fire ....................................................................................... F-43

F-1
GEK 97310
VOLUME I
ADDENDUM F
Figure Title Page
1 Transient Temperature Limits ....................................................................... F-5

2 Deleted
3 Acceleration Fuel Flow Schedule ................................................................. F-7
4 Fuel Manifold Pressure vs. Fuel Flow When Operating on Natural Gas ..... F-16
5 Fuel Manifold Pressure vs. Fuel Flow When Operating on Liquid Fuel ...... F-18
6 NOX Suppression - Total Flow vs. Fuel Nozzle Pressure Drop ................... F-19
7 NOX Suppression - Total Flow vs. Fuel Nozzle Pressure Drop ................... F-20
8 Deleted
9 Deleted
10 Deleted
11 Deleted
12 Deleted
13 Deleted
LIST OF TABLES
Table Title Page
1 INSTRUMENTATION CONNECTIONS - 7LM2500PC104A................... F-9

2 SUPPLY CONNECTIONS - 7LM2500PC104A.......................................... F-10
3 GAS TURBINE OPERATING LIMITS....................................................... F-23
4 PRESTART CHECKS .................................................................................. F-30
5 START-UP AND OPERATION.................................................................... F-32
6 GAS TURBINE SHUTDOWN .................................................................... F-39
7 EMERGENCY SHUTDOWN...................................................................... F-42
8 DELETED
9 DELETED
10 DELETED
11 DELETED
12 DELETED
13 DELETED

F-2
GEK 97310
VOLUME I
ADDENDUM F
1-0 INTRODUCTION. Compressor Stator, Front 307(139)
Compressor Stator, Rear 93(42)
7LM2500PC104A model gas turbine basic
configuration and control system differences. Compressor Rear Frame 421(191)
In addition, the coverage of reference data, Combustor 120(54)
instrumentation and supply connections, spe- High Pressure Turbine Rotor 419(190)
cial servicing requirements, optional hardware
instructions for the 7LM2500PC104A model Stg 1 68(31)
are included. High Pressure Turbine Nozzle,
Stg 2 127(58)
2-0 REFERENCE DATA. Turbine Mid Frame 530(240)
EQUIPMENT
Gas Turbine Assembly Turbine Rear Frame 1071(486)
Model No. 7LM2500PC104A Forward Adapter 91(41)
Dwg. No. L24330G01
PERFORMANCE RATING Exhaust Duct 1565(710)
Outer Cone 410(186)
Refer to paragraph 9-1
Inner Deflector 255(116)
GAS TURBINE WEIGHTS Ring Seal 49(22)
Ring Support 74(34)
The average weights of the major engine com- Insulation 269(122)
ponents are:
Component Wt-Lbs/(Kg) Variable Stator Actuating
Mech 19(9)
Gas turbine - including inlet
duct, centerbody, exhaust dif- Outside Piping and Bracketing 278(126)
Exhaust duct without exhaust DRAWING LIST
diffuser 2313(1049)
Drawing No.
Power Turbine 2777(1260) Gas Turbine Installation
Drawing L31705
Lubrication System Flow
Diagram L24328

F-3
GEK 97310
VOLUME I
ADDENDUM F
Drawing No. 5-0 GAS TURBINE CONTROL.
Ignition Units L21454P02 a. The transition from natural gas to liq-

Gas Turbine Assembly uid fuel and vice versa shall be smooth and
Drawing L24330G01 shall not result in abrupt changes in gas gener-
ator speed or temperatures. The rate of change
3-0 INSTALLATION DRAWINGS. from natural gas to liquid fuel or vice versa is a
A complete set of installation drawings have function of the operator’s control system, so
been provided. long as the change in total fuel flow does not
exceed that shown on the maximum accelera-
4-0 EQUIPMENT DESCRIPTION. tion fuel flow curve. (See figure 3.)
The 7LM2500PC104A is a dual - fueled, (nat-
ural gas and liquid fuel), marinized gas turbine 5-1 NOX SUPPRESSION SYSTEM
and is furnished complete with an exhaust duct (WATER INJECTION SYSTEM).
and exhaust inner diffuser as standard equip-
ment. The on-engine mounted duel-fuel sys- a. As an option, the 7LM2500PC104A
tem consists of a natural gas manifold, a liquid gas turbine can be equipped for suppression of
fuel manifold and 30 dual-fuel nozzles. The oxides of nitrogen (NOX) in the gas generator
7LM2500PC104A gas turbine is designed to exhaust gases. This is accomplished by intro-
operate on 100 percent natural gas, 100 per- duction of water into the liquid fuel manifold.
cent liquid fuel or a combination of the two. The LM2500 NOX suppression system has
The minimum fuel flow for each fuel, when been designed to meet the requirements of the
operating on dual fuel, should be selected so U.S.E.P.A. standard for NOX emissions for
that if one fuel is cut off, the gas generator stationary gas turbines and includes a conser-
speed will not decrease below 5000 RPM vative margin for meeting the requirements of
before the governor action restores the gas other, possibly more restrictive, local codes
generator to normal operation. Should the gas where applicable.
turbine be configured with the optional NOX
Suppression equipment, and prior to initiation 6-0 INSTRUMENTATION AND SUP-
of water flow for NOX Suppression, it is rec- PLY REQUIREMENTS. See Tables 1 and 2.
ommended that the gas generator be operating
at a stabilized steady-state condition.

F-4
GEK 97310
VOLUME I
ADDENDUM F

F-5
GEK 97310
VOLUME I
ADDENDUM F
Figure 2. Deleted

F-6
GEK 97310
VOLUME I
ADDENDUM F
Figure 3. Acceleration Fuel Flow Schedule (Sheet 1 of 2)

F-7
GEK 97310
VOLUME I
ADDENDUM F
Figure 3. Acceleration Fuel Flow Schedule (Sheet 2 of 2)

F-8
GEK 97310
VOLUME I
ADDENDUM F
Table 1. INSTRUMENTATION CONNECTIONS - 7LM2500PC104A

or 364450
E6 Accessory gearbox scavenge oil MS3106Rl2S-3S
temperature
or 364450
(optional) mid frame AN818-6C or MS20819-6C
F3 Natural gas fuel manifold pressure tap 1/4 inch line MS 33656-4
(optional)
F5 Fuel manifold Liquid pressure tap 3/8 inch line AN818-6C or MS20819-6C
(optional)

F-9
GEK 97310
VOLUME I
ADDENDUM F
Table 1. INSTRUMENTATION CONNECTIONS - 7LM2500PC104A - (Cont.)

E10 Starter speed switch (optional) MS3100R10-4P
NOTE
gas turbine.
Table 2. SUPPLY CONNECTIONS - 7LM2500PC104A

CAUTION
ALL LINES MUST BE FLEXIBLE ENOUGH TO ALLOW 3/4 INCH (19 MM)
THERMAL GROWTH OF GAS GENERATOR WITHOUT PLACING STRAIN ON
LINES OR ON GAS GENERATOR. IF EXCESSIVE FORCE IS USED TO COM-
PLETE A CONNECTION, LOOSEN ALL CONNECTIONS AND CHECK/ADJUST
ROUTING AS REQUIRED.
F2 Liquid fuel supply 0.750 inch line from fuel control unit to the
gas generator liquid fuel manifold AN818-12C
or MS20819-12C
F4 Liquid fuel manifold shroud drain 1/2 inch line to fuel manifold shroud AN818-
8C or MS20819-8C
L1 Oil Supply 1-1/2 inch line to Lube Pump on Gas Genera-
tor AN818-24C or MS20819-24C
ters AN818-16C or MS20819-16C
L4 Lube supply inlet port 1 inch line from Oil Supply Filters to Gas Gen-
erator AN818-16C or MS20819-16C

F-10
GEK 97310
VOLUME I
ADDENDUM F
Table 2. SUPPLY CONNECTIONS - 7LM2500PC104A - (Cont.)
AN818-20C or MS20819-20C
1.92 inch ID
A12 Air/Oil Separator Discharge Port 3 inch line from air/oil separator to atmo-
A16 Discharge spheric vent or to exhaust duct (flame arrestor)
MS33649-16
MS33649-16
AN818-6C or MS20819-6C
S1 Waterwash manifold 1 inch line - hot water line to waterwash mani-
fold on Gas Generator Inlet Duct AN818-16C
or MS20819-16C
NOTE
turbine.

F-11
GEK 97310
VOLUME I
ADDENDUM F
7-0 SERVICE REQUIREMENTS. b. The fuel temperature supplied to the
gas turbine shall be a minimum of 20ºF
7-1.1 Natural Gas. (-6.7ºC) above the wax point of the fuel and a
maximum of 150ºF (66ºC). The fuel shall be
a. The required supply pressure to the filtered to 20 microns absolute. The maximum
fuel manifold on the gas turbine is 350±5 psig fuel flow required is 13,000 pph with a lower
(2415±35 kPa). heating value of 18,400 Btu/lb.
b. The temperature of the gas must be in 7-1.3 Water Servicing and Pumping Require-
the range of -65º to +150ºF (-54 to +60ºC). If ments (NOX Suppression).
day basis it will be necessary to change the a. The maximum allowable water deliv-
starting fuel adjustment to adjust the supply ery pressure at the manifold connection shall
pressure to the engine to maintain a constant not exceed 1200 psig (8280 kPa). The temper-
Btu-per-cubic-foot supply. Once started, the ature of the water supplied to the manifold
engine will accept variations in supply temper- shall not exceed 180ºF (82ºC) and shall be free
ature of ±20ºF (±11ºC). The maximum fuel of pressure pulsations in the 0 to 300 Hz range.
flow required is 13,400 pph (5443 kg/h) with a The water must be controlled in a manner to
lower heating value of 19,000 Btu/1b. prevent any sudden pressure spikes which
could momentarily displace the fuel. Refer to
7-1.2 Liquid Fuel. applicable gas turbine performance data and
fuel nozzle flow charactistic curve for water
a. The required supply pressure to the pump size determination. Other criteria, such
fuel manifold on the gas turbine is 390±5 psig as calculated gas generator water flow required
(2691±35 kPa). to meet the requirement of the applicable EPA
standard or other local codes, corresponding
fuel flow and the gas generator internal cycle
pressure level may be obtained from the tabu-
lar performance data sheets.

F-12
GEK 97310
VOLUME I
ADDENDUM F
8-0 OPTIONAL HARDWARE KITS - WARNING
7LM2500PC104A.
a. Refer to Volume II, WP 001 00 for a EXISTS, DO NOT OPERATE THE
detailed list of optional kits available for this GAS TURBINE UNTIL A THOR-
particular gas turbine model. OUGH INVESTIGATION HAS
9-0 GAS TURBINE OPERATION. HOT STARTS, COMPRESSOR
a. These instructions contain the detailed PROBLEMS WITHOUT PRIOR
gas turbine operating procedures and limits THOROUGH INVESTIGATION.
recommended by the General Electric Com- FAILURE TO DO SO CAN RESULT
pany for the 7LM2500PC104A Gas Generator. IN UNDUE STRESS BEING
b. The instructions are intended to pro- PONENTS, WITH IMMEDIATE OR
vide operating personnel with the information SUBSEQUENT DESTRUCTIVE
required to operate the gas turbine. They per- FAILURE OF THE GAS TURBINE
tain to routine and emergency conditions and AND INJURY TO PERSONNEL.
procedures. When a fault exists, refer to Vol-
ume I, Chapter 4, TROUBLESHOOTING. 9-1 PERFORMANCE RATINGS AND
OPERATING LIMITS.
NOTE
equipment or contingency to be met in connec- Ratings published in this manual apply
tion with the operation of the gas turbine. to the gas turbine. The driven unit rat-
Refer requests for additional information to the ings/limits may be lower in some cases
General Electric Company; Marine and Indus- and shall take precedence over the gas
trial Engine Division; Cincinnati, Ohio 45215. turbine manual limits.
NOTE
The S.I. units shown in this chapter are a. The rated performance of the
direct mathematical conversions and 7LM2500PC104A gas turbine in the new and
may be rounded off in most instances clean condition as compared to gas turbine
at the users discretion. Examples of performance with water injection, is as
units that may be rounded off are those follows:
utilized for temperatures, torque val- NOTE
S.I. units may not be rounded off are The use of water injection to control
those utilized for drop checks, rigging NOX emissions results in a change in
adjustments, runouts, etc. gas turbine performance. Unless spe-
cifically agreed to in the applicable
contract documents, all performance
guarantees are based upon “dry” opera-
tion with no water injection.

F-13
GEK 97310
VOLUME I
ADDENDUM F
With NOX With NOX

Normal (Dry) Suppression Normal (Dry) Suppression
Brake Horse- 27,500 27,500 Fuel Flow

power - Gas 9996 Lbs/Hr 10072 Lbs/Hr
(4534 kg/h) (4569 kg/h)
Inlet Air 59ºF 59ºF (15ºC)
- Liquid 10399 Lbs/hr 10567 Lbs/Hr
Temperature (15ºC)
(4717 kg/h) (4793 kg/h)
Inlet Losses 0” H2O 0” H2O
NOX Emissions
Exhaust Back 0” H2O 0” H2O (ppm at 15%
Pressure O2)
Relative 60% 60% - Gas 170 109
Humidity
- Liquid 290 108
Compressor 0 Lbs/Sec 0 Lbs/Sec b. The gas turbine is designed to operate
Bleed on 100% natural gas fuel, 100% liquid fuel, or
Accessory 0 0 on combinations of the two with a limit on nat-
Horsepower ural gas/liquid fuel ratios of 10/90 to 90/10.
Extraction The gas turbine can be started on either natural
Power Turbine 3600 RPM 3600 RPM gas or liquid fuel but not on a combination of
Speed the two. The starting fuel flows on natural gas
are:
Heat Rate, Max
- Gas 6907 BTU/ 6959 BTU/ 465 pph (211 kg ph) ± 25 pph (11 kg) @
hp-hr hp-hr -65ºF (-54ºC) Inlet Air Temperature
- Liquid 6958 BTU/ 7070 BTU/
hp-hr hp-hr 550 pph (249 kg ph) ± 25 pph (11 kg) @
Power Turbine +60ºF (16ºC) Inlet Air Temperature
Inlet Gas
Temperature 595 pph (270 kg ph) ± 25 pph (11 kg) @
- Gas 1406ºF 1404ºF +130ºF (54ºC) Inlet Air Temperature
(763ºC) (762ºC)
- Liquid 1427ºF 1402ºF The starting fuel flows on liquid fuel are:
(775ºC) (761ºC)
Water Injection 530 pph (240 kg ph) ± 25 pph (11 kg) @
- Gas 0 Lbs/Hr 1828 Lbs/Hr -65ºF (-54ºC) Inlet Air Temperature
(829 kg/h)
- Liquid 0 Lbs/Hr 3984 Lbs/Hr 625 pph (284 kg ph) ± 25 pph (11 kg) @
(1807 kg/h) +60ºF (16ºC) Inlet Air Temperature
680 pph (308 kg ph) ± 25 pph (11 kg) @

+130ºF (54ºC) Inlet Air Temperature

F-14
GEK 97310
VOLUME I
ADDENDUM F
c. The minimum fuel flow for each fuel, j. The liquid fuel system must be free of
when operating on dual fuel, should be periodic or random hunting which result in
selected so that if one fuel is cut off the gas cycling of gas generator speed or temperature.
generator speed will not decrease below 5000 The frequency of the fuel flow fluctuations
rpm before the governor action restores the shall not be a harmonic of the natural fre-
engine to normal operation. quency of the springs in the fuel nozzles. The
d. Figure 3 defines the maximum fuel Cycling of these parameters will reduce time
acceleration schedule for the gas generator. between hot section repairs and the life of the
When operating on dual fuel, the schedule, liq- engine. The transition from natural gas to liq-
uid or natural gas, which gives the lower fuel uid fuel and vice versa shall be smooth and
rate must be used. shall not result in abrupt changes in gas gener-
ator speed or temperature. The rate of change,
natural gas to liquid fuel or vice versa, must be
another at full power shall not exceed 10 sec-
tion fuel rates lower than those shown can
onds.
result in “hung” starts in the below idle speed
range.
f. Above the idle speed point, low accel- 7LM2500PC104A gas turbine will be a func-
eration fuel rates will not harm the gas turbine tion of the ratio of natural gas fuel and liquid
and will only result in slower acceleration fuel used. The time between repairs of the hot
times. section will also change as a function of the
ratio of the natural gas and liquid fuels used
with the longest times being associated with
give starting times to 5000 rpm idle of 60 to 90
100% natural gas.
9-1.1A Water Scheduling Requirements Dur-
h. For normal accelerations from idle to ing Operations (Nox Suppression). Water
power settings, the changes should be made flow must be scheduled as a function of fuel
more slowly to enhance the time between hot flow and must be shut off during starting and
section repairs and the life of the gas turbine. acceleration to idle. Water flow should be initi-
A time of 2 to 3 minutes is reasonable. ated at a fuel flow of 3000 pph ± 250 pph
(1361 kg/h ± 113 kg/h) on acceleration when
i. The maximum deceleration fuel flow operating with liquid fuel and at 5300 pph
rate should consist of a step fuel decrease of ±450 pph (2404 kg/h ± 204 kg/h) on accelera-
1500 (680 kg/h) ± 10% pph followed by a rate tion when operating on natural gas. Subse-
change of 1330 pph (603 kg/h) ± 10% per sec- quently, the water should be shut off at these
ond to idle fuel flow. Rates greater than this points on a deceleration. During initiation of
can cause the engine to lose fire. Normal water flow, the gas turbine should be operating
decelerations from maximum power to idle at a stabilized steady-state condition. Refer to
should be made in approximately 2 to 3 min- figures 4, 5, 6, and 7 for water/fuel ratios, sup-
utes - this will enhance the time between hot ply pressures and manifold pressure/flow
section repairs and the life of the gas turbine. requirements.

F-15
GEK 97310
VOLUME I
ADDENDUM F
Figure 4. Fuel Manifold Pressure vs. Fuel Flow When Operating on Natural Gas (Sheet 1 of 2)

F-16
GEK 97310
VOLUME I
ADDENDUM F
Figure 4. Fuel Manifold Pressure vs. Fuel Flow When Operating on Natural Gas (Sheet 2 of 2)

F-17
GEK 97310
VOLUME I
ADDENDUM F
Figure 5. Fuel Manifold Pressure vs. Fuel Flow When Operating on Liquid Fuel

F-18
GEK 97310
VOLUME I
ADDENDUM F
Figure 6. NOX Suppression - Total Flow vs. Fuel Nozzle Pressure Drop

F-19
GEK 97310
VOLUME I
ADDENDUM F

F-20
GEK 97310
VOLUME I
ADDENDUM F
a. Water Purity. The water supplied to the NOTE
gas generator must meet the following mini- When water is injected at the flow rates
mum requirements: necessary to meet U.S.E.P.A. require-
ments, the maximum gas generator
• Sodium + Potassium + Lead + Vanadium + corrected speed limit must be reduced
Lithium + Silica = 0.1 ppm maximum. to 9650 RPM. There is no change to
9800 RPM maximum physical speed
• Total ionizable solids, both dissolved and limit.
undissolved shall not exceed 5 ppm maxi-
mum. 9-1.2 Operating Limits. Refer to Table 3.
• PH = 6.5 to 7.5. NOTE
• Water solid contaminants shall not exceed If any operating limit is exceeded, ver-
10 mg per gallon with a maximum contam- ify instrumentation accuracy before
inant size not exceeding 20 microns abso- troubleshooting or inspecting gas gen-
lute. erator.
9-2 INITIAL OPERATION.

on the system.

F-21
GEK 97310
VOLUME I
ADDENDUM F
9-2.2 Special Instrumentation Required For Gas turbine inlet air 0-150ºF
Operation and Monitoring. temperature (-18 to 66ºC )
Gas generator speed sensor 0-10,000 rpm (0-690 kPa)
Lube oil scavenge temperature 0-400ºF Remote reading variable vane -5º to +45º
sensors (A-, B-, C-, D- sumps (-18 to 204ºC) indicator
and transfer gearbox)
Lube oil supply temperature 0-400ºF (optional) (0-345 kPa)
sensor (-18 to 204ºC)
Vibration indicators 9-2.3 Preparation. The gas turbine and asso-
gas generator 0-3 in/sec or ciated systems must be inspected and checked
0-10 mil DA out for proper installation and operation before
power turbine 0-3 in/sec or normal operation can commence.
0-10 mil DA
Power turbine speed sensor 0-5000 rpm 9-2.4 Gas Turbine and Associated Equip-
Power turbine inlet gas 0-2000ºF ment Check List. Complete the following
temperature (T5.4) (-18-1093ºC) check list.

a. Gas Turbine Assembly
(0-690 kPa)
S/N _________
Fuel manifold pressure sensor-
Liquid fuel 0-1200 psi b. Mounting base secured to
(0-8280 kPa) foundation _________
Natural gas 0-400 psi c. Intake air and exhaust gas
(0-2760 kPa) ducts in place and secured _________
Compressor inlet total pres- 10-16 psia
sure sensor (69-110 kPa) d. Bonding straps in place
and secure _________
pressure (0-517.5 kPa) e. Gas turbine and exhaust
Compressor discharge 0-300 psig duct support mounts and
pressure (0-2070 kPa) links in place and secure _________
Fuel supply pressure - f. All service connections
Liquid fuel 0-1200 psig made and secure _________
(0-8280 kPa)
g. All lines have been
Natural gas 0-400 psig
flushed per Packager’s
(0-2760 kPa)
manual _________
Fuel supply temperature -
Liquid fuel 0-250ºF h. All instrumentation con-
(-18 to 121ºC) nections made and secure _________
Natural gas 0-250ºF i. All accessories are secure
(-18 to 121ºC) per Packager’s manual _________

F-22
GEK 97310
VOLUME I
ADDENDUM F
j. Gas turbine assembly free p. All filters are serviced per

of loose objects and all Packager’s manual _________
lines/electrical leads
q. Fire alarm/extinguish sys-
connected _________
tem ON and operative _________
r. T5.4 thermocouple system
functioning properly _________
Inlet screen secure _________
s. Ignition system operative _________
l. Gas turbine compressor
rear frame leakage ports, t. Compressor inlet total
struts 7 and 10, are open pressure probe aligned
(not capped) _________ properly and free of
damage _________
m. Starter is serviced per
Packager’s manual _________ u. Variable stator system
secure _________
n. Lube oil storage tank ser-
viced to full level _________ v. Required checks and
o. Lube oil supply valves
Packager’s manual for gas
open _________
turbine control have been
performed _________
Normal
Alarm/ Operating
NOTE

System - Lube Pump (55 kPa ± 6.9 (138 - 413 rpm
Settings and Discharge kPa) below kPa)
(103 kPa ± 6.9
kPa) above
8000 rpm

F-23
GEK 97310
VOLUME I
ADDENDUM F
Normal
Alarm/ Operating
Trip 6 psig ± 1 psig 20 - 60 psig Bypass until 4500
(41 kPa ± 6.9 (138 - 413 rpm
kPa) kPa)
Gas Turbine Alarm 110 psig ± 10 10 - 100 psig Scavenge Discharge
Scavenge psig (69 - 690 kPa) Pressure shall not ex-
Discharge (759 kPa ± 69 ceed 180 psig
Pressure kPa) (1242 kPa)
Lube Pump (82º - 105ºC) (60º - 71ºC) Range reflects tem-
above idle speed
Lube (166º - 177ºC) (102º - 135ºC) Range reflects tem-
Scavenge perature expected
Tempera- during operation
tures - Five above idle speed
(143º - 154ºC)
Fuel Fuel Mani-
System fold Pressure
Natural Gas 20-390 psig Supply Pressure as
(138-2689 reflected at the fuel
kPa) manifold inlet on the
gas turbine
Liquid Fuel 150-900 psig Supply Pressure as
(1034-6205 reflected at the fuel
kPa) manifold inlet on the
gas turbine
Fuel Supply
Temperature

F-24
GEK 97310
VOLUME I
ADDENDUM F
Normal
Alarm/ Operating
Natural Gas Alarm 150º - 170ºF -65º to 150ºF Starting Fuel Flow
(66º - 77ºC) (-54º to 66°C) Adjustments may be
required to compen-
Liquid Fuel 20ºF (-7ºC)
sate for fuel tempera-
above wax
ture variation
point of fuel to
150ºF (66ºC)
maximum
on engine starter
torque requirements
of Fuel and
Ignition
of Fuel and start after purge cycle
Ignition (If
purge cycle
is used)
Starting Trip 1200 ± 100 rpm Activate 20 seconds
Time to 1200 time delay simulta-
rpm neously with start ini-
tiation
Failure to Trip 380º - 420ºF Activate 20 seconds
Light-Off (193º- 216ºC) time delay simulta-
neously with applica-
tion of fuel and
ignition
Time to 4500 time delay simulta-
rpm neously with start ini-
tiation. De-energize
ignition, fuel system
and starter air supply

F-25
GEK 97310
VOLUME I
ADDENDUM F
Normal
Alarm/ Operating
Time to time delay upon com-
4500 rpm (If pletion of purge. De-
purge cycle energize fuel and
is used) ignition systems and
starter air supply
bine Inlet Light-Off (193º - 216ºC) (-18 - 871ºC) does not reach 400ºF
(T5. 4) (204ºC) within
Tempera- 20 seconds after fuel
ture (Gas and ignition are
Generator applied
Exhaust)
Overtemper-
ature:
Natural Gas Trip 1450ºF (788ºC) 1378º - 1438ºF Values given are for
Alarm 1438ºF (781ºC)
as the power limit.
Liquid Fuel Trip 1470ºF (799ºC) 1400º - 1460ºF Installations using
(760º - 793ºC) constant power con-
Alarm 1460ºF (793ºC) trol mode should con-
sult the contract
mining alarm and trip
settings, which are
unique to each appli-
cation, but never to
exceed 1616ºF
(880ºC) (alarm) and
1625ºF (885ºC) (trip)

F-26
GEK 97310
VOLUME I
ADDENDUM F
Normal
Alarm/ Operating
Vibration Gas Genera- Trip 7 mils ± 1 mil 0-3 mils DA Avoid continuous
tor DA operation above
4 mils
DA
Power Tur- Trip 10 mils ± 1 mil 0 - 6 mils DA Avoid continuous
bine DA operation above
7 mils
DA
Generator
Turbine
upon loss of flame

F-27
GEK 97310
VOLUME I
ADDENDUM F
9-2.5 Governor and Manual Control Check. • THE ENCLOSURE DOOR
Refer to Packager’s manual. SHALL BE KEPT OPEN. IF THE
9-2.6 Start-up and Checkout. AN OBSERVER SHALL BE STA-
WARNING
WHEN ENTERING THE GAS TUR- BE FOLLOWED.
ING REQUIREMENTS SHALL BE • ALLOW THE GAS TURBINE TO
MET: COOL DOWN. AVOID CON-
• THE GAS TURBINE SHALL BE WEAR THERMALLY INSU-
SHUT DOWN. LATED GLOVES AS
NECESSARY.
ENGINE OPERATION IS PRO- • EAR PROTECTION SHALL BE
HIBITED IN GENERAL. IF WORN IF GAS TURBINE IS
ENTRY SHOULD BE OPERATING.
OPERATION, CONTACT GE • DO NOT REMAIN IN THE
FIELD SERVICE FOR A REPRE- ENCLOSURE OR IN THE
SENTATIVE WHO IS TRAINED PLANE OF ROTATION OF THE
TO ENTER THE ENCLOSURE STARTER WHEN STARTING OR
UNDER SUCH CONDITIONS. MOTORING THE GAS
TURBINE.
SYSTEM SHALL BE MADE a. When entering enclosure wear proper
INACTIVE ACCORDING TO ear protection.
DURES. b. Perform prestart checks per Table 4.
• SECONDARY AIR TO THE c. Perform ignition checkout per

ENCLOSURE SHALL BE SHUT paragraph 9-2.7.
FLOW MAY PREVENT OPEN- d. Perform motoring procedure per
ING OR CLOSING THE paragraph 9-2.8.
ENCLOSURE DOOR.
e. Perform false start per paragraph 9-2.9.
f. Perform governor check per

paragraph 9-2.10.

F-28
GEK 97310
VOLUME I
ADDENDUM F
g. Perform a wet prestart per a. To clear combustor of any residual
paragraph 9-2.11. fuel, motor gas turbine for one minute; allow
paragraph 9-2.12. b. Disconnect number one ignition exciter
i. Operate to maximum power per lead away from the exciter.
paragraph 9-2.13.
j. Check automatic operation per system (No. 2 ignition exciter energized). An
paragraph 9-2.14. audible report (approximately two sparks per
9-2.7 Ignition Check. igniter fires.

WARNING
• ASSURE POWER TO IGNITION safety-wire connector.
SYSTEMS ARE OFF WHEN DIS-
CONNECTING AND CONNECT- e. Repeat steps b, c and d, disconnecting
ING IGNITION EXCITER INPUT the No. 2 exciter.
SERVICE TO PRECLUDE INAD- f. If an audible report is not heard on
VERTENT ACTIVATION. No. 1 and/or No. 2 igniters, check out the sys-
• ASSURE FUEL VALVES ARE ate corrective action.
PROCEDURE.

F-29
GEK 97310
VOLUME I
ADDENDUM F
Item Requirements
Fuel valves Closed
Ignition Off
Ventilation inlet air Off-air temp.
(secondary cooling air) below 70ºF
(21ºC)
Ventilation exit air 180ºF (82ºC) max
Oil tank level Full
Lube oil temperature 140º to 160ºF
(60º to 71ºC)
Fuel supply - Natural gas
(2413 ± 35 kPa)
temperature -65° to 150ºF
(-54 to 66ºC)
flow 13,400 pph
(6078 kg/h) max
(2691 ± 35 kPa)
flow 13,000 pph max

F-30
GEK 97310
VOLUME I
ADDENDUM F
9-2.8 Motoring. After all preliminary checks 9-2.10 Governor Check. Check governor sys-
have been completed and lines flushed, gas tem per packager’s manual.
a. Make ignition, liquid fuel, and natural follows:
gas supply systems inoperative as follows:
(1) Disconnect power supply to igni- connected, with either the liquid fuel or the
tion units. natural gas manual shutoff valve closed and
the other valve open, and the governing system
(2) Close liquid fuel and natural gas operating, make an automatic start of the gas
manual shutoff valves to fuel control unit. turbine per the operator’s manual.
b. Depress MOTORING pushbutton. Gas b. Gas generator should accelerate to

generator will start to rotate. If it does not, light-off speed (1100 to 1300 rpm). Fuel valve
refer to packager’s manual for supply pressure should open and fuel manifold pressure should
to starter. be approximately 3 psig (20.7 kPa). Adjust
fuel supply if required. Start will then abort
c. Hold MOTORING pushbutton closed because of lack of flame.
for oil pressure. If there is no indication of oil c. Allow gas generator to coast to a stop.
pressure, release MOTORING pushbutton; Motor it to purge any remaining natural gas
while gas generator is coasting down, loosen from the gas turbine or drain liquid fuel from
oil fittings at lube pump to bleed air from sys- manifold if liquid fuel was used in the wet pre-
tem. Starter should motor gas generator to start. Purge fuel nozzles of liquid fuel with nat-
minimum of 2200 RPM. ural gas or compressed air at 200 psid
(1380 kpa) maximum. Remain on starter for
d. Repeat motoring and bleeding proce- 60 seconds to purge fuel from gas turbine.
dure until an indication of oil pressure appears.
9-2.12 Manual Start and Operation. Perform
9-2.9 False Start. Perform false start as manual start per packager’s manual with fuel
follows: system normal and with ignition lead con-
nected. Refer to Table 5.
connected and manual fuel shutoff valves NOTE
closed, make automatic start of gas turbine per Power turbine, except in a new installa-
operator’s manual. tion, will be rotating when gas genera-
tor idle speed is attained.
of flame.

F-31
GEK 97310
VOLUME I
ADDENDUM F

1. Assure that prestart checks Automatic shutdown at
are completed per Table 4 1450ºF (788ºC) for
natural gas or 1470°F
(799ºC) for liquid fuel.
Refer to Table 3.
CAUTION
(781°C) FOR NATURAL GAS OR 1460°F (793°C) FOR
LIQUID FUEL, ABORT START.
100% NATURAL GAS FUEL, 100% LIQUID FUEL, OR
ON A COMBINATION OF THE TWO. THE GAS TUR-
BINE CAN BE STARTED ON EITHER NATURAL GAS
FUEL OR LIQUID FUEL BUT NOT ON A COMBINA-
TION OF THE TWO. WHEN OPERATING ON BOTH
FUELS, NEITHER THE NATURAL GAS OR LIQUID
FUEL FLOW SHOULD BE LESS THAN THE IDLE FUEL
FLOW; I.E. IF OPERATING ON BOTH FUELS, THE
MINIMUM FLOW TO THE GAS TURBINE WILL BE
LIQUID FUEL IDLE FLOW PLUS NATURAL GAS IDLE
FLOW.
• WHEN OPERATING ON 100% LIQUID FUEL OR A
RATIO OF LIQUID AND NATURAL GAS, IT IS NECES-
SARY TO DRAIN THE LIQUID FUEL MANIFOLD
WHEN THE GAS TURBINE IS SHUT DOWN. THE
MAXIMUM TEMPERATURE OF THE FUEL WILL BE
200°F (94°C). REFER TO OPERATOR’S MANUAL FOR
PROCEDURE.

F-32
GEK 97310
VOLUME I
ADDENDUM F
NOTE
• A start may be aborted at any time by closing the fuel valve,
allowing the gas generator to motor for 60 seconds, then clos-
ing the starter shutoff valve.
• When switching from liquid fuel burning to 100% natural gas
burning, it is necessary to purge and cool the liquid portion of
the fuel nozzles. Either natural gas or compressed air may be
used to purge the fuel nozzles. Refer to the operator’s
manual.
4. At 1100 to 1300 rpm NGG
a. Ignition on
b. Natural gas fuel valve- Fuel manifold pressure
open approx 3 psig (21 kPa)
Liquid fuel valve-closed (natural gas) 90-150 psig
or (621-1035 kPa) (liquid
Natural gas fuel valve- fuel)
closed
Liquid fuel valve-open
[T5.4 above 400ºF (204ºC)] shutdown
5. Note time to 4500 ± 200 rpm 90 seconds maximum Troubleshoot system
and take corrective
action if rpm stops
accelerating or if it takes
longer than 90 seconds
to reach 4300 rpm
6. At 4300 to 4500 rpm NGG
a. Starter shutoff valve closes Valve closed Close fuel valve and
automatically allow gas generator to
motor for 60 sec., then
shut off the starter

F-33
GEK 97310
VOLUME I
ADDENDUM F
a. Oil pressure See applicable figures in Shutdown if below
Chapter 5 6 psig (41 kPa)
b. Fuel manifold pressure Troubleshoot system
and take corrective
action. See figure 4
Natural gas Approx. 25 psig
(173 kPa)
Liquid fuel Approx. 150 psig
(1035 kPa)
d. Maximum NGG with 7000 rpm NGG maximum Shut down and investi-
power turbine seizure for 30 seconds (for early gate/correct cause per
(thermal seizure) model gas turbines that paragraph 9-2.12
have tighter LPT blade tip
clearances, do not exceed
6000 rpm NGG and
30 seconds of gas turbine
operation without power
turbine rotation)
e. T5.4 1000ºF (538ºC) Emergency shutdown
maximum per Table 7
f. NPT (unloaded) 1600 - 1900 rpm
g. Gas generator vibration 0 to 3 mils DA Alarm above 4 mils.
corrective action
h. Power turbine vibration 0 to 6 mils DA Alarm above 7 mils.
corrective action

F-34
GEK 97310
VOLUME I
ADDENDUM F
i. Compressor inlet Approximately equal to Troubleshoot sensing
temperature (T2) outside air temperature and indicating system.
Correct as required
9. Set desired power setting. (Natural gas) 1438ºF Correct as required.
Observe T5.4 during (781ºC) maximum Refer to transient tem-
transient operation (Liquid fuel) 1460ºF perature limits con-
(793ºC) maximum tained in figure 1
a. T5.4 (Natural gas) Ref. Note 1
1378º-1438ºF
(748º-781ºC)
(Liquid fuel)
1400º-1460ºF
(760º-793ºC)
b. NGG 9850 rpm maximum Ref. Note 1
c. NPT 3600 rpm maximum Ref. Note 1
d. Oil pressure See applicable table and Emergency or
figure in Chapter 5 automatic shutdown if
5 psig (3 kPa) out of
limits
e. Scavenge oil temperature 215ºF to 275ºF Automatic shutdown if
(102° to 135ºC) above 340ºF (171ºC)
f. Gas generator vibration 3 mils max. Ref. Note 1. Trouble-
4 mils (Alarm) shoot emergency or
g. Power turbine vibration 7 mils max. (Alarm) Ref. Note 1. Emergency
10 mils max. (Trip) or automatic shutdown

F-35
GEK 97310
VOLUME I
ADDENDUM F
h. Fuel manifold inlet pres-
sure
Natural gas 25-320 psig Ref. Note 2
(173-2208 kPa)
Liquid fuel 150-900 psig Ref. Note 2
(1035-6210 kPa)
i. Fuel inlet temperature
Natural gas -65º to +150ºF Ref. Note 2
(-54° to 66ºC)
Liquid Fuel 20ºF (-7ºC) above wax Ref. Note 2
+150ºF (66ºC) maximum
manual
manual
m. Stator vane angle See applicable figure in Correct as required per
WP 118 00 WP 118 00
NOTE 1. Reduce power to stay within limits. If reducing power does not bring parameters
NOTE 2. If all other parameters are normal, correct discrepancy at next opportunity.

F-36
GEK 97310
VOLUME I
ADDENDUM F
CAUTION (1) Shutdown gas turbine.
DO NOT EXCEED 7000 RPM NGG (2) Immediately after the gas turbine
AND 30 SECONDS OF GAS TUR- stops rotating, re-start and stabilize at idle
BINE OPERATION WITHOUT speed (4950 + 50 rpm) for 30 seconds.
FOR EARLY MODEL GAS TUR- (3) Repeat steps (1) and (2) for two
BINES THAT HAVE TIGHTER LPT additional start-up and shutdown cycles.
NOT EXCEED 6000 RPM NGG AND (4) If the power turbine does not
30 SECONDS OF GAS TURBINE rotate after accomplishing substeps (1) through
OPERATION WITHOUT POWER (3), shut down the gas turbine.
TURBINE ROTATION.
a. The power turbine must rotate by the rotation stops, re-start and accelerate to
time the gas generator speed reaches 7000 rpm 7000 rpm NGG maximum and stabilize for
NGG. If power turbine speed indication is not 30 seconds. If the power turbine still does not
obtained and it is determined that a “thermal rotate, shut down and investigate/correct the
seizure” of the power turbine has occurred, cause. During the investigation for the cause of
proceed as follows: a thermally seized rotor, inspect the LPT
NOTE unlatching. If blades have become unlatched,
Thermal seizure of the power turbine they may be relatched. LPT blades that have
rotor can occur when a hot gas turbine encountered shingling may be bent and must
is shut down and is most likely to occur be replaced accordingly.
turbine operation. Thermal seizure is CAUTION
the condition where the power turbine FOR EARLY MODEL GAS TUR-
rotor is prevented from rotating by hard BINES THAT HAVE TIGHTER LPT
contact between LPT blades and BLADE TIP CLEARANCES, DO
shrouds, interstage seals and other NOT EXCEED 6000 RPM NGG AND
TURBINE ROTATION.

F-37
GEK 97310
VOLUME I
ADDENDUM F
9-2.13 Operation to Maximum Power. 9-2.14 Automatic Operation. Check automatic
operation per packager’s manual.
CAUTION
ITS SHALL NOT BE EXCEEDED. c. Log all instrument readings.
a. Slowly increase manual control setting d. Decelerate to idle.
generator speed. After each 500 rpm increase, e. Check for fuel or lube oil leaks.
attention to variable stator vane position and f. After a total of five minutes at idle,
vibration. If variable stator system is not shut down gas turbine.
within limits, adjust it per WP 118 00. If vibra-
tions are not within limits, consult the local g. Check lube oil and fuel filters and
General Electric Company representative. strainers; clean or replace as necessary.
b. Operate gas turbine up to rated power, h. Correct any leaks observed.
perature (T5.4) limit. Hold at this power setting i. Remove all temporary instrumentation.
system is unstable, adjust per packager’s j. Check gas turbine and mounting sys-
manual. tem for loose parts; tighten as necessary.
c. Log all instrument readings once they 9-3 NORMAL OPERATION.

d. Reduce gas generator speed to idle. tine operation of an installed gas turbine. For
After stabilizing for three minutes, record all directions in the use of manual or automatic
instrument readings. Refer to Table 6, step 2. operation for normal operation, refer to pack-
ager’s manual.
tem per packager’s manual. 9-3.2 Interlocks. Refer to Volume I, Chapter
2 for description of interlocks which affect gas
f. After gas turbine has been stabilized at turbine operation.

F-38
GEK 97310
VOLUME I
ADDENDUM F
. .

(unloaded)
following:
(55 kPa)
b. Fuel manifold pressure Troubleshoot system
and take corrective
action
Natural gas Approx. 25 psig
d. T5.4 1000ºF (538ºC) max. Troubleshoot system
and take corrective
action
f. Gas generator vibration 3 mils max Alarm above 4 mils.
corrective action
g. Power turbine vibration 6 mils max Alarm above 7 mils.
corrective action
h. Fuel inlet temperature

F-39
GEK 97310
VOLUME I
ADDENDUM F
Table 6. GAS TURBINE SHUTDOWN - (Cont.)

Natural gas -65º to + 150ºF
(-54º to +66º C)
Liquid fuel 20ºF (-7ºC) above wax
i. Scavenge oil filter ∆P Refer to packager’s
manual
j. Lube oil supply filter ∆P Refer to packager’s
manual
3. After stabilizing at idle for 5 T5.4 drops below 400ºF Shut off fuel supply
minutes, close fuel valves (204ºC) NGG and NPT
decelerate and stop
4. Observe T5.4 for 3 minutes 700ºF (371ºC) max Motor gas turbine and

F-40
GEK 97310
VOLUME I
ADDENDUM F
9-3.3 Operation. ENTRY PROCEDURES SHALL
BE FOLLOWED.
WARNING
WHEN ENTERING THE GAS TUR- COOL DOWN. AVOID CON-
BINE ENCLOSURE, THE FOLLOW- TACT WITH HOT PARTS, AND
ING REQUIREMENTS SHALL BE WEAR THERMALLY INSU-
MET: LATED GLOVES AS
NECESSARY.
SHUT DOWN. • EAR PROTECTION SHALL BE
• ENCLOSURE ENTRY DURING OPERATING.
HIBITED IN GENERAL. IF • DO NOT REMAIN IN THE
ENTRY SHOULD BE ENCLOSURE OR IN THE
REQUIRED DURING ENGINE PLANE OF ROTATION OF THE
OPERATION, CONTACT GE STARTER WHEN STARTING OR
FIELD SERVICE FOR A REPRE- MOTORING THE GAS
SENTATIVE WHO IS TRAINED TURBINE.
UNDER SUCH CONDITIONS. a. When entering enclosure at or below
SYSTEM SHALL BE MADE b. Start and operate the gas turbine per
INACTIVE ACCORDING TO Table 5. Do not exceed operating limits of
THE CUSTOMER’S PROCE- Table 3.
DURES.
c. Shut down the gas turbine per Table 6.
NOTE
FLOW MAY PREVENT OPEN- During normal shut down with Nox
ING OR CLOSING THE suppression being used, closure of the
ENCLOSURE DOOR. fuel valve should be delayed after
water is shut off to allow purging of
• THE ENCLOSURE DOOR water from the fuel manifold.
GAS TURBINE IS OPERATING, d. Emergency shut down the gas turbine
AN OBSERVER SHALL BE STA- per Table 7.

F-41
GEK 97310
VOLUME I
ADDENDUM F
CAUTION
ROTOR MAY OCCUR DUE TO TIGHT CLEARANCES. NORMALLY THE
CHECK FOR FREEDOM OF ROTATION BY TURNING BY HAND.
1. Conditions permitting, decelerate gas T5.4 drops below 400ºF Manually shut off fuel
turbine to idle and close fuel valves (204ºC) and NGG and supply
NPT decelerate
2. Observe T5.4 for 3 minutes after shut- 700ºF (371ºC) max Motor gas turbine.
down Continue motoring until
power setting (T5.4) greater than 1150ºF
(621ºC) has occurred, and a “hot
restart” is required, proceed as follows:
system can be cleared and the gas
turbine can be restarted within 1
minute following coastdown of the
HPC rotor, acceptable restarts can be
made using the normal starting
procedure.
between 1 minute and 2 hours fol-
lowing the emergency shutdown,
motor the gas turbine at
2000-2500 rpm NGG for 5 minutes.
At the end of the 5 minute motoring/
purge cycle, perform normal restart
and accelerate to idle. Acceleration
to the desired power setting can then
be accomplished.

F-42
GEK 97310
VOLUME I
ADDENDUM F
e. Refer to paragraph 5-3.30 and 5-3.31, 9-4 EMERGENCY OPERATION.
pressure characteristics. (See tables V-21A, 9-4.1 Emergency Shutdown.
5-32B, 5-32E, 5-32F, 5-32J, 5-32L, 5-32N, a. In an emergency, the gas generator may
and 5-32Q.) be shut down from any power setting by clos-
ing the gas and/or liquid fuel valve. However,
f. Idle lube oil pressure is 29 psig this should only be done in an emergency,
(200.1 kPa) maximum after five minutes since rapid shutdown will decrease life of gas
stabilization. generator.
g. The corrected operating pressure of the b. Emergency shut-down shall be made

5 at standard conditions of 9000 RPM gas gen-
erator speed and 150ºF (65.6ºC) at lube pump c. If an emergency shutdown must be ini-
at conditions other than standard shall be cor- on-line, the water and fuel valves can be shut
h. Prior to initiation of water flow for start-up.
NOTE gas temperature should decrease. If during
Refer to figures 3 through 5 for fuel time gas generator is coasting to stop, tempera-
system requirements when operating ture increases instead of decreases, it indicates
on natural gas, liquid fuel or a combi- that combustion is still taking place because of
nation of the two. Refer to figures 6 a leaking fuel valve. (A slight temperature
and 7 when operating with NOX increase after rotation stops is normal.) Make
suppression. certain fuel is shut off, and motor the gas gen-
erator. This will blow out the fire. As soon as
motoring.
.

F-43
GEK 97310
VOLUME I
ADDENDUM F
TABLE 8. Deleted

F-44
GEK 97310
VOLUME I
ADDENDUM F
Figures 8 through figure 13. Deleted

F-45/(F-46 Blank)
GEK 97310
VOLUME I
ADDENDUM G
ADDENDUM
7LM2500PC104B

GEK 97310
VOLUME I
ADDENDUM G
TABLE OF CONTENTS
1-0 INTRODUCTION....................................................................................... G-3

2-0 REFERENCE DATA .................................................................................. G-3
3-0 INSTALLATION DRAWINGS.................................................................. G-4
4-0 EQUIPMENT DESCRIPTION ................................................................. G-4
5-0 NOX SUPPRESSION (WATER INJECTION SYSTEM)....................... G-4
6-0 INSTRUMENTATION AND SUPPLY REQUIREMENTS ................... G-4
7-0 SERVICE REQUIREMENTS ................................................................... G-9
7-1.1 Natural Gas ................................................................................................... G-9
7-1.2 Water Servicing and Pumping Requirements (NOX Suppression)............... G-9
8-0 OPTIONAL HARDWARE KITS - 7LM2500PC104B ............................ G-9
9-0 GAS TURBINE OPERATION .................................................................. G-9
9-1 PERFORMANCE RATINGS AND OPERATING LIMITS .................. G-10
9-1.1 Performance Ratings ..................................................................................... G-11
9-1.2 Water Scheduling Requirements During Operations (NOX Suppression) ... G-11
9-1.3 Operating Limits ........................................................................................... G-11
9-2 INITIAL OPERATION .............................................................................. G-19
9-2.1 General .......................................................................................................... G-19
9-2.2 Special Instrumentation Required for Operation .......................................... G-19
9-2.3 Special Instrumentation Required for Monitoring and Troubleshooting ...... G-19
9-2.4 Preparation .................................................................................................... G-19
9-2.5 Gas Turbine and Associated Equipment Check List..................................... G-20
9-2.6 Governor and Manual Control Check........................................................... G-21
9-2.7 Start-Up and Checkout.................................................................................. G-21
9-2.8 Ignition Check............................................................................................... G-23
9-2.9 Motoring........................................................................................................ G-23
9-2.10 False Start...................................................................................................... G-23
9-2.11 Governor Check ............................................................................................ G-23
9-2.12 Wet Prestart ................................................................................................... G-24
9-2.13 Manual Start and Operation .......................................................................... G-24
9-2.14 Operation to Maximum Power...................................................................... G-33
9-1.15 Automatic Operation..................................................................................... G-33
9-3 NORMAL OPERATION............................................................................ G-35
9-3.1 General .......................................................................................................... G-35
9-3.2 Interlocks....................................................................................................... G-35
9-3.3 Operation....................................................................................................... G-35
9-4 EMERGENCY OPERATION ................................................................... G-36
9-4.1 Emergency Shutdown ................................................................................... G-36
9-4.2 Post Shutdown Fire ....................................................................................... G-36

G-1
GEK 97310
VOLUME I
ADDENDUM G
Figure Title Page
1 Water/Fuel Ratio Requirement When Operating on Natural Fuel........................... G-5

2 Water Pressure at Fuel Manifold Inlet - Natural Gas Fuel, ISO Conditions............ G-6
3 Fuel Manifold Pressure and Flow Requirements With NOX Suppresion -
Natural Gas Fuel ...................................................................................................... G-12
4 Deleted
5 Deleted
6 Transient Temperature Limits .................................................................................. G-18
7 Deleted
8 Typical Acceleration Fuel Flow Schedule ............................................................... G-31
LIST OF TABLES
Table Title Page
1 INSTRUMENTATION CONNECTIONS - 7LM2500PC104B ................... G-7

2 SUPPLY CONNECTIONS - 7LM2500PC104B .......................................... G-8
3 GAS TURBINE OPERATING LIMITS....................................................... G-13
4 PRESTART CHECKS .................................................................................. G-22
5 START-UP AND OPERATION.................................................................... G-25
6 GAS TURBINE SHUTDOWN .................................................................... G-29
7 EMERGENCY SHUTDOWN...................................................................... G-32
8 DELETED

G-2
GEK 97310
VOLUME I
ADDENDUM G
1-0 INTRODUCTION. GAS TURBINE WEIGHTS
7LM2500PC104B model gas turbine basic The average weights of the major gas
configuration and control system differences. turbine components are:
In addition, the coverage of reference data,
instrumentation and supply connections, spe- Wt-Lbs/
Component
cial servicing requirements, optional hardware (Kg)
Gas Turbine - including inlet
instructions for the 7LM2500PC104B model
are included.
NOTE Gas Generator 4212(1911)
The 7LM2500PC104B gas turbine Power Turbine 2777(1260)
requires a natural gas manifold and Inlet Gearbox 38(17)
30 natural gas fuel nozzles as standard Transfer Gearbox 245(111)
equipment when operating on natural
gas fuel. This configuration is replaced
on PC104B models that employ the Compressor Rotor 552(250)
optional NOX suppression system with Compressor Stator, Front 307(139)
a configuration 1 or 2 liquid fuel mani- Compressor Stator, Rear 93(42)
fold, a natural gas manifold and 30
dual fuel nozzles. Consult Illustrated Compressor Rear Frame 421(191)
Parts Breakdown GEK 50336 for the Combustor 120(54)
appropriate configuration of the gas High Pressure Turbine Rotor 419(190)
turbine model selected.
High Pressure Turbine Nozzle,
Stage-1 68(31)
2-0 REFERENCE DATA.
EQUIPMENT Stage-2 127(58)
Gas Turbine Assembly Low Pressure Turbine Rotor 1095(497)
(General Electric Co., Cincinnati, Ohio)
Model No. 7LM2500PC104B Low Pressure Turbine Stator 601(273)
Dwg. No. L24290G02 Turbine Rear Frame 1071(486)
High Speed Coupling Shaft
PERFORMANCE RATING Forward Adapter 91(41)
Variable Stator Actuating Mech 19(9)
Refer to paragraph 9-1.1.

G-3
GEK 97310
VOLUME I
ADDENDUM G
DRAWING LIST 4-0 EQUIPMENT DESCRIPTION.
The 7LM2500PC104B is a natural gas fired,
Drawing No. marinized gas turbine. An exhaust duct is not
furnished as standard equipment however, the
Gas Turbine Installation Dwg. L31705 gas turbine is provided with an exhaust duct
Fuel System Flow Diagram L24327 inner diffuser. Figures 1 and 2 depict a dual
fuel system configuration used with the
Lubrication System Flow Dia. L24328 optional NOX Suppression system.
Ignition Units L21454P02 5-0 NOX SUPPRESSION (WATER
INJECTION SYSTEM).
Gas Turbine Assembly Dwg. L24290
a. As an option, the 7LM2500PC104B
3-0 INSTALLATION DRAWINGS. gas turbine can be equipped for suppression of
A complete set of installation drawings have oxides of nitrogen (NOX) in the gas generator
been provided. exhaust gases. This is accomplished by intro-
duction of water into the liquid fuel manifold.
The LM2500 NOX suppression system has
been designed to meet the requirements of the
U.S.E.P.A. standard for NOX emissions for
stationary gas turbines and include a conserva-
tive margin for meeting the requirements of
other, possibly more restrictive, local codes
where applicable.
6-0 INSTRUMENTATION AND

See tables 1 and 2.

G-4
GEK 97310
VOLUME I
ADDENDUM G
Figure 1. Water/Fuel Ratio Requirement When Operating on Natural Fuel

G-5
GEK 97310
VOLUME I
ADDENDUM G
Figure 2. Water Pressure at Fuel Manifold Inlet - Natural Gas Fuel, ISO Conditions

G-6
GEK 97310
VOLUME I
ADDENDUM G

E1 Vibration pickup, Gas Generator Bell & Howell Electronics Part No.
173960 or 364450
E18 D-sump scavenge oil temperature MS3106R12D-3S
E13 Vibration pickup, power turbine Bell & Howell Electronics Part No.
173960 or 364450
F3 Natural gas fuel manifold pressure tap (optional) MS33656-4
-- Remote reading variable stator vane protractor
(optional)
NOTE
For all other instrumentation connections, refer to Installation Drawings provided with gas
turbine.

G-7
GEK 97310
VOLUME I
ADDENDUM G

CAUTION
ON GAS GENERATOR.
F1 Natural gas supply 2 inch line from Fuel Control Unit to Gas Generator Fuel
Manifold
L1 Oil supply 1-1/2 inch line to Lube Pump on Gas Generator
AN818-24C or MS20819-24C
AN818-16C or MS20819-16C
AN818-16C or MS20819-16C
L3 Scavenge oil discharge 1-1/4 inch line from Gas Generator Scavenge Pump to Oil
Scavenge Filter and Cooler AN818-20C or MS20819-20C
A4 Inlet duct seal (If required)
A10 CDP seal leakage No. 1 (If required) 2-inch line
A12 Air/Oil separator 3 inch line from air/oil separator to atmospheric vent or to
exhaust duct (flame arrestor)
S1 Waterwash manifold 1 inch line - hot water line to waterwash manifold on Gas
Generator Inlet Duct AN818-16C or MS20819-16C
NOTE
turbine.

G-8
GEK 97310
VOLUME I
ADDENDUM G
7-0 SERVICE REQUIREMENTS. 8-0 OPTIONAL HARDWARE KITS -
7LM2500PC104B.
7-1.1 Natural Gas.
Item Kit PN Nomenclature Qty.
a. The required supply pressure to the
fuel manifold on the gas turbine is 1 537L333 Kit, On-Engine 1
315-325 psig (2174-2243 kPa) Mounted Hardware
b. The temperature of the gas must be in 2 537L334 Kit, Off-Engine 1

the range of -65º to +150ºF (-54º to +66ºC). If Mounted Hardware
the temperature is not repeatable on a 3 537L365G02 Thermocouple 1
day-to-day basis it will be necessary to change
the starting fuel adjustment to adjust the sup-
NOTE
ply pressure to the engine to maintain a con-
stant Btu-per-cubic-foot supply. Once started, Optional hardware kits, 537L333 and
the engine will accept variations in supply 537L334 contain numerous items and
temperature of ± 20ºF (±11ºC). The maximum the specific kit requirements for initial
fuel flow required is 13,400 pph gas turbine installation vary for each
(6078 kg/h) with a lower heating value of gas turbine model. Refer to Illustrated
19,000 Btu/lb. Parts Breakdown GEK 50336 to obtain
the correct optional hardware kit part
7-1.2 Water Servicing and Pumping Require- number for the particular gas turbine
ments (NOX Suppression). model purchased.
a. The maximum allowable water deliv- 9-0 GAS TURBINE OPERATION.

ery pressure at the manifold connection shall
not exceed 1200 psig (8274 kPa). The temper- a. These instructions contain the gas tur-
ature of the water supplied to the manifold bine operating procedures and limits recom-
shall not exceed 180°F and shall be free of mended by the General Electric Company for
pressure pulsations in the 0 to 300 Hz range. the 7LM2500PC104B Gas Turbine.
The water must be controlled in a manner to
prevent any sudden pressure spikes which b. The instructions are intended to pro-
could momentarily displace the fuel. Refer to vide operating personnel with the information
applicable gas turbine performance data and required to operate the gas turbine. They per-
fuel nozzle flow characteristic curve for water tain to routine and emergency conditions and
pump size determination. Other criteria, such procedures. When a fault exists, refer to Vol-
as calculated gas generator water flow required ume I, Chapter IV, TROUBLESHOOTING.
to meet the requirement of the applicable EPA c. It is possible that these instructions
standard or other local codes, corresponding may not provide for every possible variation in
fuel flow and the gas generator internal cycle equipment or contingency to be met in connec-
pressure level may be obtained from the tabu- tion with the operation of the gas turbine.
lar performance data sheets. Refer requests for additional information to the

G-9
GEK 97310
VOLUME I
ADDENDUM G
WARNING Normal With NOX

(Dry) Suppression
EXISTS, DO NOT OPERATE THE NOTE
GAS TURBINE UNTIL A THOR- The use of water injection to control NOX
OUGH INVESTIGATION HAS emissions results in a change in gas turbine
BEEN MADE. DO NOT REPEAT performance. Unless specifically agreed to
HOT STARTS, COMPRESSOR in the applicable contract documents, all
STALLS, OR OTHER RECOGNIZED performance guarantees are based upon
PROBLEMS WITHOUT PRIOR “dry” operation with no water injection.
THOROUGH INVESTIGATION. Brake 27,500 27,500
FAILURE TO DO SO CAN RESULT Horsepower
IN UNDUE STRESS BEING Inlet Air 59ºF 59ºF
IMPOSED ON GAS TURBINE COM- Temperature (15ºC) (15ºC)
SUBSEQUENT DESTRUCTIVE
FAILURE OF THE GAS TURBINE Exhaust Back 0” H2O 0” H2O
AND INJURY TO PERSONNEL. Pressure
Relative 60% 60%
NOTE Humidity
The S.I. units shown in this chapter are Altitude 0 Ft. 0 Ft.
direct mathematical conversions and Compressor 0 Lbs/Sec 0 Lbs/Sec
may be rounded off in most instances Bleed
at the users discretion. Examples of Accessory 0 0
units that may be rounded off are those Horsepower
utilized for temperatures, torque val- Extraction
ues, pressures, etc. Examples where Power Turbine 3600 RPM 3600 RPM
S.I. units may not be rounded off are Speed
those utilized for drop checks, rigging Heat Rate, Max 6907 BTU/ 6959 BTU/
adjustments, runouts, etc. hp-hr hp-hr
9-1 PERFORMANCE RATINGS AND Power Turbine 1406ºF 1404ºF
OPERATING LIMITS. Inlet Gas (763ºC) (762ºC)
Temperature
NOTE
Water 0 Lbs/Hr 1828 Lbs/Hr
Ratings published in this manual apply Injection (829 kg/hr)
Fuel Flow 9996 Lbs/Hr 10072 Lbs/Hr
ings/limits may be lower in some cases
(4525 kg/hr (4569 kg/hr
turbine manual limits. NOX Emis- 170 *109
sions (ppm at
15% O2)
*Limit is per US-EPA and is based upon
27,500 BHP at 4-1 ISO or standard day
conditions.

G-10
GEK 97310
VOLUME I
ADDENDUM G
9-1.1 Performance Ratings. can cause the engine to lose fire. Normal
a. The rated performance of the should be made in approximately 2 to 3 min-
7LM2500PC104B gas turbine in the new and utes - this will enhance the time between hot
clean condition as compared to gas turbine section repairs and the life of the engine.
performance with water injection, is as
follows: 9-1.2 Water Scheduling Requirements Dur-
ing Operations (NOX Suppression).
b. Approximate starting fuel flow require-
ments based on applying fuel and ignition at a. Water flow must be scheduled as a
1200 rpm are: function of fuel flow and must be shut off dur-
ing starting and acceleration to idle. Water
465 pph (211 kg/h) ± 25 pph (11 kg) @ flow should be initiated at a fuel flow of
-65ºF (-54ºC) Inlet Air Temperature 5300 pph ± 450 pph on acceleration when
550 pph (250 kg/h) ± 25 pph (11 kg) @ operating on natural gas. Subsequently, the
+60ºF (16ºC) Inlet Air Temperature water should be shut off at these points on a
deceleration. During initiation of water flow,
595 pph (270 kg/h) ± 25 pph (11 kg) @ +130ºF the gas turbine should be operating at a stabi-
(54ºC) Inlet Air Temperature lized steady-state condition. Refer to figures
1, 2, and 3 for water/fuel ratios, supply pres-
c. The tolerance on the fuel schedules is
sures and manifold pressure/flow require-
+4% of point. The schedule is plotted against ments.
compressor discharge pressure.
NOTE
d. Acceleration fuel rates greater than
those shown will result in over-temperature When water is injected at the flow rates
and possible stall of the engine. Acceleration necessary to meet U.S.E.P.A. require-
fuel rates lower than those shown can result in ments, the maximum gas generator
“hung” starts in the below idle speed range. corrected speed limit must be reduced
to 9650 RPM. There is no change to
e. Above the idle speed point, low accel- 9800 RPM maximum physical speed
eration fuel rates will not harm the engine and limit.
will only result in slower acceleration times.
9-1.3 Operating Limits. Refer to
f. For normal accelerations from idle to table 3.
power settings the changes should be made
more slowly to enhance the time between hot NOTE
section repairs and the life of the engine; a If any operating limit is exceeded, ver-
time of 2 to 3 minutes is reasonable. ify instrumentation accuracy before
g. The fuel rate shown on the curve will troubleshooting or inspecting gas
give starting times to 5000 rpm (idle) of generator.
maximum power of 15 seconds.
h. The maximum deceleration fuel flow
1500 (680.4 kg ph) ± 10% pph followed by a
rate change of 1330 pph (604 kg ph) ± 10% per
second to idle fuel flow. Rates greater than this

G-11
GEK 97310
VOLUME I
ADDENDUM G
Figure 3. Fuel Manifold Pressure and Flow Requirements With

NOX Suppresion - Natural Gas Fuel

G-12
GEK 97310
VOLUME I
ADDENDUM G
Normal
Alarm/ Operating
NOTE
System - Lube Pump (55 kpa ± 6.9 kPa) (138 - 413 kPa) 4500 rpm
Ranges (103 kpa ± 6.9 kPa)
above 8000 rpm
(41 kpa ± 6.9 kPa) (138 - 413 kPa) 4500 rpm
Scavenge (759 kpa ± 69 kPa) (69 - 690 kPa) charge Pressure
Lube Pump (82º - 104ºC) (60º - 71ºC) Range reflects
operation above
idle speed
Lube (166º - 177ºC) (102º - 135ºC) Range reflects tem-
Scavenge perature expected
Tempera- during operation
tures - Five above idle speed
(143º - 154ºC)

G-13
GEK 97310
VOLUME I
ADDENDUM G
Normal
Alarm/ Operating
Fuel Fuel 20-355 psig Supply Pressure as
System Manifold (138-2448 kPa) reflected at the fuel
(Natural Pressure manifold inlet on
Gas) the gas turbine
Fuel Supply Alarm 150º - 170ºF 65º to 150ºF Starting Fuel Flow
Temperature (66º - 77ºC) (-54º to 66ºC) Adjustments may
be required to com-
pensate for fuel
temperature
variation
Starting Starter 40 psig Starting Pressure
System Supply (276 kPa) Requirement based
Pressure on gas generator
starter torque
requirements
of Fuel and
Ignition
Ignition (If cycle
purge cycle
is used)
Time to time delay simulta-
1200 rpm neously with start
initiation
Failure to Trip 380º- 420ºF Activate 20 seconds
Light-Off (193º- 216ºC) time delay simulta-
neously with appli-
cation of fuel and
ignition

G-14
GEK 97310
VOLUME I
ADDENDUM G
Normal
Alarm/ Operating
Time to time delay simulta-
gize ignition, fuel
system and starter
air supply
Time to 4500 time delay upon
rpm (If purge completion of
fuel and ignition
systems and starter
air supply
Power Failure to Trip 380º - 420ºF 0 -1600ºF Trip if temperature
Turbine Light-Off (193º - 216ºC) (-18º - 871ºC) does not reach
Inlet (T5.4) 400ºF (204ºC)
Tempera- within 20 seconds
ture (Gas after fuel and igni-
Generator tion are applied
Exhaust)

G-15
GEK 97310
VOLUME I
ADDENDUM G
Normal
Alarm/ Operating
Overtemperature:
Natural Gas Trip 1450ºF (788ºC) 1378º - 1438ºF Values given are for
Alarm 1438ºF (781ºC) constant T5.4 con-
trol as the power
limit. Installations
using constant
power control mode
should consult the
contract documents
for determining
alarm and trip set-
tings, which are
unique to each
application, but
never to exceed
1616ºF (880ºC)
(alarm) and 1625ºF
(885ºC) (trip)
4 mils
mils
Generator
Turbine
upon loss of flame

G-16
GEK 97310
VOLUME I
ADDENDUM G
Figures 4. and 5. Deleted

G-17
GEK 97310
VOLUME I
ADDENDUM G

G-18
GEK 97310
VOLUME I
ADDENDUM G
that period of operation immediately following Fuel manifold pressure .......... 0-400 psi
gas turbine replacement or major maintenance sensor (0-2760 kPa)
on the system. Compressor inlet total............ 10-16 psia
Operation. Power turbine inlet gas .......... 0-75 psia
Gas generator speed Compressor discharge............ 0-300 psig
sensor ................................... 0-10,000 rpm pressure (0-2070 kPa)
Lube oil scavenge .................. 0-400ºF Fuel supply ............................ 0-400 psig
temperature sensors (-18 to 204ºC) pressure (0-2760 kPa)
(A-, B-, C-, D-sumps and Fuel supply ............................ 0-250ºF
transfer gearbox) temperature (-18 to 121ºC)
Lube oil supply temperature Gas turbine inlet air ............... 0-150ºF
sensor .................................. 0-400ºF temperature (-18 to 66ºC)
(-18 to 204ºC) Lube oil scavenge .................. 0-100 psig
Vibration indicators gas pressure (0-690 kPa)
generator ............................ 0-3 in/sec or Remote reading variable........ -5º to +45º
0-10 mil DA vane indicator
power turbine....................... 0-3 in/sec or Starter air supply pressure ..... 0-50 psig
0-10 mil DA (optional) (0-345 kPa)
Power turbine speed
sensor ................................... 0-5000 rpm 9-2.4 Preparation. The gas turbine and asso-
Power turbine inlet gas ciated systems must be inspected and checked
temperature (T5.4) ............... 0-2000ºF out for proper installation and operation before
(-18 to 1093ºC) normal operation can commence.
Lube oil supply
pressure................................ 0-100 psig
(0-690 kPa)

G-19
GEK 97310
VOLUME I
ADDENDUM G
9-2.5 Gas Turbine and Associated Equip- m. Starter is serviced per _____
ment Check List. Complete the following Packager’s manual
check list.
n. Lube oil storage tank serviced _____
a. Gas Turbine Assembly _____ to full level
S/N
o. Lube oil supply valves open _____
b. Mounting base secured to _____
foundation p. All filters are serviced per _____
Packager’s manual
c. Intake air and exhaust gas _____
ducts in place and secured q. Fire alarm/extinguish system _____
ON and operative
d. Bonding straps in place _____
and secure r. T5.4 thermocouple system _____
functioning properly
e. Gas turbine and exhaust duct _____
support mounts and links in s. Ignition system operative _____
place and secure
t. Compressor inlet total _____
f. All service connections made _____ pressure probe aligned
and secure properly and free of damage
g. All lines have been flushed per _____ u. Variable stator system secure _____
Packager’s manual
v. Required checks and _____
h. All instrumentation connections _____ inspections specified in
made and secure Packager’s manual for gas turbine
control have been performed
i. All accessories are secure per _____
Packager’s manual
j. Gas turbine assembly free of _____

electrical leads connected
k. Gas turbine inlet air area free _____

secure
l. Gas turbine compressor rear _____

and 10, are open (not capped)

G-20
GEK 97310
VOLUME I
ADDENDUM G
9-2.6 Governor and Manual Control Check. • ALLOW THE GAS TURBINE TO
Refer to Packager’s manual. COOL DOWN. AVOID CON-
9-2.7 Start-Up and Checkout. WEAR THERMALLY INSU-
LATED GLOVES AS NECES-
WARNING SARY.
MET:
MOTORING THE GAS TUR-
BINE.
ENTRY SHOULD BE a. When entering enclosure wear proper
REQUIRED DURING ENGINE ear protection.
TO ENTER THE ENCLOSURE c. Perform ignition checkout per
UNDER SUCH CONDITIONS. paragraph 9-2.8.
• THE FIRE EXTINGUISHING d. Perform motoring procedure per
SYSTEM SHALL BE MADE paragraph 9-2.9.
THE CUSTOMER’S PROCE- e. Perform false start per
DURES. paragraph 9-2.10.
• SECONDARY AIR TO THE f. Perform governor check per
FLOW MAY PREVENT OPEN- g. Perform a wet prestart per
ENCLOSURE DOOR.
• THE ENCLOSURE DOOR paragraph 9-2.13.
GAS TURBINE IS OPERATING, i. Operate to maximum power per
AN OBSERVER SHALL BE STA- paragraph 9-2.14.
DOOR AND CONFINED SPACE j. Check automatic operation per
ENTRY PROCEDURES SHALL paragraph 9-2.15.
BE FOLLOWED.
G-21
GEK 97310
VOLUME I
ADDENDUM G
Item Requirement
Fuel valves Closed
Ignition Off
Ventilation inlet air (secondary cooling air) Off - air temp. below 70ºF (21ºC)
Oil tank level Full
(60º to 71ºC)
Fuel supply
(2413 ± 35 kPa)
(-54º to 66ºC)
flow 13,400 pph
(6078 kg ph) max

G-22
GEK 97310
VOLUME I
ADDENDUM G
9-2.8 Ignition Check. 9-2.9 Motoring. After all preliminary
WARNING
• ASSURE POWER TO IGNITION a. Make ignition and natural-gas supply
SYSTEMS ARE OFF WHEN DIS- systems inoperative as follows:
CLOSED THROUGH OUT THIS b. Depress MOTORING pushbutton. Gas
lead away from the exciter. while gas generator is coasting down, loosen
d. Turn off electrical power to the ignition 9-2.10 False Start. Perform false start as fol-
system. Reconnect input lead to exciter and lows:
a. With ignition leads disconnected and
e. Repeat steps b, c and d, disconnecting manual gas valve closed, make automatic start
the No. 2 exciter. of gas turbine per packager’s manual.
f. If an audible report is not heard on b. Gas generator should go through nor-

No. 1 and/or No. 2 igniters, check out the sys- mal start cycle and then abort because of lack
tem to isolate the problem, and take appropri- of flame.
9-2.11 Governor Check. Check governor
system per packager’s manual.

G-23
GEK 97310
VOLUME I
ADDENDUM G
a. With ignition lead disconnected, but obtained and it is determined that a “thermal
with manual gas valve open and governing seizure” of the power turbine has occurred,
system operating, make automatic start of gas proceed as follows:
generator per packager’s manual.
NOTE
b. Gas generator should accelerate to
should open and fuel manifold pressure should
be approximately 3 psig (21 kPa). Adjust fuel
because of lack of flame.
c. Allow gas generator to coast to stop;
then motor it to purge any remaining natural
gas from gas generator. Continue to motor for
60 seconds to purge fuel from the gas turbine.
9-2.13 Manual Start and Operation. Per-
form manual start per packager’s manual with
be reduced by operating gas turbine at
fuel valve open and with ignition lead con-
idle power for at least five minutes
NOTE cooling of the power turbine.
tion, will be rotating when gas genera- (1) Shutdown gas turbine.
CAUTION stops rotating, re-start and stabilize at idle
speed (4950 ± 50 rpm) for 30 seconds.
TURBINE ROTATION.

G-24
GEK 97310
VOLUME I
ADDENDUM G
(5) Immediately after gas turbine CAUTION
rotation stops, re-start and accelerate to 7000
rpm NGG maximum and stabilize for 30 sec- FOR EARLY MODEL GAS TUR-
BINES THAT HAVE TIGHTER LPT
onds. If the power turbine still does not rotate,
shut down and investigate/correct the cause.
During the investigation for the cause of a
thermally seized rotor, inspect the LPT blades 30 SECONDS OF GAS TURBINE
in stages 4, 5 and 6 for shingling and unlatch- OPERATION WITHOUT POWER
ing. If blades have become unlatched, they TURBINE ROTATION.
may be relatched. LPT blades that have
turbine.

1. Assure that prestart checks Automatic shutdown (trip)

are completed per Table 4 at 1450ºF (788ºC). Refer to
Table 3
CAUTION
IF T5.4 RAPIDLY APPROACHES OR EXCEEDS 1438ºF (781ºC), ABORT START.
NOTE
A start may be aborted at any time by closing fuel valve, allowing gas generator to motor
for 60 seconds, then closing starter shutoff valve.
NOTE
3. At 1100 to 1300 rpm NGG
a. Ignition on
approximately 3 psig
c. Note time to lightoff 20 seconds max. Abort start-automatic
(T5.4 above 400ºF shutdown
204ºC) 1200 rpm

G-25
GEK 97310
VOLUME I
ADDENDUM G

4. Note time to 4500 ± 200 rpm 90 seconds max. Troubleshoot system and
stops accelerating or it takes
longer than 90 sec. to reach
4300 rpm
5. At 4300 to 4700 rpm NGG
a. Starter shutoff valve, Valve closed Close fuel valve and allow
close automatically gas generator to motor for
60 seconds, then shutoff
starter
7. At idle check the following:

a. Oil pressure See applicable figures in Shutdown if below 6 psig
Chapter 5 (41 kPa)
b. Maximum NGG with 7000 rpm NGG maximum Shut down and investigate/
power turbine seizure for 30 seconds (for early correct cause per
(thermal seizure) model gas turbines that have paragraph 8-2.13
tighter LPT blade tip clear-
ances, do not exceed 6000
rpm NGG and 30 seconds of
gas turbine operation with-
out power turbine rotation)
d. T5.4 1000ºF (538ºC) max. Emergency shutdown

Table 7
f. Gas generator vibration 0 to 3 mils DA Alarm at 4 mils. Automatic

normal shutdown if above 7
mils. Troubleshoot and take
corrective action

G-26
GEK 97310
VOLUME I
ADDENDUM G

g. Power turbine vibration 0 to 6 mils DA Alarm at 7 mils. Automatic

normal shutdown if above
10 mils. Troubleshoot and
h. Compressor inlet tem- Approximately equal to out- Normal shutdown
perature (T2) side air temperature
i. Check for fuel or oil No leaks allowed Correct as required
leaks
8. Set desired power setting. 1438ºF (781ºC) max. Correct as required. Refer
Observe T5.4 during tran- to figure 6
sient operation
a. T5.4 1438ºF (781ºC) *
b. NGG 9850 rpm max. *
c. NPT 3600 rpm max. *
d. Oil pressure See applicable table and Emergency or automatic

figure in Chapter 5 shutdown if below 6 psig
(41 kPa)
e. Scavenge oil 215ºF to 275ºF Automatic shutdown if
temperature (102º to 135ºC) above 340ºF (171ºC)
f. Gas generator Vibration 3 mils max *
4 mils (alarm) Troubleshoot
7 mils (trip) Emergency or automatic
shutdown
g. Power turbine vibration 7 mils max (alarm) Emergency or automatic
10 mils max (trip) shutdown
h. Fuel manifold pressure 350 ± 5 psig **
(2413 ± 35 kPa)

G-27
GEK 97310
VOLUME I
ADDENDUM G

i. Fuel inlet temperature -65º to 150ºF **

(-54º to +66ºC)
l. T2 Approximately equal to out- **
side air temperature
WP 118 00 WP 118 00
* Reduce power to stay within limits. If reducing power does not bring parameters within lim-
its, shutdown.

G-28
GEK 97310
VOLUME I
ADDENDUM G


power (unloaded)
following:
a. Oil pressure See applicable figure in Automatic normal shutdown
Chapter 5 if below 8 psig (55 kPa)
b. NGG 4950-5050 rpm Adjust
c. T5.4 1000ºF (538ºC) max. Troubleshoot and take correc-

tive action
d. NPT (unloaded) 1600-1900 rpm
e. Gas generator vibration 3 mils max. Alarm at 4 mils. Automatic

corrective action
f. Power turbine vibration 6 mils max. Alarm at 7 mils. Automatic
corrective action
g. Fuel inlet temperature -65º to 150ºF (-54 to 66ºC)
i. Lube oil supply filter Refer to packager’s manual
∆P
erate and stop
4. Observe T5.4 for 3 minutes 700ºF (371ºC) Motor gas turbine and shutoff
after shutdown fuel supply. Continue motor-
ing until temperature
decreases

G-29
GEK 97310
VOLUME I
ADDENDUM G
Figure 7. Deleted

G-30
GEK 97310
VOLUME I
ADDENDUM G

G-31
GEK 97310
VOLUME I
ADDENDUM G

CAUTION
1. Conditions permitting, decelerate gas tur- T5.4 drops below 400ºF Manually shut off
bine to idle and close fuel valves (204ºC) and NGG and fuel supply
NPT decelerate
2. Observe T5.4 for 3 minutes after shutdown 700ºF (371ºC) max. Motor gas turbine.
Continue motoring
until temperature
decreases
(621ºC) has occurred, and a “hot restart” is
required, proceed as follows:
turbine at 2000-2500 rpm NGG for 5
minutes. At the end of the 5 minute
motoring/purge cycle, perform normal
restart and accelerate to idle. Accelera-
tion to the desired power setting can
then be accomplished.

G-32
GEK 97310
VOLUME I
ADDENDUM G
9-2.14 Operation to Maximum Power. e. Check fail-safe section of control sys-
CAUTION
MANUAL OPERATION MAY idle for five minutes, make normal shut-down.
TIVE CIRCUITS. OPERATING
LIMITS SHALL NOT BE 9-1.15 Automatic Operation. Check auto-
EXCEEDED. matic operation per packager’s manual.
a. Slowly increase manual control setting a. Accelerate to idle.
generator speed. After each 500 rpm increase, b. Accelerate to rated power.
attention to variable stator vane position and c. Log all instrument readings.
within limits, adjust it per WP 118 00. If d. Decelerate to idle.
local General Electric Company e. Check for fuel or lube oil leaks.
representative.
b. Operate gas turbine up to rated power, shut down gas turbine.
perature (T5.4) limit. Hold at this power set- g. Check lube oil and fuel filters and
ting until all temperatures stabilize. If strainers; clean or replace as necessary.
governing system is unstable, adjust per pack-
ager’s manual. h. Correct any leaks observed.
c. Log all instrument readings once they i. Remove all temporary instrumentation.
d. Reduce gas generator speed to idle. tem for loose parts; tighten as necessary.

G-33
GEK 97310
VOLUME I
ADDENDUM G
Table 8. DELETED

G-34
GEK 97310
VOLUME I
ADDENDUM G
9-3 NORMAL OPERATION. • THE ENCLOSURE DOOR
9-3.1 General. Normal operation is the rou- GAS TURBINE IS OPERATING,
tine operation of an installed gas turbine. For AN OBSERVER SHALL BE STA-
directions in the use of manual or automatic TIONED AT THE ENCLOSURE
operation for normal operation, refer to pack- DOOR AND CONFINED SPACE
ager’s manual. ENTRY PROCEDURES SHALL
9-3.2 Interlocks. Refer to packager’s man- BE FOLLOWED.
ual for description of interlocks which affect • ALLOW THE GAS TURBINE TO
gas turbine operation. COOL DOWN. AVOID CON-
9-3.3 Operation. TACT WITH HOT PARTS, AND
WARNING SARY.
OPERATING.
MET:
ENCLOSURE OR IN THE
SHUT DOWN.
• ENCLOSURE ENTRY DURING STARTER WHEN STARTING OR
ENGINE OPERATION IS PRO- MOTORING THE GAS TUR-
HIBITED IN GENERAL. IF BINE.
ENTRY SHOULD BE
REQUIRED DURING ENGINE a. When entering enclosure wear proper
OPERATION, CONTACT GE ear protection.
SENTATIVE WHO IS TRAINED b. Start and operate the gas turbine per
TO ENTER THE ENCLOSURE Table 5. Do not exceed operating limits of
UNDER SUCH CONDITIONS. Table 3.
INACTIVE ACCORDING TO NOTE
THE CUSTOMER’S PROCE- During normal shut down with NOX
DURES. suppression being used, closure of the
• SECONDARY AIR TO THE fuel valve should be delayed after
ENCLOSURE SHALL BE SHUT water is shut off to allow purging of
OFF. HIGH SECONDARY AIR- water from the fuel manifold.
ING OR CLOSING THE d. Emergency shut down the gas turbine
ENCLOSURE DOOR. per Table 7.

G-35
GEK 97310
VOLUME I
ADDENDUM G
e. Refer to paragraph 5-3.30 and 5-3.31, b. Emergency shut-down shall be made
for lube correction factors and lube supply per Table 7.
V-21B, V-21E, and V-21F, and figures 5-32A, c. If an emergency shutdown must be ini-
5-32B, 5-32E, 5-32F, 5-32J, 5-32L, 5-32N, tiated while operating with NOX suppression
and 5-32Q.) on-line, the water and fuel valve can be shut
off simultaneously. Action must be taken to
f. Idle lube oil pressure is 29 PSIG maxi- purge the water from the fuel manifold at the
mum after five minutes stabilization. earliest opportunity and prior to the next start-
up.
g. The operating pressure of the lube oil
shall be 40 to 50 PSIG at standard conditions 9-4.2 Post Shutdown Fire.
of 9000 RPM gas generator speed and 150°F at
lube pump discharge temperature. Oil pressure a. During a normal shutdown, exhaust
measured at conditions other than standard gas temperature should decrease. If during
shall be corrected to standard conditions using time gas generator is coasting to stop, tempera-
Table 8. ture increases instead of decreases, it indicates
that combustion is still taking place because of
h. Prior to initiation of water flow for a leaking fuel valve. (A slight temperature
NOX suppression, it is recommended that the increase after rotation stops is normal.) Make
gas generator be operating at a stabilized certain fuel is shut off, and motor the gas gen-
steady-state condition. erator. This will blow out the fire. As soon as
9-4 EMERGENCY OPERATION. motoring.


G-36
GEK 97310
VOLUME I
ADDENDUM H
ADDENDUM
7LM2500PC104C

GEK 97310
VOLUME I
ADDENDUM H
TABLE OF CONTENTS
1-0 INTRODUCTION....................................................................................... H-3

2-0 REFERENCE DATA .................................................................................. H-3
3-0 INSTALLATION DRAWINGS.................................................................. H-4
4-0 EQUIPMENT DESCRIPTION ................................................................. H-4
5-0 GAS TURBINE CONTROL ...................................................................... H-4
6-0 OPTIONAL NOX SUPPRESSION (WATER INJECTION SYSTEM) H-4
7-0 INSTRUMENTATION AND SUPPLY REQUIREMENTS ................... H-8
8-0 SERVICE REQUIREMENTS ................................................................... H-11
8-1.1 Natural Gas ................................................................................................... H-11
8-1.2 Liquid Fuel.................................................................................................... H-11
8-1.3 Water Servicing and Pumping Requirements (NOX Suppression)............... H-11
9-0 OPTIONAL HARDWARE KITS - 7LM2500PC104C ............................ H-11
10-0 GAS TURBINE OPERATION .................................................................. H-12
10-1 PERFORMANCE RATINGS AND OPERATING LIMITS .................. H-12
10-1.1 Performance Ratings ..................................................................................... H-13
10-1.2 Water Scheduling During Operations (NOX Suppression) .......................... H-15
10-1.3 Operating Limits ........................................................................................... H-15
10-2 INITIAL OPERATION .............................................................................. H-21
10-2.1 General .......................................................................................................... H-21
10-2.2 Special Instrumentation Required for Operation and Monitoring ................ H-21
10-2.3 Preparation .................................................................................................... H-21
10-2.4 Gas Turbine and Associated Equipment Check List..................................... H-22
10-2.5 Governor and Manual Control Check........................................................... H-22
10-2.6 Start-Up and Checkout.................................................................................. H-23
10-2.7 Ignition Check............................................................................................... H-25
10-2.8 Motoring........................................................................................................ H-25
10-2.9 False Start...................................................................................................... H-25
10-2.10 Governor Check ............................................................................................ H-25
10-2.11 Wet Prestart ................................................................................................... H-26
10-2.12 Manual Start .................................................................................................. H-26
10-2.13 Operation to Maximum Power...................................................................... H-27
10-2.14 Automatic Operation..................................................................................... H-27
10-3 NORMAL OPERATION............................................................................ H-28
10-3.1 General .......................................................................................................... H-28
10-3.2 Interlocks....................................................................................................... H-28
10-3.3 Operation....................................................................................................... H-28
10-4 EMERGENCY OPERATION ................................................................... H-41
10-4.1 Emergency Shutdown ................................................................................... H-41
10-4.2 Post Shutdown Fire ....................................................................................... H-41

H-1
GEK 97310
VOLUME I
ADDENDUM H
Figure Title Page
1 Deleted
2 Deleted
3 Deleted
4 Deleted
5 Deleted
6 Typical Acceleration Fuel Flow Schedule When Operating on Natural Gas H-6
7 Typical Acceleration Fuel Flow Schedule When Operating on Liquid Fuel H-7
8 Fuel Manifold Pressure vs. Fuel Flow When Operating on Natural Gas ..... H-35
9 Fuel Manifold Pressure vs. Fuel Flow When Operating on Natural Gas ..... H-36
10 Fuel Manifold Pressure vs. Fuel Flow When Operating on Liquid Fuel ...... H-37
11 NOX Suppression - Total Flow vs. Fuel Nozzle Pressure Drop ................... H-38
12 NOX Suppression - Total Flow vs. Fuel Nozzle Pressure Drop ................... H-39
13 Transient Temperature Limits ....................................................................... H-40
LIST OF TABLES
Table Title Page
1 INSTRUMENTATION CONNECTIONS - 7LM2500PC104C ................... H-8

2 SUPPLY CONNECTIONS - 7LM2500PC104C .......................................... H-9
3 GAS TURBINE OPERATING LIMITS....................................................... H-16
4 PRE-START CHECKS ................................................................................. H-24
5 START-UP AND OPERATION.................................................................... H-29
6 GAS TURBINE SHUTDOWN .................................................................... H-33
7 EMERGENCY SHUTDOWN...................................................................... H-42
8 DELETED
9 DELETED

H-2
GEK 97310
VOLUME I
ADDENDUM H
1-0 INTRODUCTION.
GAS TURBINE WEIGHTS
7LM2500PC104C model gas turbine basic The average weights of the major engine
configuration and control system differences. components are:
In addition, the coverage of reference data, Component Wt-Lbs/(Kg)
cial servicing requirements, optional hardware Gas turbine - including inlet 7396(3355)
kits and the complete gas turbine operating duct, centerbody, exhaust
instructions for the 7LM2500PC104C are diffuser, and coupling nut
included. Gas Generator 4212(1911)
NOTE
The 7LM2500PC104C gas turbine
requires a natural gas manifold, a liq- Transfer Gearbox 245(111)
uid fuel manifold and 30 dual fuel noz- Compressor Front Frame 517(235)
zles as standard equipment. When Compressor Rotor 552(250)
configured for the optional NOX sup-
Compressor Stator, Front 307(139)
pression system, the gas turbine
requires the installation of a configura- Compressor Stator, Rear 93(42)
tion 3 liquid fuel manifold for water Compressor Rear Frame 421(191)
injection. Consult Illustrated Parts Combustor 120(54)
Breakdown GEK 50336 for the appro-
priate configuration. High Pressure Turbine Rotor 419(190)
2-0 REFERENCE DATA. Stg 1
EQUIPMENT Stg 2
(General Electric Co., Cincinnati, Ohio) Low Pressure Turbine Rotor 1095(497)
Model No. 7LM2500PC104C Dwg. No. Low Pressure Turbine Stator 601(273)
L24330G02 Turbine Rear Frame 1071(486)
PERFORMANCE RATING High Speed Coupling Shaft 91(41)
Forward Adapter
Refer to paragraph 10-1. Ring Seal 49(22)
Ring Support 74(34)
Variable Stator Actuating 19(9)
Mech

H-3
GEK 97310
VOLUME I
ADDENDUM H
5-0 GAS TURBINE CONTROL.
DRAWING LIST
Drawing No. a. The transition from natural gas to liq-
Gas Turbine Installation L31705 shall not result in abrupt changes in gas gener-
Drawing ator speed or temperatures. The rate of change
Fuel System Flow Diagram L24354 from natural gas to liquid fuel or vice versa is a
Lubrication System Flow L24328 function of the operator’s control system, so
Diagram long as the change in total fuel flow does not
exceed that shown on the maximum accelera-
tion fuel flow curve. See figures 6 and 7.
Ignition Units L21454P02
Gas Turbine Assembly L24330G02 6-0 OPTIONAL NOX SUPPRESSION
Drawing (WATER INJECTION SYSTEM).
As an option, the 7LM2500PC104C gas tur-
3-0 INSTALLATION DRAWINGS. bine can be equipped for suppression of oxides
A complete set of installation drawings have of nitrogen (NOX) in the gas generator exhaust
been provided. gases. This is accomplished by introduction of
water into the liquid fuel manifold. Emulsifi-
4-0 EQUIPMENT DESCRIPTION. The cation of the liquid fuel and water occurs
LM2500PC104C is a dual fuel (liquid and nat- within the manifold and the mixture is dis-
ural gas) marinized gas turbine that incorpo- charged through the dual fuel nozzles into the
rates a natural gas manifold, a liquid fuel combustor. The LM2500 NOX suppression
manifold and 30 dual fuel nozzles. The gas tur- system has been designed to meet the require-
bine is not provided with an exhaust duct as ments of the U.S.E.P.A. Standard for NOX
standard equipment but an exhaust duct inner emissions for stationary gas turbines and
diffuser is provided with the basic gas turbine includes a conservative margin for meeting the
assembly. The LM2500PC104C is designed to requirements of other, possibly more restric-
operate on 100 percent natural gas fuel, 100 tive, local codes where applicable.
percent liquid fuel or a combination of the two.
The minimum fuel flow for each fuel, when
operating on dual fuel, should be selected so
that if one fuel is cut off, the gas generator
speed will not decrease below 5000 RPM
before the governor action restores the gas tur-
bine to normal operation. Should the gas tur-
bine be configured with the optional NOX
Suppression equipment, and prior to initiation
of water flow for NOX Suppression, it is rec-
ommended that the gas generator be operating
at a stabilized steady-state condition.

H-4
GEK 97310
VOLUME I
ADDENDUM H

H-5
GEK 97310
VOLUME I
ADDENDUM H

H-6
GEK 97310
VOLUME I
ADDENDUM H

H-7
GEK 97310
VOLUME I
ADDENDUM H
See Table 1 and 2.
Table 1. INSTRUMENTATION CONNECTIONS - 7LM2500PC104C

or 364450
E6 Accessory gearbox scavenge oil MS3106R12S-3S
temperature
or 364450
(optional) mid frame AN818-6C or MS20819-6C
F3 Natural gas fuel manifold pressure tap 1/4 inch line MS33656-4
(optional)
F5 Liquid fuel manifold pressure tap 3/8 inch line AN818-6C or MS20819-6C
(optional)

H-8
GEK 97310
VOLUME I
ADDENDUM H
Table 1. INSTRUMENTATION CONNECTIONS - 7LM2500PC104C (Cont.)

-- Remote reading variable stator vane pro-
tractor (optional)
NOTE
gas turbine.
Table 2. SUPPLY CONNECTIONS - 7LM2500PC104C

CAUTION
ALL LINES MUST BE FLEXIBLE ENOUGH TO ALLOW 3/4 INCH (19.05 MM)
LINES OR ON GAS GENERATOR.
F2 Liquid fuel supply 0.750 inch line from fuel control unit to
the gas generator liquid fuel manifold
AN818-12C or MS20819-12C
F4 Liquid fuel manifold shroud drain 1/2 inch line to fuel manifold shroud
AN818-8C or MS20819-8C
L1 Lube Oil Supply 1-1/2 inch line to Lube Pump on Gas
Filters AN818-16C or MS20819-16C
L3 Scavenge oil discharge 1-1/4 inch line from Gas Generator
Scavenge Pump to Oil Scavenge Filter and
Cooler AN818-20C or MS20819-20C

H-9
GEK 97310
VOLUME I
ADDENDUM H
Table 2. SUPPLY CONNECTIONS - 7LM2500PC104C (Cont.)

A2 Bleed air 16th stage compressor bleed air lines (if
used) 1.92 inch ID
A12 Air/Oil Separator 3 inch line from air/oil separator to
A16 Discharge atmospheric vent or to exhaust duct (flame
arrestor)
MS33649-16
MS33649-16
D3 Oil drain, forward 3/8 inch line to drain manifold under trans-
fer gearbox AN818-6C or MS20819-6C
AN818-6C or MS20819-6C
AN818-16C or MS20819-16C
NOTE
turbine.

H-10
GEK 97310
VOLUME I
ADDENDUM H
8-0 SERVICE REQUIREMENTS. 8-1.3 Water Servicing and Pumping
Requirements (NOX Suppression).
8-1.1 Natural Gas.
a. The maximum allowable water deliv-
a. The required supply pressure to the ery pressure at the manifold connection shall
fuel manifold on the gas turbine is 350 ± 5 psig not exceed 1200 psig (8280 kpa). The temper-
(2415 ± 35 kPa). ature of the water supplied to the manifold
b. The temperature of the gas must be in shall not exceed 180°F (82°C) and shall be
the range of -65° to +150°F (-54 to +66°C). If free of pressure pulsations in the 0 to 300 Hz
the temperature is not repeatable on a day-to- range. The water must be controlled in a man-
day basis it will be necessary to change the ner to prevent any sudden pressure spikes
starting fuel adjustment to adjust the supply which could momentarily displace the fuel.
pressure to the engine to maintain a constant Refer to applicable gas turbine performance
Btu-per-cubic-foot supply. Once started, the data and fuel nozzle flow characteristic curve
engine will accept variations in supply temper- for water pump size determination. Other cri-
ature of ±20°F (±11°C). The maximum fuel teria, such as calculated gas generator water
flow required is 13,400 pph (6078 kg/h) with a flow required to meet the requirement of the
lower heating value of 19,000 Btu/lb. applicable EPA standard or other local codes,
corresponding fuel flow and the gas generator
8-1.2 Liquid Fuel. internal cycle pressure level may be obtained
from the tabular performance data sheets.
fuel manifold on the gas turbine is 390 ± 5 psig 9-0 OPTIONAL HARDWARE KITS -
(2691 ± 35 kPa). 7LM2500PC104C.
b. The fuel temperature supplied to the a. Refer to Volume II WP 001 00 for a
gas turbine shall be a minimum of 20°F (11°C) detailed list of optional kits available for this
above the wax point of the fuel and a maxi- particular gas turbine model.
mum of 150°F (66°C). The fuel shall be fil-
tered to 20 microns absolute. The maximum
fuel flow required is 13,000 pph (5897 kg/h)
with a lower heating value of 18,400 Btu/lb.

H-11
GEK 97310
VOLUME I
ADDENDUM H
10-0 GAS TURBINE OPERATION. NOTE
a. These instructions contain the detailed The S.I. units shown in this chapter are
gas turbine operating procedures and limits direct mathematical conversions and
recommended by the General Electric Com- may be rounded off in most instances
pany for the 7LM2500PC104C Gas Generator. at the users discretion. Examples of
b. The instructions are intended to pro- utilized for temperatures, torque val-
vide operating personnel with the information ues, pressures, etc. Examples were S.I.
required to operate the gas turbine. They units may not be rounded off are those
pertain to routine and emergency conditions utilized for drop checks, rigging adjust-
and procedures. When a fault exists, refer to ments, runouts, etc.
Volume I, Chapter IV,
TROUBLESHOOTING. 10-1 PERFORMANCE RATINGS AND
OPERATING LIMITS.
may not provide for every possible variation in NOTE
trial Engine Division, Cincinnati, Ohio 45215. turbine manual limits.
WARNING

H-12
GEK 97310
VOLUME I
ADDENDUM H
10-1.1 Performance Ratings. Normal With NOX
(Dry) Suppression
a. The rating of the 7LM2500PC104C
gas turbine in the new and clean condition as Power Turbine
compared to gas turbine performance with Inlet Gas
water injection is as follows: Temperature
- Gas 1406°F 1404°F
NOTE (763°C) (762°C)
The use of water injection to control - Liquid 1427°F 1402°F
NOX emissions results in a change in (775°C) (761°C)
gas turbine performance. Unless spe- Water Injection
cifically agreed to in the applicable - Gas 0 lbs/hr 1828 lbs/hr
contract documents, all performance (829 kg/h)
guarantees are based upon “dry” or - Liquid 0 lbs/hr 3984 lbs/hr
normal operation with no water (1807 kg/h)
injection.
Fuel Flow
- Gas 9996 lbs/ hr 10072 lbs/hr
Normal With NOX (4534 kg/h) (4569 kg/h)
(Dry) Suppression - Liquid 10399 lbs/hr 10567 lbs/hr
Brake 27,500 27,500 (4717 kg/h) (4793 kg/h)
Horsepower NOX Emissions
Inlet Air 59°F (15°C) 59°F (15°C) - Gas (ppm 170
Temperature at 15% O2)
- Liquid 290 108
Inlet Losses 0" H2O 0" H2O
Exhaust Back 0" H2O 0" H2O b. The gas turbine is designed to operate
Pressure on 100% natural gas fuel, 100% liquid fuel, or
Relative Humidity 60% 60% on combinations of the two with a limit on nat-
Altitude 0 ft. 0 ft. ural gas/liquid fuel ratios of 10/90 to 90/10.
Compressor 0 lbs/Sec 0 lbs/Sec The gas turbine can be started on either natural
Bleed gas or liquid fuel but not on a combination of
the two. Approximate starting fuel flows on
Accessory 0 0
natural gas are:
Horsepower
Extraction
465 pph (211 kg/h) ± 25 pph (11 kg) @ -65°F
Power Turbine 3600 RPM 3600 RPM (-54°C) Inlet Air Temperature
Speed
Heat Rate, Max 550 pph (249 kg/h) ± 25 pph (11 kg) @ +60°F
- Gas 6907 BTU/ 6959 BTU/ (16°C) Inlet Air Temperature
hp-hr hp-hr
- Liquid 6958 BTU/ 7070 BTU/ 595 pph (270 kg/h) ± 25 pph (11 kg) @
hp-hr hp-hr +130°F (54°C) Inlet Air Temperature

H-13
GEK 97310
VOLUME I
ADDENDUM H
Approximate starting fuel flows on liquid fuel h. For normal accelerations from idle to
are: power settings, the changes should be made
530 pph (240 kg/h) ± 25 pph (11 kg) @ section repairs and the life of the gas turbine.
-65°F (-54°C) Inlet Air Temperature A time of 2 to 3 minutes is reasonable.
625 pph (284 kg/h) ± 25 pph (11 kg) @ i. The maximum deceleration fuel flow
+60°F (16°C) Inlet Air Temperature rate should consist of a step fuel decrease of
1500 (680 kg/h) ± 10% pph followed by a rate
680 pph (308 kg/h) ± 25 pph (11 kg) @ change of 1330 pph (603 kg/h) ± 10% per sec-
+130°F (54°C) Inlet Air Temperature ond to idle fuel flow. Rates greater than this
can cause the engine to lose fire. Normal
c. The minimum fuel flow for each fuel, decelerations from maximum power to idle
when operating on dual fuel, should be should be made in approximately 2 to 3 min-
selected so that if one fuel is cut off the gas utes - this will enhance the time between hot
generator speed will not decrease below section repairs and the life of the gas turbine.
5000 rpm before the governor action restores
the engine to normal operation. j. The liquid fuel system must be free of
periodic or random hunting which results in
d. Figures 6 and 7 define the maximum cycling of gas generator speed or temperature.
fuel acceleration schedule for the gas genera- The frequency of the fuel flow fluctuations
tor. When operating on dual fuel, the schedule, shall not be a harmonic of the natural fre-
liquid or natural gas, which gives the lower quency of the springs in the fuel nozzles. The
fuel rate shall be used. natural frequency of these springs is 200 Hz.
e. Acceleration fuel rates greater than between hot section repairs and the life of the
those shown will result in over-temperature engine. The transition from natural gas to liq-
and possible stall of the gas turbine. Accelera- uid fuel and vice versa shall be smooth and
tion fuel rates lower than those shown can shall not result in abrupt changes in gas gener-
result in “hung” starts in the below idle speed ator speed or temperature. The rate of change,
range. natural gas to liquid fuel or vice versa, must be
f. Above the idle speed point, low accel- another at full power shall not exceed 10 sec-
eration fuel rates will not harm the gas turbine onds. For transfers at lower power settings,
and will only result in slower acceleration i.e., at 50% power the transfer time shall not
times. exceed 5 seconds.
g. The fuel rates shown on the curves will


H-14
GEK 97310
VOLUME I
ADDENDUM H
k. The actual performance of the b. Water Scheduling Requirements. Water
7LM2500PC104C gas turbine will be a func- flow must be scheduled as a function of fuel
tion of the ratio of natural gas fuel and liquid flow and must be shut off during starting and
fuel used. The time between repairs of the hot acceleration to idle. Water flow should be initi-
section will also change as a function of the ated at a fuel flow of 3000 pph ± 250 pph
ratio of the natural gas and liquid fuels used (1361 kg/h ± 113 kg/h) on acceleration when
with the longest times being associated with operating with liquid fuel and at 5300 pph
100% natural gas. ± 450 pph (2404 kg/h ± 204 kg/h) on accelera-
tion when operating on natural gas. Subse-
10-1.2 Water Scheduling During Operations quently, the water should be shut off at these
(NOX Suppression). points on deceleration. During initiation of
water flow, the gas turbine should be operating
a. Water Purity. The water supplied to the at a stabilized steady-state condition. Refer to
gas generator must meet the following mini- figures 9 and 10 for water/fuel ratios, supply
mum requirements: pressures and manifold pressure/flow
requirements.
• Sodium + Potassium + Lead + Vanadium
+ Lithium + Silica = 0.1 ppm maximum. NOTE
When water is injected at the flow rates
• Total ionizable solids, both dissolved and necessary to meet U.S.E.P.A. require-
undissolved shall not exceed 5 ppm ments, the maximum gas generator
maximum. corrected speed limit must be reduced
to 9650 RPM. There is no change to
• PH = 6.5 to 7.5 the 9800 RPM maximum physical
speed limit.
• Water solid contaminants shall not exceed
10 mg. per gallon with a maximum con- 10-1.3 Operating Limits. Refer to Table 3.
taminant size not exceeding 20 microns
absolute. NOTE
troubleshooting or inspecting gas
generator.

H-15
GEK 97310
VOLUME I
ADDENDUM H
Alarm/ Normal
NOTE

above 8000 rpm

(41 kPa ± 6.9 kPa) (138 - 413 kPa) 4500 rpm
Pressure 180 psig
(1242 kPa)
Gas Turbine Lube Alarm 180°- 220°F 140°- 160°F Normal Operating
Pump Discharge (82°- 104°C) (60°- 71°C) Range reflects
Temperature temperature
expected during
operation above
idle speed
Gas Turbine Lube Trip 330°- 350°F 215°- 275°F Normal Operating
Scavenge Tem- (166°- 177°C) (102°- 135°C) Range reflects
peratures - Five temperature
expected during
operation above
idle speed
Alarm 290° 310°F

(143°- 154°C)

H-16
GEK 97310
VOLUME I
ADDENDUM H
Alarm/ Normal
Fuel Fuel Manifold

System Pressure
Natural Gas 20 - 390 psig Supply Pressure

Pressure (138 - 2689 kPa) as reflected at the
fuel manifold
inlet on the gas
turbine
Liquid Fuel 150 - 900 psig Supply Pressure

(1034 - 6205 kPa) as reflected at the
fuel manifold
inlet on the gas
turbine
Fuel Supply
Temperature
Natural Gas Alarm 150°- 170°F -65° to 150°F Starting Fuel

(66°- 77°C) (-54° to 66°C) Flow Adjust-
ments may be
Liquid Fuel 20°F (-7°C) required to com-
above wax point pensate for fuel
of fuel to 150°F temperature
(66°C) maximum variation
Starting Starter 40 psig (276 kPa) Starting Pressure

System Supply Requirement
Pressure based on engine
starter torque
requirements

Fuel and Ignition

Fuel and Ignition for start after
(If purge cycle is purge cycle
used)

H-17
GEK 97310
VOLUME I
ADDENDUM H
Alarm/ Normal

simultaneously
with start
initiation
Failure to Light- Trip 380°- 420°F Activate 20 sec-

Off (193°- 216°C) onds time delay
simultaneously
with application
of fuel and
ignition

simultaneously
with start initia-
tion. De-energize
ignition, fuel sys-
tem and starter air
supply

used) of purge. De-
energize fuel and
ignition systems
and starter air
supply

H-18
GEK 97310
VOLUME I
ADDENDUM H
Alarm/ Normal
Power Tur- Failure to Light- Trip 380°- 420°F 0 - 1600°F Trip if tempera-
bine Inlet Off (193°- 216°C) (-18°- 871°C) ture does not
(T5.4) Tem- reach 400°F
perature (204°C) within
(Gas 20 seconds after
Generator fuel and ignition
Exhaust) are applied
Overtemperature:
Natural Gas Trip 1450°F (788°C) 1378°- 1438°F Values given are
(748°- 781°C) for installations
using constant
Alarm 1438°F (781°C) T5.4 control as the
Liquid Fuel Trip 1470°F (799°C) 1400°- 1460°F power limit.
(760°- 793°C) Installations using
constant power
Alarm 1460°F (793°C) control mode
should consult the
contract docu-
ments for deter-
mining alarm and
trip settings,
which are unique
to each applica-
tion, but never to
exceed 1616°F
(880°C) (alarm)
and 1625°F
(885°C) (trip)

H-19
GEK 97310
VOLUME I
ADDENDUM H
Alarm/ Normal

4 mils

7 mils

Generator

Turbine
Loss of Combustor Flame Close and lock

Flame out fuel shutoff
valve upon loss of
flame

H-20
GEK 97310
VOLUME I
ADDENDUM H
10-2 INITIAL OPERATION. Fuel supply pressure -
Liquid fuel 0-1200 psig
10-2.1 General. Initial operational period is (0-8280 kPa)
that period of operation immediately following Natural gas 0-400 psig
gas turbine replacement or major maintenance (0-2760 kPa)
on the system.
Fuel supply temperature -
10-2.2 Special Instrumentation Required for Liquid fuel 0-250°F
Operation and Monitoring. (-18 to 121°C)
Natural gas 0-250°F
Gas generator speed sensor 0-10,000 rpm (-18 to 121°C)
Lube oil scavenge temperature 0 - 400°F Gas turbine inlet air 0-150°F
sensors (A-, B-, C-, D-sumps (-18 to 204°C) temperature (-18 to 66°C)
Lube oil supply temperature 0 - 400°F (0-690 kPa)
Remote reading variable vane -5°to +45°
Lube oil supply pressure 0-100 psig indicator
0-690 kPa)
Vibration indicators (optional) (0-345 kPa)
gas generator 0-3 in/sec or
0-10 mil DA 10-2.3 Preparation. The gas turbine and
power turbine 0-3 in/sec or associated systems must be inspected and
0-10 mil DA checked out for proper installation and opera-
Power turbine speed sensor 0-5000 rpm tion before normal operation can commence.
Power turbine inlet gas tem- 0-2000°F
perature (T5.4) (0-1093°C)
Fuel manifold pressure sensor 0-1200 psi
Liquid fuel (0-8280 kPa)
Natural gas 0-400 psi
(0-2760 kPa)
Compressor inlet total pres- 10-16 psia
sure sensor (69-110 kPa)

H-21
GEK 97310
VOLUME I
ADDENDUM H
ment Check List. Complete the following frame leakage ports, struts 7
check list. and 10, are open (not capped) _______
a. Gas Turbine Assembly S/N _______ m. Starter is serviced per

b. Mounting base secured to
foundation _______ n. Lube oil storage tank serviced
c. Intake air and exhaust gas
ducts in place and secured _______ o. Lube oil supply valves open _______

secure _______ Packager’s manual _______
e. Gas turbine and exhaust duct q. Fire alarm/extinguish system

support mounts and links in ON and operative _______
place and secure _______ r. T5.4 thermocouple system
f. All service connections made functioning properly _______
and secure _______
s. Ignition system operative _______
g. All lines have been flushed per
t. Compressor inlet total pres-
sure probe aligned properly
h. All instrumentation connec- and free of damage _______
u. Variable stator system secure _______
i. All accessories are secure per
v. Required checks and inspec-
tions specified in Packager’s
j. Gas turbine assembly free of manual for gas turbine control
loose objects and all lines/ have been performed _______
k. Gas turbine inlet air area free
secure _______

H-22
GEK 97310
VOLUME I
ADDENDUM H
10-2.6 Start-Up and Checkout. • ALLOW THE GAS TURBINE TO
WARNING TACT WITH HOT PARTS, AND

• THE FIRE EXTINGUISHING c. Perform ignition checkout per

INACTIVE ACCORDING TO d. Perform motoring procedure per
THE CUSTOMER’S paragraph 10-2.8.
PROCEDURES.
• SECONDARY AIR TO THE paragraph 10-2.9.
OFF. HIGH SECONDARY AIR- f. Perform governor check per
FLOW MAY PREVENT OPEN- paragraph 10-2.10.
AN OBSERVER SHALL BE STA- i. Operate to maximum power per
DOOR AND CONFINED SPACE j. Check automatic operation per
BE FOLLOWED.

H-23
GEK 97310
VOLUME I
ADDENDUM H
Table 4. PRE-START CHECKS
Item Requirement
Fuel valves Closed
Ignition Off
Ventilation inlet air (secondary cooling air) Off-air temp below 70°F
(21.1°C)
Oil tank level Full
Lube oil temperature 140°F to 160°F (60-71°C)
Fuel supply - Natural gas
temperature -65°F to +150°F (-54 to +66°C)
flow 13,400 pph (6078 kg/ph) max

flow 13,000 ppg max (5897 kg/ph)

H-24
GEK 97310
VOLUME I
ADDENDUM H
10-2.7 Ignition Check. a. Make ignition, liquid fuel, and natural
gas supply systems inoperative as follows:
WARNING
• ASSURE POWER TO IGNITION tion units.
CONNECTING AND CONNECT- (2) Close liquid fuel and natural gas
ING IGNITION EXCITER INPUT manual shutoff valves to fuel control unit.
SERVICE TO PRECLUDE INAD- b. Depress MOTORING pushbutton. Gas
VERTENT ACTIVATION. generator will start to rotate. If it does not,
• ASSURE FUEL VALVES ARE refer to packager’s manual for supply pressure
CLOSED THROUGHOUT THIS to starter.
PROCEDURE.
a. To clear combustor of any residual until gas generator speed stabilizes, and check
fuel, motor gas turbine for one minute; allow for oil pressure. If there is no indication of oil
gas turbine to coast down. pressure, release MOTORING pushbutton;
b. Disconnect number one ignition exciter oil fittings at lube pump to bleed air from sys-
input lead at exciter. Temporarily secure input tem. Starter should motor gas generator to
lead away from the exciter. minimum of 2200 RPM.
c. Turn on electrical power to the ignition d. Repeat motoring and bleeding proce-
system (No. 2 ignition exciter energized). An dure until an indication of oil pressure appears.
second) should be heard when the No. 2 spark 10-2.9 False Start. Perform false start as
igniter fires. follows:
connected and manual fuel shutoff valves
closed, make automatic start of gas turbine per
e. Repeat steps b, c and d, disconnecting operator’s manual.
the No. 2 exciter.
f. If an audible report is not heard on mal start cycle and then abort because of lack
No. 1 and/or No. 2 igniters, check out the sys- of flame.
ate corrective action. 10-2.10 Governor Check. Check governor

H-25
GEK 97310
VOLUME I
ADDENDUM H
10-2.11 Wet Prestart. Perform wet prestart as OPERATION WITHOUT POWER
follows: TURBINE ROTATION.
a. With power supply to ignition unit dis- a. The power turbine must rotate by the
connected, with either the liquid fuel or the time the gas generator speed reaches 7000 rpm
natural gas manual shutoff valve closed and NGG. If power turbine speed indication is not
the other valve open, and the governing system obtained and it is determined that a “thermal
operating, make an automatic start of the gas
seizure” of the power turbine has occurred,
turbine per the operators manual.
proceed as follows:
light-off speed (1100 to 1300 rpm). Fuel valve NOTE
should open and fuel manifold pressure should Thermal seizure of the power turbine
be approximately 3 psig (20.7 kPa). Adjust rotor can occur when a hot gas turbine
fuel supply if required. Start will then abort is shut down and is most likely to occur
because of lack of flame. within 30 to 40 minutes following gas
c. Allow gas generator to coast to a stop. turbine operation. Thermal seizure is
Motor it to purge any remaining natural gas the condition where the power turbine
from the gas turbine or drain liquid fuel from rotor is prevented from rotating by hard
manifold if liquid fuel was used in the wet pre- contact between LPT blades and
start. Purge fuel nozzles of liquid fuel with nat- shrouds, interstage seals and other
ural gas or compressed air at 200 psid internal interference. This condition is
(1380 kpa) maximum. Remain on starter for the result of unequal cooling rates of
60 seconds to purge fuel from gas turbine. the various power turbine components.
10-2.12 Manual Start. Perform manual start The possibility of thermal seizures can
per packager’s manual with fuel system nor- be reduced by operating the gas turbine
mal and with ignition lead connected. Refer to at idle power for at least five minutes
Table 5. prior to shutdown to achieve proper
NOTE (1) Shutdown gas turbine.
Power turbine, except in a new installa- (2) Immediately after the gas turbine
tion, will be rotating when gas genera- stops rotating, re-start and stabilize at idle
tor idle speed is attained. speed (4950 ± 50 rpm) for 30 seconds.
CAUTION
DO NOT EXCEED 7000 RPM NGG additional start-up and shutdown cycles.
AND 30 SECONDS OF GAS TUR- (4) If the power turbine does not
BINE OPERATION WITHOUT rotate after accomplishing substeps (1) through
(3), shut down the gas turbine.

H-26
GEK 97310
VOLUME I
ADDENDUM H
rotation stops, re-start and accelerate to if possible, but do not exceed exhaust gas tem-
7000 rpm NGG maximum and stabilize for perature (T5.4) limit. Hold at this power setting
30 seconds. If the power turbine still does not until all temperatures stabilize. If governing
rotate, shut down and investigate/correct the system is unstable, adjust per packager’s
cause. During the investigation for the cause of manual.
a thermally seized rotor, inspect the LPT
blades in stages 4, 5 and 6 for shingling and c. Log all instrument readings once they
unlatching. If blades have become unlatched, stabilize. Refer to Table 5, step 10.
encountered shingling may be bent thereby d. Reduce gas generator speed to idle.
necessitating replacement of the power After stabilizing for three minutes, record all
turbine. instrument readings. Refer to Table 6, step 2.
CAUTION e. Check fail-safe section of control sys-

BINES THAT HAVE TIGHTER LPT f. After gas turbine has been stabilized at
BLADE TIP CLEARANCES, DO idle for five minutes, make normal shut-down.
NOT EXCEED 6000 RPM NGG AND Refer to Table 6, steps 3 and 4.
TURBINE ROTATION.
CAUTION
MANUAL OPERATION MAY c. Log all instrument readings.
ELIMINATE CERTAIN PROTEC- d. Decelerate to idle.
ITS SHALL NOT BE EXCEEDED. e. Check for fuel or lube oil leaks.
a. Slowly increase manual control setting f. After a total of five minutes at idle,
(refer to packager’s manual) to increase gas shut down gas turbine.
log all instrument readings, paying particular g. Check lube oil and fuel filters and
attention to variable stator vane position and strainers; clean or replace as necessary.
tions are not within limits, consult the local i. Remove all temporary instrumentation.
General Electric Company representative.

H-27
GEK 97310
VOLUME I
ADDENDUM H
ager’s manual.
gas turbine operation. AN OBSERVER SHALL BE STA-
WARNING BE FOLLOWED.
BINE ENCLOSURE, THE FOLLOW- • ALLOW THE GAS TURBINE TO
ING REQUIREMENTS SHALL BE COOL DOWN. AVOID CON-
MET: TACT WITH HOT PARTS, AND
• THE GAS TURBINE SHALL BE LATED GLOVES AS NECES-
SHUT DOWN. SARY.
• ENCLOSURE ENTRY DURING • EAR PROTECTION SHALL BE

ENGINE OPERATION IS PRO- WORN IF GAS TURBINE IS
HIBITED IN GENERAL. IF OPERATING.
ENTRY SHOULD BE
REQUIRED DURING ENGINE • DO NOT REMAIN IN THE
OPERATION, CONTACT GE ENCLOSURE OR IN THE
FIELD SERVICE FOR A REPRE- PLANE OF ROTATION OF THE
SENTATIVE WHO IS TRAINED STARTER WHEN STARTING OR
TO ENTER THE ENCLOSURE MOTORING THE GAS TUR-
UNDER SUCH CONDITIONS. BINE.

• THE FIRE EXTINGUISHING idle speed, wear proper ear protection.
THE CUSTOMER’S PROCE- Table 5. Do not exceed operating limits of
DURES. Table 3.

H-28
GEK 97310
VOLUME I
ADDENDUM H
1. Assure that prestart checks are Automatic shutdown at
completed per Table 4 1450°F (788°C) for nat-
ural gas or 1470°F
(799°C) for liquid fuel.
Refer to Table 3.
CAUTION
• IF T5.4 RAPIDLY APPROACHES OR EXCEEDS 1438°F (781°C) FOR
NATURAL GAS OR 1458°F (792°C) FOR LIQUID FUEL, ABORT
START.
• THE GAS TURBINE IS DESIGNED TO OPERATE ON 100% NATU-
RAL GAS FUEL, 100% LIQUID FUEL, OR ON A COMBINATION OF
THE TWO. THE GAS TURBINE CAN BE STARTED ON EITHER NAT-
URAL GAS FUEL OR LIQUID FUEL BUT NOT ON A COMBINATION
OF THE TWO. WHEN OPERATING ON BOTH FUELS, NEITHER THE
NATURAL GAS OR LIQUID FUEL FLOW SHOULD BE LESS THAN
THE IDLE FUEL FLOW; I.E. IF OPERATING ON BOTH FUELS, THE
MINIMUM FLOW TO THE GAS TURBINE WILL BE LIQUID FUEL
IDLE FLOW PLUS NATURAL GAS IDLE FLOW.
• WHEN OPERATING ON 100% LIQUID FUEL OR A RATIO OF
LIQUID AND NATURAL GAS, IT IS NECESSARY TO DRAIN THE
LIQUID FUEL MANIFOLD WHEN THE GAS TURBINE IS SHUT
DOWN. THE MAXIMUM TEMPERATURE OF THE FUEL WILL BE
200°F (93°C). REFER TO OPERATOR’S MANUAL FOR PROCEDURE.
NOTE
• A start may be aborted at any time by closing the fuel valve, allowing the
gas generator to motor for 60 seconds, then closing the starter shutoff valve.
• When switching from liquid fuel burning to 100% natural gas burning, it is
necessary to purge and cool the liquid portion of the fuel nozzles. Either nat-
ural gas or compressed air may be used to purge the fuel nozzles. Refer to
the operator’s manual.
4. At 1100 to 1300 rpm NGG
a. Ignition on

H-29
GEK 97310
VOLUME I
ADDENDUM H
b. Natural gas fuel valve-open Fuel manifold pressure approx
Liquid fuel valve-closed 3 psig (21 kPa)
or (natural gas) 90-150 psig
Natural gas fuel valve- (621-1035 kPa) (Liquid fuel)
closed
c. Note time to light-off [T5.4 20 seconds max Abort start-automatic
above 400°F (204°C)] shutdown
5. Note time to 4500 ± 200 rpm 90 seconds max Troubleshoot system
and take corrective
action if rpm stops
accelerating or if it takes
longer than 90 seconds
to reach 4300 rpm
6. At 4300 to 4500 rpm NGG
a. Starter shutoff valve closes Valve closed Close fuel valve and
automatically allow gas generator to
motor for 60 sec., then
shut off the starter
a. Oil pressure See applicable figure in Shutdown if below 6
Chapter 5 psig (41 kPa)
b. Fuel manifold pressure
Natural gas Approx. 25 psig (173 kPa) Troubleshoot system

and take corrective
Liquid fuel Approx. 150 psig (1035 kPa) action. See figures 8, 9,
or 10

H-30
GEK 97310
VOLUME I
ADDENDUM H
d. Maximum NGG with power 7000 rpm NGG maximum for Shut down and investi-
turbine seizure (thermal 30 seconds (for early model gate/correct cause per
seizure) gas turbines that have tighter paragraph 10-2.12
LPT blade tip clearances, do
not exceed 6000 rpm NGG and
30 seconds of gas turbine
operation without power tur-
bine rotation)
e. T5.4 1000°F (538°C) max Emergency shutdown
Table 7
g. Gas generator vibration 0 to 3 mils DA Alarm is above 4 mils.
corrective action
h. Power turbine vibration 0 to 6 mils DA Alarm if above 7 mils.
corrective action
i. Compressor inlet Approximately equal to out- Troubleshoot sensing
temperature (T2) side air temperature and indicating system.
Correct as required.
j. Check for fuel and oil leaks No leaks allowed Correct as required
9. Set desired power setting. (Natural gas) 1438°F (781°C) Correct as required.
Observe T5.4 during transient maximum Refer to transient tem-
operation (Liquid fuel) 1460°F (793°C) perature limits
maximum contained in
figure 13
following:
a. T5.4 (Natural gas) 1378°-1438°F Ref. Note 1
(748°- 781°C)
(Liquid fuel) 1400°-1460°F
(760°-793°C)

H-31
GEK 97310
VOLUME I
ADDENDUM H
b. NGG 9850 rpm max (Corrected) Ref. Note 1
c. NPT 3600 rpm max Ref. Note 1
figure in Chapter 5 shutdown if 5 psig
(34 kPa) out of limits
(101 to 135°C) above 340°F
f. Gas generator vibration 3 mils max Ref. Note 1. Trouble-
4 mils (Alarm) shoot. Emergency or
g. Power turbine vibration 7 mils (Alarm) Ref. Note 1. Emergency
10 mils (Trip) or automatic shutdown
h. Fuel manifold inlet pressure
Natural gas 25-350 psig (173-2413 kPa) Ref. Note 2
Liquid fuel 150-900 psig (1035-6210 kPa) Ref. Note 2

i. Fuel inlet temperature
Natural gas -65°F to +150°F Ref. Note 2
(-54 to 66°C)
Liquid fuel 20°F (-7°C) minimum above Ref. Note 2
wax point of fuel to +150°F
(83°C) maximum
l. T2 Approximately equal to out- Ref. Note 2
WP 118 00 WP 118 00
NOTE 1: Reduce power to stay within limits. If reducing power does not bring parameters
within limits shut down.
NOTE 2: If all other parameters are normal, correct discrepancy at next opportunity.

H-32
GEK 97310
VOLUME I
ADDENDUM H
c. Shut down the gas turbine per Table 6. g. The corrected operating pressure of the
lube oil shall be per applicable table in
NOTE Chapter 5 at standard conditions of 9000 RPM
During normal shutdown with NOX gas generator speed and 150°F (65.6°C) at
Suppression being used, closure of the lube pump discharge temperature. Oil pressure
fuel valve should be delayed after measured at conditions other than standard
water is shut off to allow purging of shall be corrected to standard conditions using
water from the fuel manifold. applicable table in Chapter 5.
d. Emergency shut down the gas turbine h. Prior to initiation of water flow for
per Table 7. NOX Suppression, it is recommended that the
gas generator be operating at a stabilized
e. Refer to paragraph 5-3.30 and 5-3.31, steady-state condition.
pressure characteristics. (See tables V-21A, NOTE
5-32B, 5-32E, 5-32F, 5-32J, 5-32L, 5-32N, Refer to figures 6 through 10 for fuel
and 5-32Q.) system requirements when operating
on natural gas, liquid fuel or a combi-
f. Idle lube oil pressure is 29 psig nation of the two. Refer to figures 11
(200.1 kPa) maximum after five minutes and 12 when operating with NOX
stabilization. suppression.

power
following:
b. Fuel manifold pressure Troubleshoot system and take
corrective action
Natural gas Approx. 25 psig (173 kPa).
See figures 8 or 9
(1035 kPa).
See figure 10

H-33
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ADDENDUM H
Table 6. GAS TURBINE SHUTDOWN (Cont.)

d. T5.4 1000°F (538°C) max Troubleshoot system and take
corrective action
f. Gas generator vibration 3 mils max Alarm if above 4 mils. Auto-
matic normal shutdown if above
7 mils. Troubleshoot and take
corrective action
g. Power turbine vibration 6 mils max Alarm if above 7 mils. Auto-
matic normal shutdown if above
corrective action
h. Fuel inlet temperature
(-54 to +66°C)
Liquid fuel 20°F (11°C) minimum
above wax point of fuel to
∆P
5 minutes, close fuel valves (264°C) NGG and NPT
decelerate and stop
4. Observe T5.4 for 3 minutes 700°F (371°C) max Motor gas turbine and shut off
after shutdown fuel supply. Continue motoring
until temperature decreases

H-34
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Figure 8. Fuel Manifold Pressure vs. Fuel Flow When Operating on Natural Gas

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ADDENDUM H
10-4 EMERGENCY OPERATION. Action must be taken to purge the water from
the fuel manifold at the earliest opportunity
10-4.1 Emergency Shutdown. and prior to the next startup.
a. In an emergency, the gas generator may 10-4.2 Post Shutdown Fire.

ing the gas and/or liquid fuel valve. However, a. During a normal shutdown, exhaust
this should only be done in an emergency, gas temperature should decrease. If during
since rapid shutdown will decrease life of gas time gas generator is coasting to stop, tempera-
generator. ture increases instead of decreases, it indicates
b. Emergency shut-down shall be made a leaking fuel valve. (A slight temperature
per Table 7. increase after rotation stops is normal.) Make
certain fuel is shut off, and motor the gas gen-
c. If an emergency shutdown must be ini- erator. This will blow out the fire. As soon as
tiated while operating with NOX Suppression temperature decreases to normal, discontinue
on-line, the water and fuel valves can be shut motoring.
off simultaneously.

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ADDENDUM H

CAUTION
1. Conditions permitting, decelerate gas tur- T5.4 drops below Manually shut off
bine to idle and close fuel valves 400°F (204°C) and fuel supply
NGG and NPT
decelerate
2. Observe T5.4 for 3 minutes after shutdown 700°F (371°C) max. Motor gas turbine.
Continue motoring
until temperature
decreases
(621°C) has occurred, and a “hot restart” is
for 5 minutes. At the end of the
idle. Acceleration to the desired power
setting can then be accomplished.

H-42
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ADDENDUM H
TABLES 8 and 9. Deleted

H-43/(H-44 Blank)
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ADDENDUM I
ADDENDUM
7LM2500PC101B

GEK 97310
VOLUME I
ADDENDUM I
TABLE OF CONTENTS
1-0 INTRODUCTION....................................................................................... I-3

2-0 REFERENCE DATA .................................................................................. I-3
3-0 INSTALLATION DRAWINGS.................................................................. I-3
4-0 EQUIPMENT DESCRIPTION ................................................................. I-3
5-0 INSTRUMENTATION AND SUPPLY REQUIREMENTS ................... I-4
6-0 SERVICE REQUIREMENTS ................................................................... I-6
6-1.1 Natural Gas ................................................................................................... I-6
7-0 OPTIONAL HARDWARE KITS - 7LM2500PC101B ............................ I-6
8-0 GAS TURBINE OPERATION .................................................................. I-6
8-1 PERFORMANCE RATINGS AND OPERATING LIMITS .................. I-7
8-1.1 Performance Ratings ..................................................................................... I-7
8-1.2 Operating Limits ........................................................................................... I-11
8-2 INITIAL OPERATION .............................................................................. I-15
8-2.1 General .......................................................................................................... I-15
8-2.2 Special Instrumentation Required for Operation .......................................... I-15
8-2.3 Special Instrumentation Required for Monitoring and Troubleshooting ...... I-15
8-2.4 Preparation .................................................................................................... I-16
8-2.5 Gas Turbine and Associated Equipment Check List..................................... I-16
8-2.6 Governor and Manual Control Check........................................................... I-17
8-2.7 Start-up and Checkout................................................................................... I-17
8-2.8 Ignition Check............................................................................................... I-19
8-2.9 Motoring........................................................................................................ I-19
8-2.10 False Start...................................................................................................... I-19
8-2.11 Governor Check ............................................................................................ I-20
8-2.12 Wet Prestart ................................................................................................... I-20
8-2.13 Manual Start and Operation .......................................................................... I-20
8-2.14 Operation to Maximum Power...................................................................... I-29
8-2.15 Automatic Operation..................................................................................... I-29
8-3 NORMAL OPERATION............................................................................ I-29
8-3.1 General .......................................................................................................... I-29
8-3.2 Interlocks....................................................................................................... I-29
8-3.3 Operation....................................................................................................... I-30
8-4 EMERGENCY OPERATION ................................................................... I-31
8-4.1 Emergency Shutdown ................................................................................... I-31
8-4.2 Post Shutdown Fire ....................................................................................... I-31

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Figure Title Page
1 Transient Temperature Limits ................................................................................ I-8

2 Deleted
3 Typical Acceleration Fuel Flow Schedule ............................................................. I-10
4 Deleted
5 Deleted
6 Deleted
7 Deleted
LIST OF TABLES
Table Title Page
1 INSTRUMENTATION CONNECTIONS - 7LM2500PC101B ............................ I-4

2 SUPPLY CONNECTIONS - 7LM2500PC101B................................................... I-5
3 GAS TURBINE OPERATING LIMITS................................................................ I-11
4 PRESTART CHECKS ........................................................................................... I-18
5 START-UP AND OPERATION ............................................................................ I-22
6 GAS TURBINE SHUTDOWN ............................................................................. I-26
7 EMERGENCY SHUTDOWN............................................................................... I-27
8 Deleted

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GEK 97310
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ADDENDUM I
1-0 INTRODUCTION. Combustor 120 (54)
The information contained herein describes the High Pressure Turbine Rotor 419 (190)
7LM2500PC101B model gas turbine basic
configuration and control system differences.
Stage-1 68 (31)
instrumentation and supply connections, spe- High Pressure Turbine Nozzle,
cial servicing requirements, optional hardware Stage-2 127 (58)
kits and the complete gas turbine operating Turbine Mid Frame 530 (240)
instructions for the 7LM2500PC101B model Low Pressure Turbine Rotor 1095 (497)
are included. Low Pressure Turbine Stator 601 (273)
Turbine Rear Frame 1071 (486)
2-0 REFERENCE DATA.
High Speed Coupling Shaft For-
EQUIPMENT ward Adapter 91 (41)
Variable Stator Actuating Mech 19 (9)
Gas Turbine Assembly Outside Piping and Bracketing 278 (126)
Model No. 7LM2500PC101B DRAWING LIST
Dwg. No. L24290G03
Drawing No.
PERFORMANCE RATING Gas Turbine Installation Dwg L31705
Refer to paragraph 8-1.
Lubrication System Flow Dia L24328
GAS TURBINE WEIGHTS Electrical Diagram L24329
Gas Turbine Assembly Dwg L24290G03
components are:
Component Wt-Lbs/(Kg) 3-0 INSTALLATION DRAWINGS.

Gas turbine - including inlet duct,
been provided.
centerbody, exhaust diffuser,
and coupling nut 7396 (3355)
Gas Generator 4212 (1911) The 7LM2500PC101B is a natural gas fired,
Power Turbine 2777 (1260) nonmarinized gas turbine. An exhaust duct is
Inlet Gearbox 38 (17) not furnished as standard equipment; however,
Transfer Gearbox 245 (111) the gas turbine is provided with an exhaust
duct inner diffuser.
Compressor Front Frame 517 (235)
Compressor Rotor 552 (250)
Compressor Rear Frame 421 (191)

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GEK 97310
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ADDENDUM I
See tables 1 and 2.
364450
E6 Accessory Gearbox scavenge oil MS3106R12S-3S
temperature
E11 Oil supply temperature MS3106Rl2S-3S
364450
(optional)
(optional)
NOTE
gas turbine.

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GEK 97310
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ADDENDUM I

CAUTION
ON GAS GENERATOR.
F1 Natural gas supply 2 inch line from Fuel Control Unit to
Gas Generator Fuel Manifold
L1 Lube Oil Supply 1-1/2 inch line to Lube Pump on Gas Generator
AN818-24C or MS20819-24C
AN818-20C or MS20819-20C
A12 Air/Oil Separator 3 inch line from air/oil separator to atmospheric
vent or to exhaust duct (flame arrestor)
AN818-16C or MS20819-16C
NOTE
turbine.

I-5
GEK 97310
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ADDENDUM I
6-0 SERVICE REQUIREMENTS. c. It is possible that these instructions
6-1.1 Natural Gas. equipment or contingency to be met in connec-
a. The required supply pressure to the Refer requests for additional information to the
fuel manifold on the gas turbine is 350 ± 5 psig General Electric Company, Marine and Indus-
(2415 ± 35 kPa). trial Engine Division, Cincinnati, OH 45215.
b. The temperature of the gas must be in
the range of -65° to +150°F (-54° to +66°C). If WARNING
day basis it will be necessary to change the IF A QUESTIONABLE CONDITION
starting fuel adjustment to adjust the supply EXISTS, DO NOT OPERATE THE
pressure to the engine to maintain a constant GAS TURBINE UNTIL A THOR-
Btu-per-cubic-foot supply. Once started, the OUGH INVESTIGATION HAS
engine will accept variations in supply temper- BEEN MADE. DO NOT REPEAT
ature of ±20°F (±11°C). The maximum fuel HOT STARTS, COMPRESSOR
flow required is 13,400 pph (6078 kg/h) with a STALLS, OR OTHER RECOGNIZED
lower heating value of 19, 000 Btu/lb. PROBLEMS WITHOUT PRIOR
7-0 OPTIONAL HARDWARE KITS - FAILURE TO DO SO CAN RESULT
7LM2500PC101B. IN UNDUE STRESS BEING
a. Refer to Volume II, WP 001 00 for a PONENTS, WITH IMMEDIATE OR
detailed list of optional kits available for this SUBSEQUENT DESTRUCTIVE
particular gas turbine model. FAILURE OF THE GAS TURBINE
NOTE
a. These instructions contain the gas tur-
bine operating procedures and limits recom- The S. I. units shown in this addendum
are direct mathematical conversions
mended by the General Electric Company for
and may be rounded off in most
the 7LM2500PC101B Gas Turbine.
instances at the user’s discretion.
b. The instructions are intended to pro- Examples of units that may be rounded
vide operating personnel with the information off are those utilized for temperatures,
required to operate the gas turbine. They per- torque values, pressures, etc. Examples
tain to routine and emergency conditions and where S.I. units may not be rounded off
procedures. When a fault exists, refer to are those utilized for drop checks, rig-
Volume I, Chapter IV, Troubleshooting. ging adjustments, runouts, etc.

I-6
GEK 97310
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ADDENDUM I
8-1 PERFORMANCE RATINGS AND Power Turbine Inlet Gas 1408°F at 27500
OPERATING LIMITS. Temperature Avg. BHP
1481°F at 30000
NOTE BHP
Ratings published in this manual apply
b. Approximate starting fuel flow require-
ments based on applying fuel and ignition at
ings/ limits may be lower in some cases
1200 rpm are:
turbine manual limits. 465 pph (211 kg/h) ± 25 pph (11 kg) @ -65°F
(-54°C) Inlet Air Temperature
550 pph (250 kg/h) ± 25 pph (11 kg) @ +60°F
a. The rated performance of the (+16°C) Inlet Air Temperature
7LM2500PC101B gas turbine in the new and
clean conditions is as follows: 595 pph (270 kg/h) ± 25 pph (11 kg) @
+130°F (+54°C) Inlet Air Temperature
• Brake Horsepower
- Continuous 27,500 BHP c. Typical transient fuel flow require-

ments are shown in Acceleration Fuel
- Maximum 30,000 PHM Schedule, figure 3.
• Heat Rate, Average 6895 Btu/HP-hr d. Deleted

(Continuous)
Heat Rate, Average 6876 Btu/HP-hr those shown will result in over-temperature
(Maximum) and possible stall of the gas turbine. Accelera-
Based on the following conditions: result in “hung” starts in the below idle speed
Inlet Air Temperature 59°F range.
Altitude Sea Level f. Above the idle speed point, low accel-
Inlet Losses 0” H2O and will only result in slower acceleration
times.
Exhaust Losses 0” H2O
g. For normal accelerations from idle to
Compressor Bleed 0 more slowly to enhance the time between hot
section repairs and the life of the gas turbine; a
Accessory Power 0 time of 2 to 3 minutes is reasonable.
Extraction
Power Turbine Speed 3600 rpm

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Figure 2. Deleted

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ADDENDUM I
h. The fuel rate shown on the curve will 8-1.2 Operating Limits. Refer to table 3.
seconds and accelerations from idle to maxi- NOTE
mum power of 15 seconds. If any operating limit is exceeded, ver-
i. The maximum deceleration fuel flow troubleshooting or inspecting gas
rate should consist of a step fuel decrease of generator.
1500 pph (680.4 kg ph) ± 10% pph followed
by a rate change of 1330 pph (604 kg ph) ±
10% per second to idle fuel flow. Rates greater
than this can cause the engine to lose fire. Nor-
mal decelerations from maximum power to
idle should be made in approximately 2 to 3
minutes - this will enhance the time between
hot section repairs and the life of the gas
turbine.
Alarm/ Normal
NOTE
Settings and Pressure below 8000 rpm.
above 8000 rpm
Gas Turbine Trip 6 psig ± 1 psig 20 - 60 psig Bypass until
Lube Supply (41 kPa ± 6.9 kPa) (138 - 413 kPa) 4500 rpm
Pressure
Scavenge Dis- (759 kPa ± 69 kPa) (69 - 690 kPa) charge Pressure
charge Pressure shall not exceed
180 psig
(1242 kPa)

I-11
GEK 97310
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ADDENDUM I
Alarm/ Normal
Gas Turbine Alarm 180° - 220°F 140° - 160°F Normal Operat-
Lube Supply (82° - 104°C) (60° - 71°C) ing Range
ture expected
during operation
above idle speed
Gas Turbine Trip 330° - 350°F 215° - 275°F Normal Operat-
Lube Scavenge (166° - 177°C) (102° - 135°C) ing Range
Five ture expected
during operation
above idle speed
Alarm 290° - 310°F
(143° - 154°C)
Fuel Fuel 20-355 psig Supply Pressure
System Manifold (138-2448 kPa) as reflected at the
(Natural Pressure fuel manifold
Gas) inlet on the gas
turbine
Fuel Supply Alarm 150° - 170° F -65° to 150°F Starting Fuel
Temperature (66° - 77°C) (-54° to 66°C) Flow Adjust-
ments may be
required to com-
pensate for fuel
temperature
variation
based on engine
starter torque
requirements
Fuel and Ignition
used)

I-12
GEK 97310
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ADDENDUM I
Alarm/ Normal
simultaneously
with start
initiation
simultaneously
with application
of fuel and
ignition
simultaneously
with start initia-
tion. De-energize
ignition, fuel sys-
tem and starter air
supply
used) of purge. De-
energize fuel and
ignition systems
and starter air
supply
Power Failure to Light- Trip 380° - 420°F 0 - 1600°F Trip if tempera-
Turbine Off (193° - 216°C) (18° - 871°C) ture does not
Inlet Tem- reach 400°F
perature (204°C) within
(Natural 20 seconds after
Gas) fuel and ignition
are applied

I-13
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ADDENDUM I
Alarm/ Normal
Overtemperature Trip 1450°F (788°C) 1378° - 1438°F Values given are
using constant
T5.4 control as the
Alarm 1438°F (781°C) power limit.
Installations
using constant
power control
mode should
consult the con-
tract documents
for determining
alarm and trip
settings, which
are unique to
each application,
but never to
exceed 1616°F
(880°C) (alarm)
and 1625°F
(885°C) (trip)
Vibration Gas Generator Trip 7 mils ± 1 mil DA 0 - 3 mils DA Avoid continu-
Alarm 4 mils ± 1 mil DA ous operation
over 4 mils
Power Turbine Trip 10 mils ± 1 mil DA 0 - 6 mils DA Avoid continu-
Alarm 7 mils ± 1 mil DA ous operation
over 7 mils
Speed Gas Generator Trip 9950 ± 50 rpm 0 - 9850 rpm
Power Turbine Trip 3960 ± 40 rpm 0 - 3600 rpm
Loss of Combustor Close and lock
Flame Flame out fuel shutoff
valve upon loss
of flame

I-14
GEK 97310
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ADDENDUM I
that period of operation immediately following Fuel manifold pressure sensor 0-400 psi
on the system. Compressor inlet total pres- 10-16 psia
sure sensor (69-111 kPa)
Operation. Power turbine inlet gas 0-75 psia
Gas generator speed sensor 0-10,000 rpm Compressor discharge 0-300 psig
Lube oil scavenge temperature 0-400°F Fuel supply pressure 0-400 psig
sensors (A-, B-, C-, D-sumps (-18 to 204°C) (0-2760 kPa)
Fuel supply temperature 0-250°F
Lube oil supply temperature 0-400°F (-18 to 121°C)
Vibration indicators 0-3 in/sec or temperature (-18 to 66° C)
gas generator 0-10 mil DA Lube oil scavenge pressure 0-100 psig
(0-690 kPa)
power turbine 0-3 in/sec or Remote reading variable vane -5° to +45°
0-10 mil DA indicator
Power turbine speed sensor 0-5000 rpm Starter air supply pressure 0-50 psig
perature (T5.4) (-18 to 1093°C)

(0-690 kPa)

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GEK 97310
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ADDENDUM I
8-2.4 Preparation. The gas turbine and k. Gas turbine inlet air area
associated systems must be inspected and free of foreign objects. Inlet
checked out for proper installation and opera- screen secure _________
tion before normal operation can commence.
l. Gas turbine compressor rear
frame leakage ports, struts
8-2.5 Gas Turbine and Associated Equip-
7 and 10, are open (not
capped) _________
check list.
m. Starter is serviced per Pack-
a. Gas Turbine Assembly S/N _________ ager’s manual _________
b. Mounting base secured to n. Lube oil storage tank ser-
foundation _________ viced to full level _________
c. Intake air and exhaust gas o. Lube oil supply valves open _________
ducts in place and secured _________ p. All filters are serviced per
d. Bonding straps in place and Packager’s manual _________
secure _________ q. Fire alarm/extinguish sys-
e. Gas turbine and exhaust tem ON and operative _________
duct support mounts and r. T5.4 thermocouple system
links in place and secure _________ functioning properly _________
f. All service connections s. Ignition system operative _________
made and secure _________ t. Compressor inlet total pres-
g. All lines have been flushed sure probe aligned properly
per Packager’s manual _________ and free of damage _________
h. All instrumentation connec- u. Variable stator vane system
tions made and secure _________ secure _________
i. All accessories are secure v. Required checks and
per Packager’s manual _________ inspections specified in
j. Gas turbine assembly free Packager’s manual for gas
of loose objects and all turbine control have been
lines/electrical leads performed _________
connected _________

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ADDENDUM I
8-2.6 Governor and Manual Control • ALLOW THE GAS TURBINE TO
Check. Refer to Packager’s manual. COOL DOWN. AVOID CON-
8-2.7 Start-up and Checkout. WEAR THERMALLY INSU-
WARNING SARY.

MET:
• THE GAS TURBINE SHALL BE • DO NOT REMAIN IN THE
SHUT DOWN. ENCLOSURE OR IN THE
ENTRY SHOULD BE
REQUIRED DURING ENGINE a. When entering enclosure at or below
OPERATION, CONTACT GE idle speed, wear proper ear protection.
paragraph 8-2.9.
INACTIVE ACCORDING TO e. Perform false start per
THE CUSTOMER’S PROCE- paragraph 8-2. 10.
DURES. f. Perform governor check per
ENCLOSURE SHALL BE SHUT g. Perform a wet prestart per
ING OR CLOSING THE h. Perform a manual start and operate per
i. Operate to maximum power per
GAS TURBINE IS OPERATING, j. Check automatic operation per
BE FOLLOWED.

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ADDENDUM I
Item Requirement
and discrepancies
Fuel valves Closed
Ignition Off
Oil tank level Full
Lube oil temperature 140° F to 160°F
(60° to 71° C)
Fuel supply
(2413 ± 35 kPa)
temperature -65 to 150°F
(-54° to 66°C)
flow 13,400 ppg
(6078 kg/h) max

I-18
GEK 97310
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ADDENDUM I
8-2.8 Ignition Check. 8-2.9 Motoring. After all preliminary
motor gas generator as follows:
WARNING
a. Make ignition and natural-gas supply
CONNECTING AND CONNECT- (1) Disconnect power supply to igni-
ING IGNITION EXCITER INPUT tion unit.
SERVICE” TO PRECLUDE (2) Close natural-gas manual shutoff
INADVERTENT ACTIVATION. valve to fuel control unit.
• ASSURE FUEL VALVES ARE b. Depress MOTORING pushbutton. Gas

CLOSED THROUGHOUT THIS generator will start to rotate. If it does not,
PROCEDURE. refer to packager’s manual for supply pressure
to starter.
a. To clear combustor of any residual c. Hold MOTORING pushbutton closed
fuel, motor gas turbine for one minute; allow until gas generator speed stabilizes, and check
gas turbine to coast down. for oil pressure. If there is no indication of oil
b. Disconnect number one ignition exciter while gas generator is coasting down, loosen
input lead at exciter. Temporarily secure input oil fittings at lube pump to bleed air from sys-
lead away from the exciter. tem. Starter should motor gas generator to
minimum of 2200 rpm.
system (No. 2 ignition exciter energized). An d. Repeat motoring and bleeding proce-
audible report (approximately two sparks per dure until an indication of oil pressure appears.
igniter fires. 8-2.10 False Start. Perform false start as
follows:
system. Reconnect input lead to exciter and a. With ignition leads disconnected and
safety-wire connector. manual gas valve closed, make automatic start
of gas turbine per packager’s manual.
the No. 2 exciter. b. Gas generator should go through nor-
f. If an audible report is not heard on No. of flame.
1 and/or No. 2 igniters, check out the system to
isolate the problem, and take appropriate cor-
rective action.

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8-2.11 Governor Check. Check governor CAUTION
8-2.12 Wet Prestart. Perform wet prestart as AND 30 SECONDS OF GAS TUR-
follows: BINE OPERATION WITHOUT
a. With ignition lead disconnected, but FOR EARLY MODEL GAS TUR-
with manual gas valve open and governing BINES THAT HAVE TIGHTER LPT
system operating, make automatic start of gas BLADE TIP CLEARANCES, DO
generator per packager’s manual. NOT EXCEED 6000 RPM NGG AND
b. Gas generator should accelerate to OPERATION WITHOUT POWER
light-off speed (1100 to 1300 rpm). Fuel valve TURBINE ROTATION.
be approximately 3 psig (21 kPa). Adjust fuel a. The power turbine must rotate by the
supply if required. Start will then abort time the gas generator speed reaches 7000 rpm
because of lack of flame. NGG. If power turbine speed indication is not
obtained and it is determined that a “thermal
seizure” of the power turbine has occurred,
proceed as follows:
gas from gas generator. Remain on the starter
for 60 seconds to purge fuel from the gas
NOTE
turbine.
8-2.13 Manual Start and Operation. Per- rotor can occur when a hot gas turbine
form manual start per packager’s manual with is shut down and is most likely to occur
fuel valve open and with ignition lead con- within 30 to 40 minutes following gas
nected. Refer to Table 5. turbine operation. Thermal seizure is
NOTE rotor is prevented from rotating by hard
Power turbine, except in a new installa- contact between LPT blades and
tion, will be rotating when gas genera- shrouds, interstage seals and other
tor idle speed is attained. internal interference. This condition is

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GEK 97310
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ADDENDUM I
(2) Immediately after the gas turbine (5) Immediately after gas turbine
stops rotating, re-start and stabilize at idle rotation stops, re-start and accelerate to
speed (4950 ± 50 rpm) for 30 seconds. 7000 rpm NGG maximum and stabilize for
(3) Repeat steps (1) and (2) for two rotate, shut down and investigate/correct the
additional start-up and shutdown cycles. cause. During the investigation for the cause of
(4) If the power turbine does not blades in stages 4, 5 and 6 for shingling and
rotate after accomplishing substeps (1) through unlatching. If blades have become unlatched,
(3), shut down the gas turbine. they may be relatched. LPT blades that have
turbine.
CAUTION
TURBINE ROTATION.

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ADDENDUM I

1. Assure that prestart checks Automatic shutdown (trip)

are completed per Table 4 at 1450°F (788°C). Refer to
Table 3
CAUTION
IF T5.4 RAPIDLY APPROACHES OR EXCEEDS 1438°F (781°C), ABORT START.
NOTE
A start may be aborted at any time by closing the fuel valve, allowing gas generator to
NOTE
3. At 1100 to 1300 rpm NGG
a. Ignition on
c. Note time to lightoff 20 seconds maximum Abort start-automatic
(T5.4 above 400°F - shutdown
204°C) 1200 rpm
NGG take corrective action if rpm
longer than 90 sec to reach
4300 rpm

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ADDENDUM I

5. At 4300 to 4700 rpm NGG
60 seconds; then shut off
starter

Chapter 5 (41 kPa)
b. Maximum NGG with 7000 rpm NGG maximum Shut down and investigate/
(thermal seizure) model gas turbines that have paragraph 8-2.13
ances, do not exceed 6000
rpm NGG and 30 seconds of
gas turbine operation with-
out power turbine rotation)
d. T5.4 1000°F (538°C) maximum Emergency shutdown,

Table 7
f. Gas generator vibration 0 to 3 mils DA Alarm at 4 mils. Automatic
normal shutdown. If above 7
corrective action
g. Power turbine vibration 0 to 6 mils DA Alarm at 7 mils. Automatic

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ADDENDUM I

h. Compressor inlet tem- Approximately equal to Troubleshoot sensing and

perature (T2) outside air temperature indicating system. Correct
as required
i. Check for fuel or oil No leaks allowed Correct as required
leaks
8. Set desired power setting. 1438°F (781°C) maximum Correct as required. Refer to
Observe T5.4 during tran- figure 1
sient operation
a. T5.4 1438°F (781°C) *

figures in Chapter 5 shutdown if 5 psig (34 kPa)
out of limits
(102° to 135°C) above 340°F (171°C)
4 mils (Alarm) Troubleshoot
7 mils (Trip) Emergency or automatic
shutdown
g. Power turbine vibration 7 mils maximum (Alarm) *
10 mils maximum (Trip) Emergency or automatic
shutdown
h. Fuel manifold inlet 350 ± 5 psig **
pressure (2413 ± 35 kPa)
i. Fuel inlet temperature -65° to 150°F **
(-54° to +66°C)

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ADDENDUM I

WP 118 00 WP 118 00
limits, shutdown.

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ADDENDUM I

(unloaded)
following:
Chapter 5 if below 8 psig
c. T5.4 1000°F (538°C) maximum Troubleshoot and take

corrective action
e. Gas generator vibration 3 mils maximum Alarm at 4 mils. Automatic

normal shut down if above
f. Power turbine vibration 6 mils maximum Alarm at 7 mils. Automatic
normal shut down if above
g. Fuel inlet temperature -65° to 150°F (-54° to 66°C)
decelerate and stop
4. Observe T5.4 for 3 minutes 700°F (371°C) Motor gas turbine and shut
after shut down off fuel supply. Continue
decreases

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ADDENDUM I

CAUTION
1. Conditions permitting, T5.4 drops below 400°F Manual shut off fuel supply
decelerate gas turbine to idle (204°C) and NGG and NPT
and close fuel valves decelerate
2. Observe T5.4 for 3 minutes 700°F (371°C) max. Motor gas turbine. Con-
after shutdown tinue motoring until temper-
ature decreases
(T5.4) greater than 1150°F
(621°C) has occurred, and a
“hot restart” is required, pro-
ceed as follows:
a. If the fault detection and
sequencing system can
be cleared and the gas
turbine can be restarted
within 1 minute follow-
HPC rotor, acceptable
restarts can be made
using the normal starting
procedure.

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GEK 97310
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ADDENDUM I

b. If a “hot restart” is to be
performed between
1 minute and 2 hours
following the emer-
gency shutdown, motor
the gas turbine at
5 minutes. At the end of
the 5 minute motoring/
purge cycle, perform
normal restart and accel-
erate to idle. Accelera-
tion to the desired power
setting can then be
accomplished.
c. After 2 hours following
coastdown of the HPC
rotor, restart can be made
procedure.

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ADDENDUM I
8-2.14 Operation to Maximum Power. 8-2.15 Automatic Operation. Check auto-
CAUTION
tions are not within limits, consult the local g. Check lube oil and fuel filters and
General Electric Company representative. strainers; clean or replace as necessary.
b. Operate gas turbine up to rated power, h. Correct any leaks observed.
perature (T5.4) limit. Hold at this power setting i. Remove all temporary instrumentation.
system is unstable, adjust per packager’s j. Check gas turbine and mounting sys-
manual. tem for loose parts; tighten as necessary.
c. Log all instrument readings once they 8-3 NORMAL OPERATION.

d. Reduce gas generator speed to idle. tine operation of an installed gas turbine. For
After stabilizing for three minutes, record all directions in the use of manual or automatic
instrument readings. Refer to Table 6, step 2. operation for normal operation, refer to pack-
ager’s manual.
tem per packager’s manual. 8-3.2 Interlocks. Refer to packager’s man-
ual for description of interlocks which affect
f. After gas turbine has been stabilized at gas turbine operation.

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ADDENDUM I
WARNING
MET:
SHUT DOWN.
ear protection.
TO ENTER THE ENCLOSURE b. Start and operate the gas turbine per
UNDER SUCH CONDITIONS. Table 5. Do not exceed operating limits of
Table 3.
SYSTEM SHALL BE MADE c. Shut down the gas turbine per Table 6.
THE CUSTOMER’S PROCE- d. Emergency shut down the gas turbine
DURES. per Table 7.
• SECONDARY AIR TO THE e. Refer to paragraph 5-3.30 and 5-3.31,

ENCLOSURE SHALL BE SHUT for lube correction factors and lube supply
OFF. HIGH SECONDARY AIR- pressure characteristics. (See tables V-21A,
FLOW MAY PREVENT OPEN- V-21B, V-21E, and V-21F, and figures 5-32A,
ING OR CLOSING THE 5-32B, 5-32E, 5-32F, 5-32J, 5-32L, 5-32N,
ENCLOSURE DOOR. and 5-32Q.)
• THE ENCLOSURE DOOR f. Idle lube oil pressure is 29 psig maxi-

SHALL BE KEPT OPEN. IF THE mum after five minutes stabilization.
BE FOLLOWED.

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ADDENDUM I
lube oil shall be per applicable table in per Table 7.
Chapter 5 at standard conditions of 9000 rpm
gas generator speed and 150°F lube pump dis- 8-4.2 Post Shutdown Fire.
charge temperature. Oil pressure measured at
conditions other than standard shall be cor- a. During a normal shutdown, exhaust
rected to standard conditions using applicable gas temperature should decrease. If during
table in Chapter 5. time gas generator is coasting to stop, tempera-
ture increases instead of decreases, it indicates
8-4 EMERGENCY OPERATION. that combustion is still taking place because of
a leaking fuel valve. (A slight temperature
8-4.1 Emergency Shutdown. increase after rotation stops is normal.) Make
a. In an emergency, the gas generator may erator. This will blow out the fire. As soon as
be shut down from any power setting by clos- temperature decreases to normal, discontinue
ing the fuel valve. However, this should only motoring.

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Table 8. Deleted

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ADDENDUM I
Figure 4 through Figure 7. Deleted

I-33/(I-34 Blank)
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ADDENDUM
7LM2500PC101A

GEK 97310
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ADDENDUM J
TABLE OF CONTENTS
1-0 INTRODUCTION....................................................................................... J-3

2-0 REFERENCE DATA .................................................................................. J-3
3-0 INSTALLATION DRAWINGS.................................................................. J-4
4-0 EQUIPMENT DESCRIPTION ................................................................. J-4
5-0 GAS TURBINE CONTROL ...................................................................... J-4
6-0 NOX SUPPRESSION (WATER INJECTION SYSTEM)....................... J-4
7-0 INSTRUMENTATION AND SUPPLY REQUIREMENTS ................... J-8
8-0 SERVICE REQUIREMENTS ................................................................... J-10
8-1.1 Natural Gas ................................................................................................... J-10
8-1.2 Liquid Fuel.................................................................................................... J-10
8-1.3 Water Servicing and Pumping Requirements (NOX Suppression)............... J-10
9-0 OPTIONAL HARDWARE KITS .............................................................. J-11
10-0 GAS TURBINE OPERATION .................................................................. J-11
10-1 PERFORMANCE RATINGS AND OPERATING LIMITS .................. J-11
10-1.1 Performance Ratings ..................................................................................... J-12
10-1.2 Water Scheduling Requirements During Operations (NOX Suppression) ... J-13
10-1.3 Operating Limits ........................................................................................... J-14
10-2 INITIAL OPERATION .............................................................................. J-18
10-2.1 General .......................................................................................................... J-18
10-2.2 Special Instrumentation Required for Operation .......................................... J-18
10-2.3 Special Instrumentation Required for Monitoring and Troubleshooting ...... J-18
10-2.4 Preparation .................................................................................................... J-19
10-2.5 Gas Turbine and Associated Equipment Check List..................................... J-19
10-2.6 Governor and Manual Control Check........................................................... J-19
10-2.7 Start-Up and Checkout.................................................................................. J-20
10-2.8 Ignition Check............................................................................................... J-21
10-2.9 Motoring........................................................................................................ J-22
10-2.10 False Start...................................................................................................... J-22
10-2.11 Governor Check ............................................................................................ J-22
10-2.12 Wet Prestart ................................................................................................... J-22
10-2.13 Manual Start and Operation .......................................................................... J-23
10-2.14 Operation to Maximum Power...................................................................... J-24
10-2.15 Automatic Operation..................................................................................... J-24
10-3 NORMAL OPERATION............................................................................ J-30
10-3.1 Interlocks....................................................................................................... J-38
10-3.2 Operation....................................................................................................... J-38
10-4 EMERGENCY OPERATION ................................................................... J-39
10-4.1 Emergency Shutdown ................................................................................... J-39
10-4.2 Post Shutdown Fire ....................................................................................... J-39

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Figure Title Page
1 Deleted
2 Deleted
3 Deleted
4 Deleted
5 Deleted
6 Typical Acceleration Fuel Flow Schedule When Operating on Natural Gas ........ J-6
7 Typical Acceleration Fuel Flow Schedule When Operating on Liquid Fuel......... J-7
8 Fuel Manifold Pressure vs. Fuel Flow When Operating on Natural Gas .............. J-32
9 Fuel Manifold Pressure vs. Fuel Flow When Operating on Natural Gas .............. J-33
10 Fuel Manifold Pressure vs. Fuel Flow When Operating on Liquid Fuel............... J-34
11 NOX Suppresion - Total Flow vs. Fuel Nozzle Pressure Drop ............................. J-35
12 NOX Suppresion - Total Flow vs. Fuel Nozzle Pressure Drop ............................. J-36
13 Transient Temperature Limits ................................................................................ J-37
LIST OF TABLES
Table Title Page
1 INSTRUMENTATION CONNECTIONS............................................................. J-8

2 SUPPLY CONNECTIONS.................................................................................... J-9
3 GAS TURBINE OPERATING LIMITS................................................................ J-14
4 PRESTART CHECKS ........................................................................................... J-21
5 START-UP AND OPERATION ............................................................................ J-25
6 GAS TURBINE SHUTDOWN ............................................................................. J-30
7 EMERGENCY SHUTDOWN............................................................................... J-40
8 DELETED

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ADDENDUM J
The information contained herein describes the Combustor 120 (54)
7LM2500PC101A model gas turbine basic High Pressure Turbine Rotor 419 (190)
configuration and control system differences. High Pressure Turbine Nozzle,
In addition, the coverage of reference data, Stage 1 68 (31)
cial servicing requirements, optional hardware Stage 2 127 (58)
kits and the complete gas turbine operating Turbine Mid Frame 530 (240)
instructions for the 7LM2500PC101A model Low Pressure Turbine Rotor 1095 (497)
are included. Low Pressure Turbine Stator 601 (273)
2-0 REFERENCE DATA. High Speed Coupling Shaft For-
ward Adapter 91 (41)
EQUIPMENT Exhaust Duct Assembly 2741 (1243)
Gas Turbine Assembly Outer Cone 410 (186)
(General Electric Co., Cincinnati OH) Inner Deflector 255 (116)
Model No. 7LM2500PC101A Ring Seal 49 (22)
Dwg. No. L24330G04 Ring Support 74 (34)
Insulation 269 (122)
PERFORMANCE RATING Cover, Insulation 62 (28)
Variable Stator Actuating Mech 19 (9)
Refer to paragraph 10-1. Outside Piping and Bracketing 278 (126)
GAS TURBINE WEIGHTS DRAWING LIST

Drawing No.
The average weights of the major gas turbine com- Gas Turbine Installation Drawing L31705
ponents are:
Lubrication System Flow Diagram L24328
Gas turbine - including inlet duct, Electrical Diagram L24329
centerbody, exhaust diffuser, and Ignition Units L21454P02
coupling nut 7396 (3355) Gas Turbine Assembly Drawing L24330G04
Inlet Gearbox 38 (17)
Transfer Gearbox 245 (111)

J-3
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ADDENDUM J
3-0 INSTALLATION DRAWINGS. 5-0 GAS TURBINE CONTROL.
A complete set of installation drawings have a. The transition from natural gas to liq-
been provided. uid fuel and vice versa shall be smooth and
shall not result in abrupt changes in gas gener-
4-0 EQUIPMENT DESCRIPTION. ator speed or temperatures. The rate of change
from natural gas to liquid fuel or vice versa is a
The 7LM2500PC101A is a dual - fueled, (nat- function of the operator’s control system, so
ural gas and liquid fuel), non-marinized gas long as the change in total fuel flow does not
turbine and is furnished complete with an exceed that shown on the maximum accelera-
exhaust duct and exhaust inner diffuser as tion fuel flow curves. (See figures 6 and 7.)
standard equipment. The on-engine mounted
dual-fuel system consists of a natural gas man- 6-0 NOX SUPPRESSION (WATER
ifold, a liquid fuel manifold and 30 dual-fuel INJECTION SYSTEM).
nozzles. The 7LM2500PC101A gas turbine is
designed to operate on 100 percent natural gas, a. As an option, the 7LM2500PC101A
100 percent liquid fuel or a combination of the gas turbine can be equipped for suppression of
two. The minimum fuel flow for each fuel, oxides of nitrogen (NOX) in the gas generator
when operating on dual fuel, should be exhaust gases. This is accomplished by intro-
selected so that if one fuel is cut off, the gas duction of water into the liquid fuel manifold.
generator speed will not decrease below The LM2500 NOX suppression system has
5000 RPM before the governor action restores been designed to meet the requirements of the
the gas generator to normal operation. Should U.S.E.P.A. standard for NOX emissions for
the gas turbine be configured with the optional stationary gas turbines and includes a conser-
NOX Suppression equipment, and prior to ini- vative margin for meeting the requirements of
tiation of water flow for NOX Suppression, it other, possibly more restrictive, local codes
is recommended that the gas generator be where applicable.
operating at a stabilized steady-state condition.

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7-0 INSTRUMENTATION
AND SUPPLY REQUIREMENTS.
See Tables 1 and 2.
Table 1. INSTRUMENTATION CONNECTIONS
El Vibration pickup, Gas Generator Bell & Howell Electronics Part No. 173960 or
364450
E3 A-sump scavenge oil temperature MS3106Rl2S-3S
E3A “A” Sump T/C (optional equipment) MS3106R-12S-3SW except pin A iron and pin
B constantan
E4A “B” sump T/C (optional equipment) MS3106R-12S-3SW except pin A iron and pin
B constantan
E5A “C” sump T/C (optional equipment) MS3106R-12S-3SW except pin A iron and pin
B constantan
temperature
E6A Accessory gearbox T/C (optional MS3106R-12S-3SW except pin A iron and pin
equipment) B constantan
E11A Inlet T/C (optional equipment) MS3106R-12S-3SW except pin A iron and pin
B constantan
E18A “D” sump T/C (optional equipment) MS3106R-12S-3SW except pin A iron and pin
B constantan
364450
(optional)
A23 CDP pressure port (optional) 0.500-20UNJF-3B
F3 Natural gas fuel manifold pressure tap MS9197-04 or AN818-4C
(optional)
F5 Fuel manifold liquid pressure tap AN818-6C or MS9197-06

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ADDENDUM J
Table 1. INSTRUMENTATION CONNECTIONS - Continued
E 17 Gas turbine electrical bond, right
NOTE
For all other instrumentation connections, refer to lnstallation Drawings
Table 2. SUPPLY CONNECTIONS

CAUTION
GROWTH OF GAS GENERATOR WITHOUT PLACING STRAIN ON LINES OR ON
GAS GENERATOR. IF EXCESSIVE FORCE IS REQUIRED TO COMPLETE A CON-
NECTION, LOOSEN ALL CONNECTIONS AND CHECK/ADJUST ROUTING AS
REQUIRED.
F1 Natural gas supply 2 inch line from fuel control unit to gas generator fuel
manifold
F2 NOX H20 Fuel manifold inlet liquid, mates with AN818-12C or
MS20819-12C or equivalent
L1 Oil supply 1-1/2 inch line to lube pump on gas generator,
AN818-24C or MS20819-24C
L2 Lube pump discharge 1 inch line from lube pump to oil supply filters,
AN819-16C or MS20819-16C
L4 Lube supply inlet port 1 inch line from oil supply filters to gas generator,
AN818-16C or MS20819-16C
L3 Scavenge oil discharge 1-1/4 inch line from gas generator scavenge pump to
oil scavenge filter and cooler, AN818-20C or
MS20819-20C
A1 Bleed air port 8th stage Shipped with cover that must remain in place if port is
not used
A6 Starter air or gas inlet port (optional
equipment)

J-9
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ADDENDUM J
Table 2. SUPPLY CONNECTIONS - Continued
A10A CDP seal leakage No. 1 If used -2-inch line attaching hardware
A20 C-sump overboard vent left bottom If used - 2-inch line attaching hardware
A21 C-sump overboard vent right bottom If used - 2-inch line attaching hardware
A22 C-sump overboard vent right top If used - 2-inch line attaching hardware
to exhaust duct (flame arrestor)
S1 or Waterwash manifold 1 inch line - hot water line to waterwash manifold on
SlA gas generator inlet duct AN818-16C or MS20819-16C
F3 H20 Manifold shroud drain Mate with AN818-4C or MS9197-04
NOTE
For all other supply connections, refer to Installation Drawings provided
with gas turbine.
8-0 SERVICE REQUIREMENTS. (-6.7ºC) above the wax point of the fuel and a
8-1.1 Natural Gas. filtered to 20 microns absolute. The maximum
fuel flow required is 13,000 pph (5897 kg/h)
a. The required supply pressure to the with a lower heating value of 18,400 Btu/lb.
fuel manifold on the gas turbine is 350 ± 5 psig
(2415 ± 35 kPa). 8-1.3 Water Servicing and Pumping
b. The temperature of the gas must be in Requirements (NOX Suppression).
the range of -65º to +150ºF (-54 to +60ºC). If a. The maximum allowable water deliv-
the temperature is not repeatable on a day-to- ery pressure at the manifold connection shall
day basis it will be necessary to change the not exceed 1200 psig (8280 kPa). The temper-
starting fuel adjustment to adjust the supply ature of the water supplied to the manifold
pressure to the engine to maintain a constant shall not exceed 180ºF (82ºC) and shall be free
Btu-per-cubic-foot supply. Once started, the of pressure pulsations in the 0 to 300 Hz range.
engine will accept variations in supply temper- The water must be controlled in a manner to
ature of ± 20ºF (± 12ºC). The maximum fuel prevent any sudden pressure spikes which
flow required is 13,400 pph (5443 kg/h) with a could momentarily displace the fuel. Refer to
lower heating value of 19, 000 Btu/lb. applicable gas turbine performance data and
fuel nozzle flow characteristic curve for water
8-1.2 Liquid Fuel. pump size determination. Other criteria, such
a. The required supply pressure to the as calculated gas generator water flow required
fuel manifold on the gas turbine is 390 ± 5 psig to meet the requirement of the applicable EPA
(2691 ± 35 kPa). standard or other local codes, corresponding
b. The fuel temperature supplied to the pressure level may be obtained from the tabu-
gas turbine shall be a minimum of 20ºF lar performance data sheets.

J-10
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ADDENDUM J
9-0 OPTIONAL HARDWARE KITS - FAILURE OF THE GAS TURBINE
7LM2500PC101A. AND INJURY TO PERSONNEL.
a. Refer to Volume II, WP 001 00 for a NOTE
particular gas turbine model. The S.I. units shown in this chapter are
10-0 GAS TURBINE OPERATION. may be rounded off in most instances
at the user’s discretion. Examples of
pany for the 7LM2500PC101A gas turbine.
S.I. units may not be rounded off are
b. The instructions are intended to pro- those utilized for drop checks, rigging
vide operating personnel with the information adjustments, runouts, etc.
tain to routine and emergency conditions and 10-1 PERFORMANCE RATINGS AND
procedures. When a fault exists, refer to Chap- OPERATING LIMITS.
ter 4 entitled, TROUBLESHOOTING.
NOTE
may not provide for every possible variation in Ratings published in this manual apply
equipment or contingency to be met in connec- to the gas turbine. The driven unit rat-
Refer requests for additional information to the and shall take precedence over the gas
General Electric Company, Marine and Indus-
trial Engine Division, Cincinnati, Ohio 45215.
WARNING

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ADDENDUM J
10-1.1 Performance Ratings. Water Injection
- Gas 0 Lbs/Hr 1828 Lbs/Hr
a. The rated performance of the (829 kg/h)
7LM2500PC101A gas turbine in the new and - Liquid 0 Lbs/Hr 3984 Lbs/Hr
clean condition as compared to gas turbine
(1807 Kg/h)
Fuel Flow
follows:
- Gas 9996 Lbs/Hr 10073 Lbs/
NOTE (4525 kg/h) Hr
- Liquid 10399 Lbs/ (4569 kg/h)
The use of water injection to control
Hr 10567 Lbs/
NOX emissions results in a change in
(4717 kg/h) Hr
gas turbine performance. Unless spe-
(4793 kg/h)
contract documents, all performance NOX Emissions
guarantees are based upon “dry” opera- (ppm at 15% 02)
tion with no water injection. -Gas 170 170
- Liquid 290 290
Normal With NOX b. The gas turbine is designed to operate
(Dry) Suppression on 100% natural gas fuel, 100% liquid fuel, or
Brake Horsepower 27,500 27,500 on combinations of the two with a limit on nat-
Inlet Air 59ºF(15ºC) 59ºF(15ºC) ural gas/liquid fuel ratios of 10/90 to 90/10.
Temperature The gas turbine can be started on either natural
Inlet Losses 0” H2O 0” H2O gas or liquid fuel but not on a combination of
Exhaust Back 0” H2O 0” H2O the two. The starting fuel flows on natural gas
Pressure are:
Relative Humidity 60% 60%
Altitude 0 Ft 0 Ft 465 pph (211 kg/h) ± 25 pph (11 kg) @ -65ºF
Compressor Bleed 0 lbs/sec 0 lbs/sec (-54ºC) Inlet Air Temperature
Accessory 0 0
550 pph (249 kg/h) ± 25 pph (11 kg) @ +60ºF
Horsepower (16ºC) Inlet Air Temperature
Extraction
Power Turbine 3600 RPM 3600 RPM 595 pph (270 kg/h) ± 25 pph (11 kg) @ +130ºF
Speed (54ºC) Inlet Air Temperature
Heat Rate, Max
- Gas 6907 BTU/ 6959 BTU/ The starting fuel flows on liquid fuel are:
hp-hr hp-hr 530 pph (240 kg/h) ± 25 pph (11 kg) @ -65ºF
- Liquid 6958 BTU/ 7070 BTU/ (-54ºC) Inlet Air Temperature
hp-hr hp-hr
Power Turbine Inlet 625 pph (284 kg/h) ± 25 pph (11 kg) @ +60ºF
Gas Temperature (16ºC) Inlet Air Temperature
- Gas 1406ºF 1404ºF
- Liquid (763ºC) (762ºC) 680 pph (308 kg/h) ± 25 pph (11 kg) @ +130ºF
1427ºF 1402ºF (54ºC) Inlet Air Temperature
(775ºC) (761ºC)

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c. The minimum fuel flow for each fuel, j. The liquid fuel system must be free of
when operating on dual fuel, should be periodic or random hunting which results in
selected so that if one fuel is cut off the gas cycling of gas generator speed or temperature.
generator speed will not decrease below 5000 The frequency of the fuel flow fluctuations
rpm before the governor action restores the shall not be a harmonic of the natural fre-
engine to normal operation. quency of the springs in the fuel nozzles. The
d. Figures 6 and 7 define the maximum Cycling of these parameters will reduce time
fuel acceleration schedule for the gas genera- between hot section repairs and the life of the
tor. When operating on dual fuel, the schedule, gas turbine. The transition from natural gas to
liquid or natural gas, which gives the lower liquid fuel and vice versa shall be smooth and
fuel rate shall be used. shall not result in abrupt changes in gas gener-
ator speed or temperature. The rate of change,
e. Acceleration fuel rates greater than natural gas to liquid fuel or vice versa, must be
those shown will result in over-temperature such that the transfer time from one fuel to
and possible stall of the engine. Acceleration another at full power shall not exceed
fuel rates lower than those shown can result in 10 seconds.
“hung” starts in the below idle speed range.
f. Above the idle speed point, low accel- 7LM2500PC101A gas turbine will be a func-
eration fuel rates will not harm the engine and tion of the ratio of natural gas fuel and liquid
will only result in slower acceleration times. fuel used. The time between repairs of the hot
section will also change as a function of the
g. For normal accelerations from idle to ratio of the natural gas and liquid fuels used
power settings the changes should be made with the longest times being associated with
more slowly to enhance the time between hot 100% natural gas.
section repairs and the life of the engine; a
time of 2 to 3 minutes is reasonable. 10-1.2 Water Scheduling Requirements Dur-
ing Operations (NOX Suppression). Water
h. The fuel rates shown on the curves will flow must be scheduled as a function of fuel
give starting times to 5000 rpm idle of flow and must be shut off during starting and
60 to 90 seconds and accelerations from idle to acceleration to idle. Water flow should be initi-
maximum power of 15 seconds. ated at a fuel flow of 3000 pph ± 250 pph
(1361 kg/h ± 113 kg/h) on acceleration when
i. The maximum deceleration fuel flow operating with liquid fuel and at
rate should consist of a step fuel decrease of 5300 pph ± 450 pph (2404 kg/h ± 204 kg/h) on
1500 (680 kg/h) ± 10% pph followed by a rate acceleration when operating on natural gas.
change of 1330 pph (603 kg/h) ± 10% per sec- Subsequently, the water should be shut off at
ond to idle fuel flow. Rates greater than this these points on a deceleration. During initia-
can cause the engine to lose fire. Normal tion of water flow, the gas turbine should be
decelerations from maximum power to idle operating at a stabilized steady-state condition.
should be made in approximately 2 to 3 min- Refer to figures 11 through 13 for water/fuel
utes. This will enhance the time between hot ratios, supply pressures and manifold pressure/
section repairs and the life of the gas turbine. flow requirements.

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a. Water Purity. The water supplied to the • Water solid contaminants shall not
gas generator must meet the following mini- exceed 10 mg per gallon with a maxi-
mum requirements: mum contaminant size not exceeding
20 microns absolute.
• Sodium + Potassium + Lead +
Vanadium + Lithium + Silica = NOTE
0. 1 ppm maximum. When water is injected at the flow rates
necessary to meet U.S.E.P.A. require-
• Total ionizable solids, both dissolved ments, the maximum gas generator
and undissolved shall not exceed corrected speed limit must be reduced
5 ppm maximum. to 9650 RPM. There is no change to
9800 RPM maximum physical (uncor-
• PH = 6.5 to 7.5. rected) speed limit.
10-1.3 Operating Limits. Refer to Table 3.

Alarm/ Normal
NOTE
System -Set- Lube Pump (55 kPa ± 6.9 kPa) (138 - 413 kPa) 4500 rpm
tings and Discharge below 8000 rpm
above 8000 rpm
(41 kPa ± 6.9 kPa) (138 - 413 kPa) 4500 rpm
Pressure 180 psig
(1242 kPa)

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ADDENDUM J
Alarm/ Normal
Gas Turbine Alarm 180º - 220ºF 140º - 160ºF Normal Operat-
Lube Pump (82º - 104ºC) (60º - 71ºC) ing Range reflects
operation above
idle speed
Gas Turbine Trip 330º - 350ºF 215º - 275ºF Normal Operat-
Lube Scav- (166º - 177ºC) (102º - 135ºC) ing Range reflects
enge Temper- temperature
atures - Five expected during
Alarm 290º - 310ºF operation above
(143º - 154ºC) idle speed
Fuel System Fuel Mani-
fold Pressure 20 - 390 psig Supply Pressure
Natural Gas (138 - 2689 kPa) as reflected at the
fuel manifold inlet
on the gas turbine
Liquid Fuel 150 - 900 psig Supply Pressure
(1034 - 6205 kPa) as reflected at the
fuel manifold inlet
on the gas turbine
Fuel Supply
Temperature
Natural Gas Alarm 150º - 170ºF -65º - 150ºF Starting Fuel Flow
(66º - 77ºC) (-54º - 66ºC) Adjustments may
be required to
compensate for
fuel temperature
variation
Liquid Fuel 20ºF (-7ºC) above
wax point of fuel
to 150ºF (66ºC)
maximum
System Supply (276 kPa) Requirement
Pressure based on engine
starter torque
requirements

J-15
GEK 97310
VOLUME I
ADDENDUM J
Alarm/ Normal
of Fuel and
Ignition
Application 1700 ± 100 rpm 1700 ± 100 rpm
Ignition (If purge cycle
purge cycle is
used)
simultaneously
with start
initiation
Failure to Trip 380º - 420ºF Activate 20 sec-
simultaneously
with application
of fuel and
ignition
simultaneously
with start initia-
tion. De-energize
ignition, fuel sys-
tem and starter air
supply
(If purge upon completion
gize fuel and igni-
tion systems and
starter air supply

J-16
GEK 97310
VOLUME I
ADDENDUM J
Alarm/ Normal
Power Tur- Failure to Trip 380º - 420ºF 0 - 1600ºF Trip if tempera-
bine Inlet Light-Off (193º - 216ºC) (-18ºC - 871ºC) ture does not
(T5.4) Tem- reach 400ºF
perature (204ºC) within
(Gas 20 seconds after
Overtemperature:
Natural Gas Trip 1450ºF (788ºC) 1378º -1438ºF Values given are
(748º - 781ºC) for installations
Alarm 1438ºF (781ºC) using constant
T5.4 control as the
Liquid Fuel Trip 1470ºF (799ºC) 1400º -1460ºF
(760º - 793ºC) power limit.
Installations using
Alarm 1460ºF (793ºC) constant power
control mode
should consult the
contract docu-
ments for deter-
mining alarm and
trip settings,
which are unique
to each applica-
tion, but never to
exceed 1616ºF
(880ºC) (alarm)
and 1625ºF
(885ºC) (trip)
Generator operation above 4
mils
mils

J-17
GEK 97310
VOLUME I
ADDENDUM J
Alarm/ Normal
Generator
Turbine
upon loss of flame
NOTE Lube oil supply pressure 0-100 psig

If any operating limit is exceeded, ver- (0-690 kPa)
ify instrumentation accuracy before Lube pump discharge pressure 0-100 psig
troubleshooting or inspecting gas gen- (0-690 kPa)
erator. Compressor discharge 0-300 psig
10-2.1 General. Initial operational period is Monitoring and Troubleshooting:
gas turbine replacement or major maintenance Fuel manifold pressure sensor:
on the system. liquid fuel 0-1200 psig
(0-8280 kPa)
Operation. natural gas 0-400 psig
(0-2760 kPa)
Gas generator speed sensor 0-10,000 rpm
Compressor inlet total 10-16 psia
Lube oil scavenge temperature 0-400ºF
pressure sensor (69-110.4 kPa)
sensors (A-, B-, C-, D-sumps (-18ºC-205ºC)
and transfer gearbox) Power turbine inlet gas 0-75 psia
Lube pump discharge 0-400ºF pressure (0-517.5 kPa)
temperature sensor (-18ºC-205ºC) Fuel supply temperature:
Vibration indicators: liquid fuel 0-250ºF
gas generator 0-3 in/sec or (-18ºC-121ºC)
0-10 mil DA natural gas 0-250ºF
power turbine 0-3 in/sec or (-18ºC-121ºC)
0-10 mil DA Gas turbine inlet air 0-150ºF
Power turbine speed sensor 0-5000 rpm temperature (-18ºC-66ºC)
Power turbine inlet gas 0-2000ºF Starter air supply pressure 0-50 psig
temperature (T5.4) (-18ºC-1093ºC) (optional) (0-345 kPa)

J-18
GEK 97310
VOLUME I
ADDENDUM J
10-2.4 Preparation. The gas turbine and 1. Starter is serviced per __________
associated systems must be inspected and packager’s manual
checked out for proper installation and opera-
tion before normal operation can commence. m. Lube oil storage tank ser- __________
viced to full level
n. Lube oil supply valves __________
open
check list.
o. All filters serviced per __________
a. Gas Turbine Assembly __________ packager’s manual
S/N p. T5.4 thermocouple system __________
b. Mounting base secured to __________ functioning properly
foundation q. Ignition system operative __________
c. Intake air and exhaust gas __________ r. Compressor inlet total __________
ducts in place and secured pressure probe aligned
properly and free of
d. Gas turbine and exhaust __________
damage
duct support mounts and
links in place and secure s. Variable stator system __________
secure
e. All service connections __________
made and secure t. Required checks and __________
f. All lines have been flushed __________
packager’s manual for gas
per packager’s manual
g. All instrumentation con- __________ performed
nections made and secure
h. All accessories are secure __________
Refer to packager’s manual.
i. Gas turbine assembly free __________
connected
j. Gas turbine inlet air area __________
Inlet screen secure
k. Gas turbine compressor __________
rear frame leakage ports,
struts 7 and 10, are open
(not capped)

J-19
GEK 97310
VOLUME I
ADDENDUM J
ING REQUIREMENTS SHALL BE • EAR PROTECTION SHALL BE
MET: WORN IF GAS TURBINE IS
SHUT DOWN. • DO NOT REMAIN IN THE
THE CUSTOMER’S PROCE- paragraph 10-2.9.
DURES.
OFF. HIGH SECONDARY AIR- f. Perform governor check per packager’s
FLOW MAY PREVENT OPEN- manual.
ING OR CLOSING THE
ENCLOSURE DOOR. g. Perform a wet prestart per
paragraph 10-2.12.
SHALL BE KEPT OPEN. IF THE h. Perform a manual start and operate per
ENTRY PROCEDURES SHALL j. Check automatic operation per
BE FOLLOWED. paragraph 10-2.15.

J-20
GEK 97310
VOLUME I
ADDENDUM J
10-2.8 Ignition Check. b. Disconnect number one ignition exciter
WARNING
• ASSURE POWER TO IGNITION system (No. 2 ignition exciter energized). An
SYSTEMS IS OFF WHEN DIS- audible report (approximately two sparks per
CONNECTING AND CONNECT- second) should be heard when the No. 2 spark
ING IGNITION EXCITER INPUT igniter fires.
SERVICE TO PRECLUDE INAD- d. Turn off electrical power to the ignition
VERTENT ACTIVATION. system. Reconnect input lead to exciter and
• ASSURE THAT FUEL VALVES safety-wire connector.
ARE CLOSED THROUGHOUT e. Repeat steps b, c and d, disconnecting
THIS PROCEDURE. the No. 2 exciter.
a. To clear combustor of any residual f. If an audible report is not heard on No.
1 and/or No. 2 igniters, check out the system to
rective action.

Item Requirement
Fuel valves Closed
Ignition Off
Oil tank level Full
(60º to 71ºC)
(2413 ± 35 kPa)
temperature -65ºF to 150ºF
(-54º to 66ºC)
flow 13,400 pph
(6078 kg/h) max
liquid fuel pressure 390 ± 5 psig
(2691 ± 35 kPa)
flow 13,000 Lb/h
(5897 kg/h)

J-21
GEK 97310
VOLUME I
ADDENDUM J
10-2.9 Motoring. After all preliminary 10-2.10 False Start. Perform false start as
checks have been completed and lines flushed, follows:
motor gas generator as follows:
a. Make ignition, liquid fuel and natural manual liquid fuel and natural gas shutoff
gas supply systems inoperative as follows: valves closed, make automatic start of gas tur-
bine per packager’s manual.
tion units. b. Gas generator should go through nor-
(2) Close liquid fuel and natural gas of flame.
manual shutoff valves to fuel control unit.
b. Depress MOTORING pushbutton. Gas system per packager’s manual.
generator will start to rotate. If it does not,
refer to packager’s manual for supply pressure 10-2.12 Wet Prestart. Perform wet prestart as
to starter. follows:
c. Hold MOTORING pushbutton closed a. With ignition lead disconnected, but

until gas generator speed stabilizes, and check with either manual natural gas or liquid fuel
for oil pressure. If there is no indication of oil valve open and governing system operating,
pressure, release MOTORING pushbutton. make automatic start of gas generator per
While gas generator is coasting down, loosen packager’s manual.
tem. Starter should motor gas generator to


J-22
GEK 97310
VOLUME I
ADDENDUM J
b. Gas generator should accelerate to a. The power turbine must rotate by the
light-off speed (1100 to 1300 rpm). Fuel valve time the gas generator speed reaches 7000 rpm
should open and fuel manifold pressure should NGG. If power turbine speed indication is not
be approximately 3 psig (21 kpa). Adjust fuel obtained and it is determined that a “thermal
supply if required. Start will then abort seizure” of the power turbine has occurred,
because of lack of flame. proceed as follows:
c. Allow gas generator to coast to a stop. NOTE

Motor it to purge any remaining natural gas
from the gas turbine or drain liquid fuel from
manifold if liquid fuel was used in the wet pre-
start. Purge fuel nozzles of liquid fuel with nat-
ural gas or compressed air at 200 psid (1380
kpa) maximum. Remain on starter for 60 sec-
onds to purge fuel from gas turbine.
10-2.13 Manual Start and Operation. Per-
form manual start per packager’s manual with
fuel system normal and with ignition lead con-
NOTE
Power Turbine, except in a new instal- at idle power for at least five minutes
lation, will be rotating at gas generator prior to shutdown to achieve proper
idle speed. cooling of the power turbine.
CAUTION (1) Shutdown gas turbine.

AND 30 SECONDS OF GAS TUR- stops rotating, re-start and stabilize at idle
BINE OPERATION WITHOUT speed (4950 ± 50 rpm) for 30 seconds.
FOR EARLY MODEL GAS TUR- (3) Repeat steps (1) and (2) for two
BINES THAT HAVE TIGHTER LPT additional start-up and shutdown cycles.
NOT EXCEED 6000 RPM NGG AND (4) If the power turbine does not
30 SECONDS OF GAS TURBINE rotate after accomplishing substeps (1) through
OPERATION WITHOUT POWER (3), shut down the gas turbine.
TURBINE ROTATION.

J-23
GEK 97310
VOLUME I
ADDENDUM J
rotation stops, re-start and accelerate to if possible, but do not exceed exhaust gas tem-
7000 rpm NGG maximum and stabilize for 30 perature (T5.4) limit. Hold at this power setting
seconds. If the power turbine still does not until all temperatures stabilize. If governing
rotate, shut down and investigate/correct the system is unstable, adjust per packager’s
cause. During the investigation for the cause of manual.
blades in stages 4, 5 and 6 for shingling and c. Log all instrument readings once they
unlatching. If blades have become unlatched, stabilize. Refer to Table 5, step 10.
encountered shingling may be bent thereby d. Reduce gas turbine speed to idle. After
necessitating replacement of the power stabilizing for three minutes, record all instru-
turbine. ment readings. Refer to Table 6, step 2.

CAUTION
BINES THAT HAVE TIGHTER LPT f. After gas turbine has been stabilized at
BLADE TIP CLEARANCES, DO idle for five minutes, make normal shut down.
NOT EXCEED 6000 RPM NGG AND Refer to Table 5, steps 3 and 4.
TURBINE ROTATION.
CAUTION
(refer to packager’s manual) to increase gas shut down gas turbine.
within limits, adjust it per work package h. Correct any leaks observed.
118 00. If vibrations are not within limits, con-
sult the local General Electric Company i. Remove all temporary instrumentation.
representative.

J-24
GEK 97310
VOLUME I
ADDENDUM J


are completed per Table 4 1450ºF (788ºC) for natural
gas or 1470ºF (799ºC) for
liquid fuel. Refer to Table 3
CAUTION
• IF T5.4 RAPIDLY APPROACHES OR EXCEEDS 1438ºF
(781ºC) FOR NATURAL GAS OR 1460ºF (793ºC) FOR LIQ-
UID FUEL, ABORT START.
100% NATURAL GAS FUEL, 100% LIQUID FUEL, OR
ON A COMBINATION OF THE TWO. THE GAS TUR-
BINE CAN BE STARTED ON EITHER NATURAL GAS
FUEL OR LIQUID FUEL BUT NOT ON A COMBINATION
OF THE TWO. WHEN OPERATING ON BOTH FUELS,
NEITHER THE NATURAL GAS OR LIQUID FUEL FLOW
SHOULD BE LESS THAN THE IDLE FUEL FLOW; I.E., IF
OPERATING ON BOTH FUELS, THE MINIMUM FLOW
TO THE GAS TURBINE WILL BE LIQUID FUEL IDLE
FLOW PLUS NATURAL GAS IDLE FLOW.
• WHEN OPERATING ON 100% LIQUID FUEL OR A
RATIO OF LIQUID AND NATURAL GAS, IT IS NECES-
SARY TO DRAIN THE LIQUID FUEL MANIFOLD WHEN
THE GAS TURBINE IS SHUT DOWN. THE MAXIMUM
TEMPERATURE OF THE FUEL WILL BE 200ºF (94ºC).
REFER TO OPERATOR’S MANUAL FOR PROCEDURE.
NOTE
• A start may be aborted at any time by closing the fuel valve,
allowing the gas generator to motor for 60 seconds, then clos-
ing the starter shutoff valve.
• When switching from liquid fuel burning to 100% natural gas
burning, it is necessary to purge and cool the liquid portion of
the fuel nozzles. Either natural gas or compressed air may be
used to purge the fuel nozzles. Refer to the operator’s manual.

J-25
GEK 97310
VOLUME I
ADDENDUM J


4. At 1100 to 1300 rpm NGG
a. Ignition on
b. Natural gas fuel Fuel manifold pressure
valve-open Approx 3 psig (21 kPa)
Liquid fuel valve- (natural gas) 90-150 psig
closed (621-1035 kPa)
or (Liquid fuel)
Natural gas fuel
valve-closed
Liquid fuel
valve-open
c. Note time to light- 20 seconds maximum Abort start-automatic
off shutdown
[T5.4 above 400ºF
(204ºC)]
takes longer than 90 seconds
to reach 4300 rpm
6. At 4300 to 4500 rpm NGG
a. Starter shutoff valve Valve closed Close fuel valve and allow
closes automatically gas generator to motor for
60 sec; then shut off the
starter

Chapter 5 (41 kPa)

J-26
GEK 97310
VOLUME I
ADDENDUM J

b. Fuel manifold Troubleshoot system and

pressure: take corrective action. See
figure 8 or 9
Natural gas Approx 25 psig (173 kPa)
Liquid fuel Approx 150 psig (1035 kPa)
d. Maximum NGG with 7000 rpm NGG maximum Shut down and investigate/
power turbine for 30 seconds (for early correct cause per paragraph
seizure (thermal model gas turbines that have 10-2.13
seizure) tighter LPT blade tip clear-
ances, do not exceed
6000 rpm NGG and 30 sec-
onds of gas turbine opera-
tion without power turbine
rotation)
e. T5.4 1000ºF (538ºC) maximum Emergency shutdown
Table 7
g. Gas generator 0 to 3 mils DA Alarm above 4 mils. Auto-

h. Power turbine 0 to 6 mils DA Alarm above 7 mils. Auto-
i. Compressor inlet Approximately equal to out- Troubleshoot sensing and
temperature (T2) side air temperature indicating system. Correct
as required
j. Check for fuel or oil No leaks allowed Correct as required
leaks

J-27
GEK 97310
VOLUME I
ADDENDUM J

9. Set desired power setting. (Natural gas) 1438ºF Correct as required. Refer to
Observe T5.4 during tran- (781ºC) maximum transient temperature limits
sient operation (Liquid fuel) 1460ºF contained in figure 13
(793ºC) maximum
a. T5.4 (Natural gas) 1378º - 1438ºF *
(748º - 781ºC)
(Liquid fuel) 1400°- 1460°F
(760º - 793ºC)
b. NGG 9850 rpm maximum. *
d. Oil pressure See applicable table and fig- Emergency or automatic

ure in Chapter 5 shutdown if 5 psig (34 kPa)
out of limits
f. Gas generator 3 mils maximum *
shutdown
g. Power turbine 7 mils maximum (Alarm) *
vibration 10 mils maximum (Trip) Emergency or automatic
shutdown
h. Fuel manifold inlet
pressure:
Natural gas 25 - 320 psig **
(173 - 2208 kPa)
Liquid fuel 150 - 900 psig **
(1035 - 6210 kPa)

J-28
GEK 97310
VOLUME I
ADDENDUM J

i. Fuel inlet
temperature:
Natural gas -65º to 150ºF **
(-54º to 66ºC)
Liquid fuel 20ºF (11ºC) above wax **
point of fuel minimum, to
∆P
k. Lube oil supply filter Refer to packager’s manual
∆P
m. VSV schedule See applicable figures in Correct as required per
WP 118 00 WP 118 00
* Reduce power to stay within limits. If reducing power does not bring parameters

J-29
GEK 97310
VOLUME I
ADDENDUM J

1. Set gas turbine at idle power Gas generator decelerates Emergency shut down
(unloaded)
following:
b. Fuel manifold
pressure:
Natural gas Approximately 25 psig
Liquid fuel Approximately 150 psig
d. T5.4 1000ºF (538ºC) maximum Troubleshoot and take cor-
rective action
f. Gas generator 3 mils maximum Alarm above 4 mils. Auto-
g. Power turbine 6 mils maximum Alarm above 7 mils. Auto-
h. Fuel inlet
temperature:
Natural gas -65ºF to +150ºF
(-54º to +66ºC)
Liquid fuel 20ºF (11ºC) above wax

J-30
GEK 97310
VOLUME I
ADDENDUM J
i. Scavenge oil filter Refer to packager’s manual
∆P
∆P
erate and stop
4. Observe T5.4 for 3 minutes 700ºF (371ºC) Motor gas turbine and shut
decreases

J-31
GEK 97310
VOLUME I
ADDENDUM J

J-32
GEK 97310
VOLUME I
ADDENDUM J

J-33
GEK 97310
VOLUME I
ADDENDUM J

J-34
GEK 97310
VOLUME I
ADDENDUM J
Figure 11. NOX Suppresion - Total Flow vs. Fuel Nozzle Pressure Drop

J-35
GEK 97310
VOLUME I
ADDENDUM J
Figure 12. NOX Suppresion - Total Flow vs. Fuel Nozzle Pressure Drop

J-36
GEK 97310
VOLUME I
ADDENDUM J

J-37
GEK 97310
VOLUME I
ADDENDUM J
10-3.1 Interlocks. Refer to packager’s man- ENTRY PROCEDURES SHALL
ual for description of interlocks which affect BE FOLLOWED.
gas turbine operation.
10-3.2 Operation. COOL DOWN. AVOID CON-
WARNING LATED GLOVES AS NECES-
SARY.
BINE ENCLOSURE, THE FOLLOW- • EAR PROTECTION SHALL BE
ING REQUIREMENTS SHALL BE WORN IF GAS TURBINE IS
MET: OPERATING.

ENTRY SHOULD BE
SENTATIVE WHO IS TRAINED Table 5. Do not exceed operating limits of
TO ENTER THE ENCLOSURE Table 3.
SYSTEM SHALL BE MADE NOTE
INACTIVE ACCORDING TO During normal shutdown using NOX
THE CUSTOMER’S PROCE- suppression, closure of the fuel valve
DURES. should be delayed after water is shut
off to allow purging of water from the
• SECONDARY AIR TO THE fuel manifold.
OFF. HIGH SECONDARY AIR- d. Emergency shut down the gas turbine
FLOW MAY PREVENT OPEN- per Table 7.
ING OR CLOSING THE
ENCLOSURE DOOR. e. Refer to paragraph 5-3.30 and
5-3.31, for lube correction factors and lube
• THE ENCLOSURE DOOR supply pressure characteristics. (See tables
SHALL BE KEPT OPEN. IF THE V-21A, V-21B, V-21E, and V-21F, and figures
GAS TURBINE IS OPERATING, 5-32A, 5-32B, 5-32E, 5-32F, 5-32J, 5-32L,
AN OBSERVER SHALL BE STA- 5-32N, and 5-32Q.)
J-38
GEK 97310
VOLUME I
ADDENDUM J
f. Idle lube oil pressure is 29 psig 10-4 EMERGENCY OPERATION.
(200 kpa) maximum after five minutes
stabilization. 10-4.1 Emergency Shutdown.
g. The corrected operating pressure of the a. In an emergency, the gas generator may
lube oil shall be per applicable table in be shut down from any power setting by clos-
Chapter 5 at standard conditions of 9000 RPM ing the natural gas and/or liquid fuel valve.
gas generator speed and 150ºF (66ºC) lube However, this should only be done in an emer-
pump discharge temperature. Oil pressure gency, since rapid shutdown will decrease life
measured at conditions other than standard of gas generator.
shall be corrected to standard conditions using
applicable table in Chapter 5. b. Emergency shutdown shall be made
per Table 7.
h. Prior to initiation of water flow for
gas generator be operating at a stabilized c. If an emergency shutdown must be ini-
steady-state condition. tiated while operating with NOX suppression
on-line, the water and fuel valves can be shut
NOTE off simultaneously. Action must be taken to
Refer to figures 6 through 10 for fuel purge the water from the fuel manifold at the
system requirements when operating earliest opportunity and prior to the next
on natural gas, liquid fuel or a combi- startup.
nation of the two. Refer to figure 11
and 12 when operating with NOX 10-4.2 Post Shutdown Fire.
suppression.
time gas generator is coasting to stop, tempera-
increase after rotation stops is normal.) Make
motoring.

J-39
GEK 97310
VOLUME I
ADDENDUM J
CAUTION
WILL FREE ITSELF AFTER A COOLING PERIOD OF 3 TO 4 HOURS. CHECK FOR
FREEDOM OF ROTATION BY TURNING ROTOR BY HAND.
1. Conditions permitting, decelerate gas turbine T5.4 drops below Manually shut off fuel
to idle and close fuel valves 400ºF (204ºC) and supply
NGG and NPT
decelerate
2. Observe T5.4 for 3 minutes after shutdown 700ºF (37lºC) max Motor gas turbine.
Continue motoring
until temperature
decreases
procedure.
be accomplished.

J-40
GEK 97310
VOLUME I
ADDENDUM J
Table 7. EMERGENCY SHUTDOWN - Continued
c. After 2 hours following coastdown
of the HPC rotor, restart can be made
Table 8. Deleted

J-41/(J-42 Blank)
GEK 97310
VOLUME I
ADDENDUM K
ADDENDUM
7LM2500PC101D

GEK 97310
VOLUME I
ADDENDUM K
TABLE OF CONTENTS
1-0 INTRODUCTION....................................................................................... K-3

2-0 REFERENCE DATA .................................................................................. K-3
3-0 INSTALLATION DRAWINGS.................................................................. K-4
4-0 EQUIPMENT DESCRIPTION ................................................................. K-4
5-0 NOX SUPPRESSION (WATER INJECTION SYSTEM)....................... K-4
6-0 INSTRUMENTATION AND SUPPLY REQUIREMENTS ................... K-5
7-0 SERVICE REQUIREMENTS ................................................................... K-8
7-1.1 Natural Gas ................................................................................................... K-8
7-1.2 Water Servicing and Pumping Requirements (Nox Suppression) ................ K-8
7-1.3 Water Purity Requirements ........................................................................... K-8
7-1.4 Water System Purge and Drain Requirements .............................................. K-8
8-0 OPTIONAL HARDWARE KITS - LM2500PC101D .............................. K-9
9-0 GAS TURBINE OPERATION .................................................................. K-9
9-1 PERFORMANCE RATINGS AND OPERATING LIMITS .................. K-9
9-1.1 Performance Ratings ..................................................................................... K-10
9-1.2 Water Scheduling Requirements During Operation (NOX Suppression)..... K-11
9-1.3 System Flow and Pressure Requirements ..................................................... K-16
9-1.4 Operating Limits ........................................................................................... K-17
9-2 INITIAL OPERATION .............................................................................. K-17
9-2.1 General .......................................................................................................... K-17
9-2.2 Special Instrumentation Required for Operation .......................................... K-17
9-2.3 Special Instrumentation Required for Monitoring and Troubleshooting ...... K-17
9-2.4 Preparation .................................................................................................... K-22
9-2.5 Gas Turbine and Associated Equipment Check List..................................... K-22
9-2.6 Governor and Manual Control Check........................................................... K-22
9-2.7 Start-up and Checkout................................................................................... K-23
9-2.8 Ignition Check............................................................................................... K-25
9-2.9 Motoring........................................................................................................ K-25
9-2.10 False Start...................................................................................................... K-25
9-2.11 Governor Check ............................................................................................ K-25
9-2.12 Wet Prestart ................................................................................................... K-25
9-2.13 Manual Start and Operation .......................................................................... K-26
9-2.14 Operation to Maximum Power...................................................................... K-31
9-2.15 Automatic Operation..................................................................................... K-31
9-3 NORMAL OPERATION............................................................................ K-33
9-3.1 Interlocks....................................................................................................... K-33
9-3.2 Operation....................................................................................................... K-33
9-4 EMERGENCY OPERATION ................................................................... K-35
9-4.1 Emergency Shutdown ................................................................................... K-35
9-4.2 Post Shutdown Fire ....................................................................................... K-35

K-1
GEK 97310
VOLUME I
ADDENDUM K
Figure Title _Page
1 Deleted
2 Deleted
3 Deleted
4 Deleted
5 Deleted
6 Typical Acceleration Fuel Flow Schedule .................................................... K-13
7 Water Supply Pressure vs Flow for NOX Suppression................................. K-14
8 Water/Fuel Ratio Requirement When Operating on Natural Gas Fuel......... K-15
9 Transient Temperature Limits ....................................................................... K-30
LIST OF TABLES
Table Title Page
1 INSTRUMENTATION CONNECTIONS - 7LM2500PC101D................... K-5

2 SUPPLY CONNECTIONS - 7LM2500PC101D.......................................... K-6
3 GAS TURBINE OPERATING LIMITS....................................................... K-18
4 PRESTART CHECKS .................................................................................. K-24
5 START-UP AND OPERATION.................................................................... K-27
6 GAS TURBINE SHUTDOWN .................................................................... K-32
7 EMERGENCY SHUTDOWN...................................................................... K-34
8 DELETED

K-2
GEK 97310
VOLUME I
ADDENDUM K
1-0 INTRODUCTION. Component Wt-Lbs/Kg)
The information contained herein describes the Compressor Stator, Rear 93(42)
7LM2500PC101D gas turbine. basic configu- Compressor Rear Frame 421(191)
ration and control system differences In addi- Combustor 120(54)
cial servicing requirements, optional hardware High Pressure Turbine Nozzle,
kits and the complete gas turbine operating Stage 1 68(31)
instructions for the 7LM2500PC101D model High Pressure Turbine Nozzle,
are included. Stage 2 127(58)
2-0 REFERENCE DATA.
EQUIPMENT Low Pressure Turbine Stator 601(273)
Model No. 7LM2500PC101D Forward Adapter 91(41)
Dwg. No. L31430G07 Exhaust Duct
Ring Seal 49(22)
PERFORMANCE RATING Ring Support 74(34)
Variable Stator Actuating 19(9)
Mech
GAS TURBINE WEIGHTS Outside Piping and Bracketing 278(125)
The average weights of the major gas tur- DRAWING LIST

bine components are: Drawing No.,
Gas Turbine Installation L31705
Component Wt-Lbs/Kg) Drawing
Gas turbine - including inlet Fuel System Kit 682L310G04
Drawing
Gas Turbine Assembly L31430G07
Transfer Gearbox 245(111) Drawing

K-3
GEK 97310
VOLUME I
ADDENDUM K
3-0 INSTALLATION DRAWINGS. b. The E.P.A. New Source Performance
Standard (NSPS) for stationary gas turbines is
A complete set of installation drawings have contained in Title 40 Code of Federal Regula-
been provided. tions, Part 60, Subpart GG. The current rule
was published in 1982 and contains different
4-0 EQUIPMENT DESCRIPTION. NOX standards depending upon whether the
gas turbine is to be used for an electric utility
The 7LM2500PC101D is a natural gas fueled, or an industrial application. The E.P.A. defines
non-marinized gas turbine that incorporates a an electric utility gas turbine application as one
natural gas manifold, a water manifold, and 30 which sells more than one-third of its potential
fuel nozzles. The gas turbine is not provided capacity to a utility power distribution system.
with an exhaust duct as standard equipment Industrial gas turbines are defined as those
but an exhaust duct inner diffuser is provided which include all stationary applications other
with the basic gas turbine assembly. The gas than electric utilities. These standards, as
turbine is configured with NOX Suppression applied to the LM2500 gas turbine, are as
equipment, and prior to initiation of water flow follows:
for NOX Suppression, it is recommended that
the gas generator be operating at a stabilized • Electric utility application gas turbines:
steady-stage condition.
STD=75 (10180/y) + F, ppm by vol-
5-0 NOX SUPPRESSION (WATER ume referenced to 15% O2
INJECTION SYSTEM).
• Industrial application gas turbines:
a. The 7LM2500PC101D gas turbine is
equipped for suppression of oxides of nitrogen STD=150 (10180/y) + F, ppm by volume
(NOX) in the gas generator exhaust gases. referenced to 15% O2
This is accomplished by introduction of water
into the fuel nozzles. The 7LM2500 NOX sup- Where:
pression system has been designed to meet the
requirements of the U.S. E.P.A. standard for y = heat rate in BTU/HP-Hr at peak
NOX emissions for stationary gas turbines and power
includes a conservative margin for meeting the F = allowance for fuel bound nitrogen
requirements of other, possibly more restric-
tive, local codes where applicable. c. Since the NOX standard is a function
of the gas turbine heat rate at peak power, it
will vary somewhat from one application to
another. Unless otherwise specified, the NOX
performance data contained in this addendum
is based upon an assumed LM2500 gas turbine
application subject to the 75 ppm standard
with an ISO site rating condition of
27,500 shp.

K-4
GEK 97310
VOLUME I
ADDENDUM K
Table 1. INSTRUMENTATION CONNECTIONS - 7LM2500PC101D

364450
E3A “A” sump T/C (optional equipment) MS3106R-12S-3SW except pin A iron and pin B
constantan
E4A “B” sump T/C (optional equipment) MS3106R-12S-3SW except pin A iron and pin B
constantan
E5A “C” sump T/C (optional equipment) MS3106R-12S-3SW except pin A iron and pin B
constantan
temperature
E6A Accessory gearbox T/C (optional MS3106R-12S-3SW except pin A iron and pin B
equipment) constantan
E11A Inlet T/C (optional equipment) MS3106R-12S-3SW except pin A iron and pin B
constantan
E18A “D” sump T/C (optional equipment) MS3106R-12S-3SW except pin A iron and pin B
constantan
364450
(optional)

K-5
GEK 97310
VOLUME I
ADDENDUM K
Table 1. INSTRUMENTATION CONNECTIONS - 7LM2500PC101D - Continued
A18 CIT sensor (part of fuel control
system)
F3 Fuel Manifold Gas Pressure Tap AN818-4C or MS20819-4C
Remote reading variable stator vane
W2 Water Inlet Liquid Pressure Tap #1 AN818-6C or MS20819-6C
W3 Water Inlet Liquid Pressure Tap #2 AN818-6C or MS 20819-6C
NOTE
turbine.
Table 2. SUPPLY CONNECTIONS - 7LM2500PC101D

CAUTION
REQUIRED.
F1 Natural gas supply 2 inch line from Fuel Control Unit to Gas Generator
Fuel Manifold
W1 Water Manifold Inlet (NOX) Water Manifold Inlet, mates with AN818-12C or
MS20819-12C or equivalent.
L1 Oil supply 1-1/4 inch line to Lube Pump on Gas Generator,
AN818-24C or MS20819-24C
L2 Lube pump discharge 1 inch line from Lube Pump to Oil Supply Filters,
AN819-16C or MS20819-16C
L4 Lube supply inlet port 1 inch line from Oil Supply Filters to Gas Generator,
AN818-16C or MS20819-16C

K-6
GEK 97310
VOLUME I
ADDENDUM K
Table 2. SUPPLY CONNECTIONS - 7LM2500PC101D - Continued
Oil Scavenge Filter and Cooler, AN818-20C or
MS20819-20C
A1 Bleed air port 8th stage Shipped with cover that must remain in place if port is
not used
A6 Starter air or gas inlet port See Addendum for Installation Drawings
A7 Starter air or gas outlet port See Addendum for Installation Drawings
A2 Bleed Air 16th stage compressor bleed air lines if used
A20 sump overboard vent left bottom If used - 2-inch line attaching hardware
A21 sump overboard vent right bottom If used - 2-inch line attaching hardware
A22 C sump overboard vent right top If used - 2-inch line attaching hardware
A12 Air/Oil Separator 3-inch line from air/oil separator to atmospheric vent
or to exhaust duct (flame arrestor)
S1 or Waterwash manifold 1-inch line - hot water line to waterwash manifold on
S1A Gas Generator Inlet Duct AN819-16C or
MS20819-16C

K-7
GEK 97310
VOLUME I
ADDENDUM K
7-0 SERVICE REQUIREMENTS. 7-1.3 Water Purity Requirements.
7-1.1 Natural Gas. a. Water supplied to the gas turbine must

meet the following minimum requirements:
fuel manifold on the gas turbine is 350 ± 5 psig • Sodium + Potassium + Lead + Vana-
(2415±35 kPa). dium + Lithium = 0.1 ppm max
b. The temperature of the gas must be in • Total ionizable solids, both dissolved
the range of -65º to +150ºF (-54 to +60ºC). If and undissolved = 5 ppm max
day basis it will be necessary to change the • Ph = 6.5 to 7.5
starting fuel adjustment to adjust the supply
pressure to the engine to maintain a constant • The water shall not contain more than
Btu-per-cubic-foot supply. Once started, the 10 mg of solid contaminants per gallon
engine will accept variations in supply temper- and the maximum contaminant size
ature of ±20ºF (±12ºC). The maximum fuel shall not exceed 20 microns
flow required is 13,400 pph (6078 kg/h) with a absolute.
lower heating value of 19, 000 Btu/lb.
7-1.4 Water System Purge and Drain
7-1.2 Water Servicing and Pumping Requirements.
Requirements (Nox Suppression).
a. It is recommended that a purge system
a. The maximum allowable water deliv- be incorporated into the water system circuit in
ery pressure at the water connection is order to ensure a continuous positive pressure
800 psig (5516 kPa). The temperature of the in that system during periods of operation in
water supplied to the manifold shall not exceed which water is not being injected. This purging
180ºF (82ºC) and shall be free of pressure pul- action will prevent the possibility of combus-
sations in the 0 to 300 Hz range. In addition, tion gases back-flowing through the water
the water must be controlled in such a manner system.
as to prevent any sudden pressure spikes which
could momentarily displace the fuel or change b. Either natural gas or compressed air
the delivery rate. may be used as the purge medium. The purge
gas or air must be filtered to 20 microns abso-
b. The required water/fuel ratio vs fuel lute and the temperature must not exceed
flow schedule in terms of water supply deliv- 350ºF (177ºC).
ery pressure may be developed from the cus-
tomers performance data package as described c. The water drain valves should be open
in paragraph 9-1.2. The design of the water only after closing the gas fuel shutoff valves
system should provide margin for varying the and should be closed before the gas fuel valves
water flow rate by ±15 percent to permit are reopened.
adjustment at the time of initial installation
testing as required to satisfy EPA or other code
requirements.

K-8
GEK 97310
VOLUME I
ADDENDUM K
d. Refer to current Installation Design WARNING
Manual for recommendations/requirements
necessary for the buyer to establish a suitable IF A QUESTIONABLE CONDITION
purging system. EXISTS, DO NOT OPERATE THE
8-0 OPTIONAL HARDWARE KITS - OUGH INVESTIGATION HAS
LM2500PC101D. BEEN MADE. DO NOT REPEAT
a. Refer to Volume II, WP 001 00 for a STALLS, OR OTHER RECOGNIZED
detailed list of optional kits available for this INVESTIGATION. FAILURE TO DO
particular gas turbine model. SO CAN RESULT IN UNDUE
STRESS BEING IMPOSED ON GAS
9-0 GAS TURBINE OPERATION. TURBINE COMPONENTS, WITH
IMMEDIATE OR SUBSEQUENT
a. These instructions contain the detailed DESTRUCTIVE FAILURE OF THE
gas turbine operating procedures and limits GAS TURBINE AND INJURY TO
recommended by the General Electric Com- PERSONNEL.
pany for the 7LM2500PC101D Gas Turbine.
NOTE
b. The instructions are intended to pro- The S.I. units shown in this chapter are
vide operating personnel with the information direct mathematical conversions and
required to operate the gas turbine. They per- may be rounded off in most instances
tain to routine and emergency conditions and at the users discretion. Examples of
procedures. When a fault exists, refer to Chap- units that may be rounded off are those
ter 4 entitled, TROUBLESHOOTING. utilized for temperatures, torque val-
c. It is possible that these instructions S.I. units may not be rounded off are
may not provide for every possible variation in those utilized for drop checks, rigging
equipment or contingency to be met in connec- adjustments, runouts, etc.
Refer requests for additional information to the 9-1 PERFORMANCE RATINGS AND
General Electric Company; Marine and Indus- OPERATING LIMITS.
NOTE
Ratings published in this manual apply

K-9
GEK 97310
VOLUME I
ADDENDUM K
9-1.1 Performance Ratings. With NOX
Suppression
a. The rated performance of the to Meet EPA
LM2500PC101D gas turbine in the new and Normal Electrical
clean condition, as compared to gas turbine (Dry) Standard
follows: Heat Rate, 6907 BTU/ 6959 BUT/
Avg. hp-hr hp-hr
NOTE Power Tur- 1406ºF 1404ºF
The use of water injection to control bine Inlet Gas (763ºC) (762ºC)
NOX emissions results in a change in Temperature
Water Injec- 0 lbs/hr 1828 lbs/hr
tion (Average) (829 kg/hr)
contract documents, all performance
guarantees are based upon “dry” opera- Fuel Flow 9,996 lbs/hr 10,072 lbs/hr
tion with no water injection. (4534 kg/hr) (4569 kg/hr)
NOX 170 109
With NOX Emissions*
Suppression
to Meet EPA *No water injection is required to meet the
Normal Electrical EPA industrial NOX standard.
(Dry) Standard
As noted above, the use of water injection to
Brake 27,500 27,500 control NOX emissions results in a change in
Horsepower gas turbine performance. Unless specifically
Inlet Air 59ºF (15ºC) 59ºF (15ºC) agreed to in the applicable contract documents,
Temperature all performance guarantees are based upon
“dry” operation of gas turbines with no water
Altitude 0 ft. 0 ft. injection. The tabulation in step a depicts a
Inlet Losses 0”H2O 0”H2O comparison of the gas turbine performance at
27,500 SHP and ISO conditions in both the
Exhaust Back 0”H2O 0”H2O “dry” operational mode and with water injec-
Pressure tion to meet EPA standards for electric utility
Relative 60% 60% applications. Water injection for NOX sup-
Humidity pression is not required in order to meet the
EPA standard for industrial applications when
Compressor 0 lbs/sec 0 lbs/sec operating the LM2500PC101D gas turbine on
Bleed natural gas fuel.
Accessory 0 0
Horsepower
Extraction
Power 3600 rpm 3600 rpm
Turbine Speed

K-10
GEK 97310
VOLUME I
ADDENDUM K
b. Approximate starting fuel flow require- h. The maximum deceleration fuel flow
ments are: rate should consist of a step fuel decrease of
1500 (680 kg/h) + 10% pph followed by a rate
465 pph (211 kg/h) ± 25 pph (11 kg) @ -65ºF change of 1330 pph (603 kg/h) ± 10% per sec-
(-54ºC) Inlet Air Temperature ond to idle fuel flow. Rates greater than this
can cause the gas turbine to lose fire. Normal
550 pph (249 kg/h) ± 25 pph (11 kg) @ +60ºF decelerations from maximum power to idle
(16ºC) Inlet Air Temperature should be made in approximately 2 to 3 min-
utes - this will enhance the time between hot
595 pph (270 kg/h) ± 25 pph (11 kg) @ +130ºF section repairs and the life of the gas turbine.
(54ºC) Inlet Air Temperature.
9-1.2 Water Scheduling Requirements Dur-
c. Figure 6 defines the maximum fuel ing Operation (NOX Suppression).
acceleration schedule for the gas generator.
a. Water schedules required to meet EPA
d. Acceleration fuel rates greater than NOX Standards for electric utility applications
those shown will result in over-temperature with natural gas fuel are shown in figure 8.
and possible stall of the gas turbine. Accelera- The lower water schedule is that calculated for
tion fuel rates lower than those shown can an average new gas turbine with a 27,500 SHP
result in “hung” starts in the below idle speed peak rating. The higher water schedule is the
range. maximum value, which considers the effects of
gas turbine to gas turbine deviation and mea-
e. Above the idle speed point, low accel- surement variability. Water to fuel ratios in
eration fuel rates will not harm the gas turbine excess of the values shown in figure 8 may be
and will only result in slower acceleration used to meet higher ratings under the EPA reg-
times. ulations, or to meet the requirements of other,
more stringent, local suppression codes.
f. For normal accelerations from idle to
time of 2 to 3 minutes is reasonable.
g. The fuel rates shown on the curves will


K-11
GEK 97310
VOLUME I
ADDENDUM K

K-12
GEK 97310
VOLUME I
ADDENDUM K

K-13
GEK 97310
VOLUME I
ADDENDUM K
Figure 7. Water Supply Pressure vs Flow for NOX Suppression

K-14
GEK 97310
VOLUME I
ADDENDUM K
Figure 8. Water/Fuel Ratio Requirement When Operating on Natural Gas Fuel

K-15
GEK 97310
VOLUME I
ADDENDUM K
b. The nominal water schedule for a site interface connector are shown in figure 7 for
rating of 27,500 HP at ISO conditions is the EPA electric utility standard of 27,500 SHP
shown on figure 8. The actual maximum on- site rating condition shown as an example in
site adjusted water flow required will fall figure 8. The water supply system and maxi-
within the range shown. Water flow must be mum water supply pressure requirements for a
scheduled as a function of fuel flow but must specific application must be established by the
be shut off during starting and acceleration to buyer on the basis of the contractual site rating
idle. Water flow should be initiated at a fuel and actual applicable emissions standard using
flow of 5300 pph ± 450 pph on accel and the method presented in paragraph 9-1.3.
should be shut off at this point on decel. For
9-1.3 System Flow and Pressure
the 27,500 HP site rating condition illustrated,
Requirements.
NOX suppression is not required below a
power level corresponding to approximately a. A tabular gas turbine performance data
5300 pph fuel flow. During initiation of water sheet will be provided for each specific NOX
flow it is recommended that the engine be suppression application upon customer request
operating at a stabilized steady state condition. following receipt of a definition of the contrac-
Figure 7 shows the water pressure vs flow tual site rating and applicable NOX suppres-
characteristics at the manifold connections sion standard or code. This performance data
based on the water to fuel schedule shown in will list the following:
figure 8. Water to fuel ratios of up to 1.2 to 1
may be used to meet higher ratings under the (1) The calculated average gas tur-
EPA regulations or to meet the requirements of bine water flow (WW) required to meet the
other codes. When water is injected at flow requirement of the applicable EPA standard or
rates necessary to meet the U.S. EPA require- other applicable code described in the contract
ments, the maximum gas generator corrected documents.
speed limit must be reduced to 9650 rpm. No (2) The corresponding fuel flow (wf).
change to the 9800 rpm maximum physical
speed limits is required. (3) The internal gas turbine cycle
pressure level (PE16D).
c. During gas turbine accelerations, after
initiation of water flow and from a lower b. The above data may then be used to
power setting to a higher power setting, two establish the fuel and water supply delivery
methods of operation or water flow regulation pressure requirements at the gas turbine inter-
are acceptable; (1) increase water flow as fuel face points utilizing the following equations:
flow is increased, or (2) accelerate the gas tur- (1) Water pressure requirements
bine to the higher power level while maintain-
ing the water flow constant, then gradually WIP = (WW)2 X 39.7 X 10-7 + PE16D
increasing the water flow to the desired level
after the gas turbine is on point. Where: WIP + water inlet pressure at
the water manifold interface connec-
d. During deceleration, including load tion in psia
shedding operation, the water flow scheduling
should follow the fuel flow decel schedule. WW = water flow - pph
e. Water flow vs water supply pressure PE16D = PS3 = fuel nozzle discharge
requirements to the gas turbine water supply pressure in psia

K-16
GEK 97310
VOLUME I
ADDENDUM K
(2) Fuel pressure requirement. The Lube oil supply pressure........ 0-100 psig
fuel supply pressure requirements for natural (0-690 kPa)
gas fuel with water injection are the same as Lube oil scavenge pressure.... 0-100 psig
those for the natural gas fuel system only. (0-690 kPa)
Refer to Installation Design Manual
Compressor discharge............ 0-300 psig
MID-IDM-2500-7.
pressure................................ (0-2070 kPa)
NOTE
If any operating limit is exceeded, ver- Fuel manifold pressure sensor 0-400 psi
ify instrumentation accuracy before (0-2760 kPa)
troubleshooting or inspecting gas Compressor inlet total pres-... 10-16 psia.
generator. sure sensor ........................... (69-110.4 kPa)
Power turbine inlet gas .......... 0-75 psia
9-2 INITIAL OPERATION. pressure ............................... (0-517.5 kPa)
Fuel supply pressure .............. 0-400 psig
(0-2760 kPa)
gas turbine replacement or major maintenance Fuel supply temperature ........ 0-250ºF
on the system. (-17.8-
121.1ºC)
9-2.2 Special Instrumentation Required for Gas turbine inlet air ............... 0-150ºF
Operation. temperature .......................... (-17.8-65.6ºC)
Remote reading variable vane -5º to +45º
Gas generator speed sensor.... 0-10,000 rpm indicator...............................
Lube oil scavenge temperature 0-400ºF Starter air supply pressure ..... 0-50 psig
sensors (A-, B-, C-, D-sumps (-17.8 to (optional) (0-345 kPa)
and transfer gearbox) ........... 205ºC)
Lube oil supply temperature .. 0-400ºF
sensor ................................... (-17.8 to
205ºC)
gas generator........................ 0-3 in/sec or
0-10 mil DA
power turbine....................... 0-3 in/sec or
0-10 mil DA
Power turbine speed sensor ... 0-5000 rpm
Power turbine inlet gas tem-.. 0-2000ºF
perature (T5.4) ...................... (-17.8 to
1093ºC)

K-17
GEK 97310
VOLUME I
ADDENDUM K
Alarm Normal
Type Parameter /Trip Setting Operating Range Remarks
NOTE
above 8000 rpm
Pressure
Pressure 180 psig
(1242 kPa)
Gas Turbine Alarm 180º - 220ºF 140º - 160ºF Normal Operat-
Lube Supply (82º - 104ºC) (60º - 71ºC) ing Range
ture expected
during operation
above idle speed
Gas Turbine Trip 330º - 350ºF 215º - 275ºF Normal Operat-
Lube Scavenge (166º - 177ºC) (102º - 135ºC) ing Range
Five ture expected
during operation
above idle speed
(143º - 154ºC)

K-18
GEK 97310
VOLUME I
ADDENDUM K
Alarm Normal
Fuel Fuel 20 - 355 psig Supply Pressure
System Manifold (138 - 2448 kPa) as reflected at the
(Natural Pressure fuel manifold
turbine
Fuel Supply Alarm 150º - 170ºF -65º to 150ºF Starting Fuel
Temperature (66º - 77ºC) (-54º to 66ºC) Flow Adjust-
ments may be
required to com-
pensate for fuel
temperature
variation
System Supply Pressure (276 kPa) Requirement
based on engine
starter torque
requirements
Fuel and Ignition
Fuel and ignition for start after
(if purge cycle is purge cycle
used)
simultaneously
with start
initiation
Failure to Trip 380º -420ºF Activate 20 sec-
Light-Off (193º -216ºC) onds time delay
simultaneously
with application
of fuel and
ignition

K-19
GEK 97310
VOLUME I
ADDENDUM K
Alarm Normal
simultaneously
with start initia-
tion. De-ener-
gize ignition, fuel
system and
starter air supply
4500 rpm (if onds time delay
used) of purge. De-
energize fuel and
ignition systems
and starter air
supply
Power Failure to Trip 380º - 420ºF 0-1600ºF Trip if tempera-
Turbine Inlet Light-Off (193º- 216ºC) (0-871ºC) ture does not
Temperature reach 400ºF
(204ºC) within
20 seconds after
fuel and ignition
are applied

K-20
GEK 97310
VOLUME I
ADDENDUM K
Alarm Normal
Overtemperature Trip 1450ºF (788ºC) 1378º-1438ºF Values given are
(748º -781ºC) for installations
T5.4 control as
the power limit.
Installations
using constant
power control
mode should
consult the con-
tract documents
for determining
alarm and trip
settings, which
are unique to
each application,
but never to
exceed 1616°F
(880°C) (alarm)
and 1625°F
(885°C) (trip)
operation over
Alarm 4 mils ± 1 mil DA 4 mils
Power Turbine Trip 10 mils ± 1 mil DA 0-6 mils DA Avoid continuos
operation over
Power Turbine Trip 3960 ± 40 rpm 0-3600 rpm

Loss of Combustor Close and lock
Flame Flame out fuel shutoff
valve upon loss
of flame

K-21
GEK 97310
VOLUME I
ADDENDUM K
9-2.4 Preparation. The gas turbine and asso- m. Lube oil storage tank serviced
ciated systems must be inspected and checked to full level _______
normal operation can commence. n. Lube oil supply valves open _______
check list. p. T5.4 thermocouple system
functioning properly _______
foundation _______ r. Compressor inlet total pres-
c. Intake air and exhaust gas and free of damage _______
s. Variable stator system secure _______
d. Gas turbine and exhaust duct
support mounts and links in t. Required checks and inspec-
place and secure _______ tions specified in packager’s
manual for gas turbine control
e. All service connections made have been performed _______
and secure _______
f. All lines have been flushed per 9-2.6 Governor and Manual Control Check.
packager’s manual _______ Refer to packager’s manual.

of foreign object. Inlet screen
secure _______
l. Starter is serviced per

K-22
GEK 97310
VOLUME I
ADDENDUM K
SARY.
OPERATING.
SHUT DOWN.
ENCLOSURE OR IN THE
ENTRY SHOULD BE
BINE.
b. Perform prestart checks per Table 4.
SYSTEM SHALL BE MADE c. Perform ignition checkout per
INACTIVE ACCORDING TO paragraph 9-2.8.
THE CUSTOMER’S PROCE- d. Perform motoring procedure per
• SECONDARY AIR TO THE e. Perform false start per
FLOW MAY PREVENT OPEN- f. Perform governor check per
ENCLOSURE DOOR.
g. Perform a wet prestart per
GAS TURBINE IS OPERATING, h. Perform a manual start and operate per
DOOR AND CONFINED SPACE i. Operate to maximum power per
BE FOLLOWED. j. Check automatic operation per
paragraph 9-2.15.
.

K-23
GEK 97310
VOLUME I
ADDENDUM K
Item Requirement
and discrepancies
Fuel valves Closed
Ignition Off
Ventilation inlet air (secondary cooling air) Off-air temp below 70ºF (21ºC)
Ventilation exit air 180ºF (82ºC) max
Oil tank level Full
Lube oil temperature 140ºF to 160ºF (60º to 71.1ºC)
Fuel supply
temperature -65 to 150ºF (-54 to 65.5ºC)
flow 13,400 pph (6078 kg/h) max @

19000 BTU/lb.

K-24
GEK 97310
VOLUME I
ADDENDUM K
9-2.8 Ignition Check. a. Make ignition and natural-gas supply
• ASSURE POWER TO IGNITION tion units.
(2) Close natural-gas manual shutoff
CONNECTING AND CONNECT- valve to fuel control unit.
ING IGNITION EXCITER INPUT
LEAD. TAG SWITCH OUT OF b. Depress MOTORING pushbutton. Gas
SERVICE TO PRECLUDE INAD- generator will start to rotate. If it does not,
VERTENT ACTIVATION. refer to packager’s manual for supply pressure
to starter.
CLOSED THROUGHOUT THIS c. Hold MOTORING pushbutton closed
PROCEDURE.
a. To clear combustor of any residual pressure, release MOTORING pushbutton;
fuel, motor gas turbine for one minute; allow while gas generator is coasting down, loosen
b. Disconnect number one ignition exciter minimum of 2200 RPM.
input lead at exciter. Temporarily secure input d. Repeat motoring and bleeding proce-
lead away from the exciter. dure until an indication of oil pressure appears.
c. Turn on electrical power to the ignition 9-2.10 False Start. Perform false start as
system (No. 2 ignition exciter energized). An follows:
second) should be heard when the No. 2 spark a. With ignition leads disconnected and
igniter fires. manual gas valve closed, make automatic start
of gas turbine per packager’s manual.
system. Reconnect input lead to exciter and b. Gas generator should go through nor-
of flame.
e. Repeat steps b, c and d disconnecting 9-2.11 Governor Check. Check governor sys-
the No. 2 exciter. tem per packager’s manual.
f. If an audible report is not heard on 9-2.12 Wet Prestart. Perform wet prestart as
No. 1 and/ or No. 2 igniters, check out the sys- follows:
tem to isolate the problem, and take appropri- a. With ignition lead disconnected but
ate corrective action. with manual gas valve open and governing
system operating, make automatic start of gas
9-2.9 Motoring. After all preliminary checks generator per packager’s manual.

K-25
GEK 97310
VOLUME I
ADDENDUM K
b. Gas generator should accelerate to NOTE
light-off speed (1100 to 1300 rpm). Fuel valve Thermal seizure of the power turbine
should open and fuel manifold pressure should rotor can occur when a hot gas turbine
be approximately 3 psig (20.7 kPa). Adjust is shut down and is most likely to occur
fuel supply if required. Start will then abort within 30 to 40 minutes following gas
because of lack of flame. turbine operation. Thermal seizure is
c. Allow gas generator to coast to stop; the condition where the power turbine
then motor it to purge any remaining natural rotor is prevented from rotating by hard
gas from gas generator. contact between LPT blades and
9-2.13 Manual Start and Operation. Perform internal interference. This condition is
manual start per packager’s manual with fuel the result of unequal cooling rates of
system normal and with ignition lead con- the various power turbine components.
nected. Refer to Table 5. The possibility of thermal seizures can
NOTE at idle power for at least five minutes
Power turbine, except in a new installa- cooling of the power turbine.
tor idle speed is attained. (1) Shutdown gas turbine.
CAUTION (2) Immediately after the gas turbine

DO NOT EXCEED 7000 RPM NGG speed (4950 ± 50 rpm) for 30 seconds.
BINE OPERATION WITHOUT (3) Repeat steps (1) and (2) for two
POWER TURBINE ROTATION. additional start-up and shutdown cycles.
a. The power turbine must rotate by the (4) If the power turbine does not
time the gas generator speed reaches 7000 rpm rotate after accomplishing substeps (1) through
NGG. If power turbine speed indication is not (3), shut down the gas turbine.
obtained and it is determined that a “thermal (5) Immediately after gas turbine
seizure” of the power turbine has occurred, rotation stops, re-start and accelerate to
proceed as follows: 7000 rpm NGG maximum and stabilize for
rotate, shut down and investigate/correct the
cause. During the investigation for the cause of
unlatching. If blades have become unlatched,
encountered shingling may be bent and must
be replaced accordingly.

K-26
GEK 97310
VOLUME I
ADDENDUM K
are completed per Table 4 1450ºF (788ºC). Refer to
figure 9
CAUTION
IF T5.4 RAPIDLY APPROACHES OR EXCEEDS 1438ºF (781.1ºC), ABORT START
NOTE
for 60 seconds, then closing starter shutoff valve
NOTE
3. At 1100 at 1300 rpm NGG
a. Ignition on
(21 kPa)
(T5.4 above shutdown
400ºF - [264ºC])
4. Note time to 4500 ± 200 90 seconds max. Troubleshoot system and
4300 rpm
5. At 4300 to 4700 rpm NGG
a. Starter shutoff valve Valve closed Close fuel valve and allow
starter

K-27
GEK 97310
VOLUME I
ADDENDUM K
Chapter 5 (41 kPa)
b. Fuel manifold pressure: Approx 25 psig (173 kPa) Troubleshoot system and
take corrective action. Refer
to paragraph 9-1.3
(thermal seizure) model gas turbine that have paragraph 9-2.13
ances, do not exceed
onds of gas turbine opera-
tion without power turbine
rotation)
e. T5.4 1000ºF (530º C) maximum Emergency shutdown
Table 7
f. NPT (unloaded) 1600 - 1900 rpm
as required
leaks
8. Set desired power setting. 1438ºF (781.1ºC) max Correct as required. Refer to
Observe T5.4 during transient temperature limits
transient operation contained in figure 11

K-28
GEK 97310
VOLUME I
ADDENDUM K
a. T5.4 1378º - 1438ºF *
(748º - 781ºC)
out of limits
shutdown
g. Power Turbine vibration 6 mils maximum *
shutdown
h. Fuel manifold inlet 25 - 320 psig **
(54º to 66ºC)
manual
WP 118 00 WP 118 00
*Reduce power to stay within limits. If reducing power does not bring parameters within limits,
shutdown.

K-29
GEK 97310
VOLUME I
ADDENDUM K

K-30
GEK 97310
VOLUME I
ADDENDUM K
9-2.14 Operation to Maximum Power. f. After gas turbine has been stabilized at
CAUTION Refer to Table 6, steps 3 and 4.
MANUAL OPERATION MAY 9-2.15 Automatic Operation. Check auto-
ELIMINATE CERTAIN PROTEC- matic operation per packager’s manual.
ITS SHALL NOT BE EXCEEDED. a. Accelerate to idle.
a. Slowly increase manual control setting b. Accelerate to rated power.
generator speed. After each 500 rpm increase, c. Log all instrument readings.
attention to variable stator vane position and d. Decelerate to idle.
within limits, adjust it per e. Check for fuel or lube oil leaks.
work package 118 00. If vibrations are not
within limits, consult the local General Elec- f. After a total of five minutes at idle,
tric Company representative. shut down gas turbine.
b. Operate gas turbine up to rated power, g. Check lube oil and fuel filters and
if possible, but do not exceed exhaust gas tem- strainers; clean or replace as necessary.
until all temperatures stabilize. If governing h. Correct any leaks observed.
manual. i. Remove all temporary instrumentation.
c. Log all instrument readings once they j. Check gas turbine and mounting sys-
stabilize. Refer to Table 5, step 9. tem for loose parts; tighten as necessary.



K-31
GEK 97310
VOLUME I
ADDENDUM K
(unloaded)
following:
b. Fuel manifold pressure: Approximately 25 psig
(173 kPa). Refer to
paragraph 9-1.3
d. T5.4 1000ºF (538ºC) maximum Troubleshoot and take cor-
rective action
e. NpT (unloaded) 1600-1900 rpm
g. Power turbine vibration 6 mils maximum Alarm above 7 mils. Auto-
(-54º to +66ºC)
j. Lube oil supply filter ∆P Refer to packager’s manual
erate and stop
4. Observe T5.4 for 3 minutes 700ºF (371ºC) Motor gas turbine and shut
decreases.

K-32
GEK 97310
VOLUME I
ADDENDUM K
9-3 NORMAL OPERATION. ENTRY PROCEDURES SHALL
BE FOLLOWED.
9-3.1 Interlocks. Refer to packager’s manual
for description of interlocks which affect gas • ALLOW THE GAS TURBINE TO
turbine operation. COOL DOWN. AVOID CON-
SARY.
MET: OPERATING.
ENTRY SHOULD BE
SYSTEM SHALL BE MADE NOTE
THE CUSTOMER’S PROCE- During normal shut down with NOX
DURES. suppression being used, closure of the
fuel valve should be delayed after
• SECONDARY AIR TO THE water is shut off to allow purging of
ENCLOSURE SHALL BE SHUT water from the fuel manifold.
FLOW MAY PREVENT OPEN- d. Emergency shut down the gas turbine
ING OR CLOSING THE per Table 7.
ENCLOSURE DOOR.
• THE ENCLOSURE DOOR for lube correction factors and lube supply
SHALL BE KEPT OPEN. IF THE pressure characteristics. (See tables V-21A,
GAS TURBINE IS OPERATING, V-21B, V-21E, and V-21F, and figures 5-32A,
AN OBSERVER SHALL BE STA- 5-32B, 5-32E, 5-32F, 5-32J, 5-32L, 5-32N,
TIONED AT THE ENCLOSURE and 5-32Q.)

K-33
GEK 97310
VOLUME I
ADDENDUM K
Corrective Action
Step for
CAUTION
bine to idle and close fuel valves 400ºF (204ºC) and fuel supply
NGG and NPT
decelerate
2. Observe T5.4 for 3 minutes after shutdown 700ºF (371ºC) max. Motor gas turbine.
Continue motoring
until temperature
decreases
bine can be restarted within 1 minute fol-
lowing coastdown of the HPC rotor,
acceptable restarts can be made using the
normal starting procedure.
turbine at 2000-2500 rpm NGG for 5
tion to the desired power setting can then
be accomplished.

K-34
GEK 97310
VOLUME I
ADDENDUM K
NOTE 9-4 EMERGENCY OPERATION.
Refer to figure 6 through 10 for fuel
system requirements. Refer to figures 7 9-4.1 Emergency Shutdown.
and 8 when operating with NOX
suppression. a. In an emergency, the gas generator may
f. Idle lube oil pressure is 29 psig ing the fuel valve. However, this should only
(200.1 kPa) maximum after five (5) minutes be done in an emergency, since rapid shutdown
stabilization. decreases life of gas generator.
g. The operating pressure of the lube oil b. Emergency shutdown shall be made
shall be 40 to 50 PSIG (276-345 kPa) at stan- per Table 7.
dard conditions of 9000 RPM gas generator
speed and 150ºF (65.6ºC) at lube pump dis- c. If an emergency shutdown must be ini-
charge temperature. Oil pressure measured at tiated while operating with NOX suppression
conditions other than standard shall be cor- on-line, the water and fuel valve can be shut
rected to standard conditions using Table 8. off simultaneously. Action must be taken to
purge the water from the fuel manifold at the
h. Prior to initiation of water flow for earliest opportunity and prior to the next
NOX suppression, it is recommended that the startup.
gas generator be operating at a stabilized
steady-state condition. 9-4.2 Post Shutdown Fire.

ture increases instead of decreasing, it indi-
cates that combustion is still taking place
because of a leaking fuel valve. (A slight tem-
perature increase after rotation stops is nor-
mal.) Make certain fuel is shut off, and motor

K-35
GEK 97310
VOLUME I
ADDENDUM K
Table 8. DELETED

K-36
GEK 97310
VOLUME I
ADDENDUM L
ADDENDUM
7LM2500-PD-MG

GEK 97310
VOLUME I
ADDENDUM L
TABLE OF CONTENTS
1-0 INTRODUCTION....................................................................................... L-3

2-0 REFERENCE DATA .................................................................................. L-3
3-0 INSTALLATION DRAWINGS.................................................................. L-4
4-0 EQUIPMENT DESCRIPTION ................................................................. L-4
5-0 INSTRUMENTATION AND SUPPLY REQUIREMENTS ................... L-4
6-0 SERVICE REQUIREMENTS ................................................................... L-4
6-1.1 Natural Gas ................................................................................................... L-4
7-0 OPTIONAL HARDWARE KITS, 7LM2500-PD-MG............................. L-4
8-0 GAS TURBINE OPERATION .................................................................. L-7
8-1.1 Performance Ratings and Operating Limits.................................................. L-7
8-1.2 Performance Ratings ..................................................................................... L-7
8-1.3 Operating Limits ........................................................................................... L-12
8-2 INITIAL OPERATION .............................................................................. L-12
8-2.1 General .......................................................................................................... L-12
8-2.2 Special Instrumentation Required for Operation .......................................... L-12
8-2.3 Special Instrumentation Required for Monitoring and Troubleshooting ...... L-12
8-2.4 Preparation .................................................................................................... L-12
8-2.5 Gas Turbine and Associated Equipment Check List..................................... L-17
8-2.6 Governor and Manual Control Check........................................................... L-18
8-2.7 Start-Up and Checkout.................................................................................. L-18
8-2.8 Ignition Check............................................................................................... L-19
8-2.9 Motoring........................................................................................................ L-19
8-2.10 False Start...................................................................................................... L-20
8-2.11 Governor Check ............................................................................................ L-20
8-2.12 Wet Prestart ................................................................................................... L-20
8-2.13 Manual Start and Operation .......................................................................... L-21
8-2.14 Operation to Maximum Power...................................................................... L-21
8-2.15 Automatic Operation..................................................................................... L-27
8-3 NORMAL OPERATION............................................................................ L-27
8-3.1 General .......................................................................................................... L-27
8-3.2 Interlocks....................................................................................................... L-27
8-3.3 Operation....................................................................................................... L-28
8-4 EMERGENCY OPERATION ................................................................... L-29
8-4.1 Emergency Shutdown ................................................................................... L-29
8-4.2 Post Shutdown Fire ....................................................................................... L-29

L-1
GEK 97310
VOLUME I
ADDENDUM L
Figure Title Page
1 Transient Temperature Limits ....................................................................... L-9

2 Deleted
3 Typical Acceleration Fuel Flow Schedule .................................................... L-11
4 Deleted
5 Deleted
LIST OF TABLES
Table Title Page
1 INSTRUMENTATION CONNECTIONS - 7LM2500-PD-MG .................. L-5

2 SUPPLY CONNECTIONS - 7LM2500-PD-MG ......................................... L-6
3 GAS TURBINE OPERATING LIMITS....................................................... L-13
4 PRESTART CHECKS .................................................................................. L-20
5 START-UP AND OPERATION.................................................................... L-22
6 GAS TURBINE SHUTDOWN .................................................................... L-25
7 EMERGENCY SHUTDOWN...................................................................... L-26
8 DELETED

L-2
GEK 97310
VOLUME I
ADDENDUM L
The information contained herein describes the Compressor Rotor 552(250)
7LM2500-PD-MG model gas turbine basic Compressor Stator, Front 307(139)
configuration and control system differences. Compressor Stator, Rear 93(42)
instrumentation and supply connections, spe- Compressor Rear Frame 421(191)
cial servicing requirements, optional hardware Combustor 120(54)
kits and the complete gas turbine operating High Pressure Turbine Rotor 419(190)
instructions for the 7LM2500-PD-MG model
are included.
Stg 1
2-0 REFERENCE DATA. High Pressure Turbine Nozzle, 127(58)
Stg 2
EQUIPMENT Turbine Mid Frame 530(240)
(General Electric Co., Cincinnati, Ohio) Low Pressure Turbine Stator 601(273)
Model No. 7LM2500-PD-MG Turbine Rear Frame 1071(486)
Dwg. No. L31430G09 High Speed Coupling Shaft 91(41)
Forward Adapter
PERFORMANCE RATING
Refer to paragraph 8-1.1. Exhaust Duct 1565(710)
Outer Cone 410(186)
GAS TURBINE WEIGHTS Inner Deflector 255(116)
The average weights of the major gas turbine Ring Seal 49(22)
components are: Ring Support 74(34)
Insulation 269(122)
Component Wt-Lbs/(Kg) Cover, Insulation 62(28)
Gas turbine - including inlet 7396(3355) Variable Stator Actuating 19(9)
duct, centerbody, exhaust dif- Mech
fuser, and coupling nut Outside Piping and Bracketing 278(126)
diffuser

L-3
GEK 97310
VOLUME I
ADDENDUM L
DRAWING LIST b. The temperature of the gas supply at
the fuel manifold connection on the gas turbine
Drawing No. must be in the range of 20ºF (-7ºC) above the
Gas Turbine Installation L31705 saturated vapor temperature of the gas at the
Drawing supply pressure as a minimum and 350ºF
Fuel System Flow Diagram L24327 (177ºC) as a maximum. Based on consider-
ation of control system components however,
Lubrication System Flow L24328 it is recommended that the maximum gas sup-
Diagram ply temperature be limited to 150ºF (66ºC). If
Electrical Diagram L24329 the supply temperature of the gas is not repeat-
Ignition Units L21454 able on a day-to-day basis it will be necessary
to change the starting fuel adjustment to adjust
the supply pressure to the gas turbine to main-
Drawing
tain a constant Btu-per-cubic-foot supply.
Once started, the engine will accept variations
3-0 INSTALLATION DRAWINGS. in supply temperature of ±20ºF (±11ºC). The
A complete set of installation drawings have maximum fuel flow required, assuming a
been provided. lower heating value of 19,000 Btu/lb, is
11,000 pph for the 7LM2500-PD-MG model
4-0 EQUIPMENT DESCRIPTION. gas turbine.
The 7LM2500-PD-MG is a natural gas fueled,
marinized gas turbine. 7-0 OPTIONAL HARDWARE KITS,
7LM2500-PD-MG.
SUPPLY REQUIREMENTS. (See Tables 1 a. Refer to Volume II, WP 001 00 for a
and 2.) detailed list of optional kits available for this
6-1.1 Natural Gas.

(2068 ± 35 kPa).

L-4
GEK 97310
VOLUME I
ADDENDUM L
Table 1. INSTRUMENTATION CONNECTIONS - 7LM2500-PD-MG
Part No. 173960 or 364450
E13 Vibration pickup, power turbine Bell & Howell Electronics
Part No. 173960 or 364450
(optional)
NOTE
gas turbine.

L-5
GEK 97310
VOLUME I
ADDENDUM L
Table 2. SUPPLY CONNECTIONS - 7LM2500-PD-MG
CAUTION
ON GAS GENERATOR.
Manifold
AN818-24C or MS20819-24C
AN818-16C or MS20819-16C
AN818-16C or MS20819-16C
A12 Air/Oil separator 3 inch line from air/oil separator to atmospheric vent or to
Generator Inlet Duct AN818-16C or MS20819-16C
NOTE
turbine.

L-6
GEK 97310
VOLUME I
ADDENDUM L
8-0 GAS TURBINE OPERATION. 8-1.1 Performance Ratings and Operating
Limits.
gas turbine operating procedures and limits NOTE
recommended by the General Electric Com- Ratings published in this manual apply
pany for the 7LM2500-PD-MG Gas Turbine. to the gas turbine. The driven unit rat-
b. The instructions are intended to pro- and shall take precedence over the gas
vide operating personnel with the information turbine manual limits.
tain to routine and emergency conditions and 8-1.2 Performance Ratings.
ume I, Chapter IV, TROUBLESHOOTING. a. The rated performance of the
7LM2500-PD-MG gas turbine in the new and
c. It is possible that these instructions clean condition is as follows:
equipment or contingency to be met in connec- • Shaft Horsepower
Refer requests for additional information to the - Continuous 16,600 17,600
trial Engine Division; Cincinnati, Ohio 45215. - Maximum 22,000 22,500
WARNING • Heat Rate, Btu/Hp-hr.

- Average (Continues) 7,614 7,338
EXISTS DO NOT OPERATE THE
- Average (Maximum) 7,026 6,990

L-7
GEK 97310
VOLUME I
ADDENDUM L
Based on the following conditions: NOTE
Inlet Air 59ºF 59ºF The acceleration fuel schedule shown
Temperature (15ºC) (15ºC) in figure 3 is provided as an example
transient fuel flow curve only. Refer to
Altitude Sea Level Sea Level Installation Design Manual MID-IDM-
Inlet Losses 0”H2O 0”H2O 2500-9 for the LM2500-PD-MG gas
Exhaust Losses 0”H2O 0”H2O turbine model transient fuel flow
requirements.
Compressor Bleed 0 0 d. Acceleration fuel rates greater than
Accessory Power those shown will result in over-temperature
Extraction 0 0 tion fuel rates lower than those shown can
Power Turbine Speed 3600 rpm 3000 rpm result in “hung” starts in the below idle speed
Power Turbine Inlet range.
Gas Temperature,
Average T5.4 e. Above the idle speed point, low accel-
- At continuous 1160ºF 1147ºF
rating (627ºC) (619ºC)
times.
- At maximum 1255ºF 1241ºF
rating (679ºC) (672ºC)
b. Starting fuel flow for the more slowly to enhance the time between hot
7LM2500-PD-MG model gas turbine is nor- section repairs and the life of the gas turbine; a
mally set by the minimum stop on the gas fuel time of 2 to 3 minutes is reasonable.
metering valve. The proper fuel flow setting
for the minimum stop, on a heat consumption
basis, is 10.45 x 106 ± 0.46 x 106 BTU/hr. for
ambient temperature of -65ºF (-54ºC) to
+130ºF (54ºC), and is based upon commencing
fuel and ignition at 1200 ± 100 rpm. Where a
minimum stop is not utilized, acceptable light
offs can be obtained in the sub-idle region,
however, during such starts, ignition should be
initiated at that fuel flow corresponding to the
minimum stop with its associated tolerance. If
starts in the sub-idle region are required, refer
to Gas Turbine Installation Design Manual
MID-IDM-2500-9.
c. Typical transient fuel flow require-

ule, figure 3.

L-8
GEK 97310
VOLUME I
ADDENDUM L

L-9
GEK 97310
VOLUME I
ADDENDUM L
Figure 2. Deleted

L-10
GEK 97310
VOLUME I
ADDENDUM L

L-11
GEK 97310
VOLUME I
ADDENDUM L
g. The fuel rates shown on the curve will Vibration indicators
give starting times to 5000 rpm idle of gas generator ....................... 0-4 in/sec or
60 to 90 seconds and accelerations from idle to 0-10 mil DA
maximum power of 15 seconds. power turbine....................... 0-2 in/sec or
0-15 mil DA
h. The maximum deceleration fuel flow
Power turbine speed sensor ... 0-5000 RPM
1500 pph (680 kg/h) ± 10 percent followed by Power turbine inlet gas .......... 0-2000ºF
a rate change of 1300 pph (603 kg/h) ± 10 per- temperature (T5.4) (-18 to 1093ºC)
cent per second to idle fuel flow. Rates greater Lube oil supply pressure........ 0-100 psig
than this can cause the gas turbine to lose fire. (0-690 kPa)
Normal declerations from maximum power to
idle should be made in approximately 2 to 3 8-2.3 Special Instrumentation Required for
minutes - this will enhance the time between Monitoring and Troubleshooting:
hot section repairs and the life of the gas
turbine. Fuel manifold pressure .......... 0-400 psi
sensor (0-2758 kPa)
8-1.3 Operating Limits. Refer to Table 3. Compressor inlet total............ 10-16 psia
NOTE Power turbine inlet gas .......... 0-75 psia
If any operating limit is exceeded, ver- pressure (0-517 kPa)
ify instrumentation accuracy before Compressor discharge............ 0-300 psig
troubleshooting or inspecting gas pressure (0-2068 kPa)
generator. Fuel supply pressure .............. 0-400 psig
(0-2758 kPa)
8-2 INITIAL OPERATION. Fuel supply temperature ........ 0-250ºF
(-18 to 121ºC)
Gas turbine inlet air ............... -65-150ºF
temperature (-54-66ºC)
on the system. Lube oil scavenge pressure.... 0-200 psig
(0-1379 kPa)
8-2.2 Special Instrumentation Required for Remote reading variable........ -5º to +45º
Operation. vane indicator
Starter air supply pressure ..... 0-50 psig
Gas Generator speed sensor... 0-11,000 RPM (optional) 0-345 kPa)
Lube oil scavenge tempera-... 0-400ºF 8-2.4 Preparation. The gas turbine and asso-
ture sensors (A-, B-, C-, (-18 to 204ºC) ciated systems must be inspected and checked
D-sumps and transfer out for proper installation and operation before
gearbox) normal operation can commence.
Lube oil supply temperature .. 0-400ºF
sensor (-18 to 204ºC)

L-12
GEK 97310
VOLUME I
ADDENDUM L
Alarm/ Normal
NOTE
Lubrication Gas Turbine Lube Alarm 8 psig ± 1 psig 20 - 60 psig Bypass until
System - Pump Discharge (55 kPa ± 6.9 kPa) (138 - 413 kPa) 4500 rpm
above 8000 rpm
(41 kPa ± 6.9 kPa) (138 - 413 kPa) 4500 rpm
Gas Turbine Scav- Alarm 110 psig ± 10 psig 10 - 100 psig Scavenge Dis-
enge Discharge (759 kPa ± 69 kPa) (69 - 690 kPa) charge Pressure
Pressure shall not exceed
180 psig
(1242 kPa)
Gas Turbine Lube Alarm 180º - 220ºF 140º - 160ºF Normal Operat-
Supply Tempera- (82º - 104ºC) (60º - 71ºC) ing Range
ture reflects tempera-
ture expected
during operation
above idle speed
Gas Turbine Lube Trip 330º - 350ºF 160º - 275ºF Normal Operat-
Scavenge Temper- (166º - 177ºC) (71º - 135ºC) ing Range
atures - Five reflects tempera-
ture expected
during operation
above idle speed
(143º - 154ºC)

L-13
GEK 97310
VOLUME I
ADDENDUM L
Alarm/ Normal
Fuel Fuel Manifold 20 - 305 psig Supply Pressure
System Pressure (138 - 2103 kPa) as reflected at the
(Natural fuel manifold
turbine
Fuel Supply Alarm 150º - 170ºF -65º to 150ºF Starting Fuel
Temperature (66º - 77ºC) (-54º to 66ºC) Flow Adjust-
ments may be
required to com-
pensate for fuel
temperature
variation
based on gas tur-
bine starter
torque
requirements
Fuel and Ignition
used)
simultaneously
with start
initiation
Failure to Trip 380º - 420ºF T5.4 Activate 10 sec-
Light-Off (193º- 216ºC) onds time delay
simultaneously
with application
of fuel and
ignition

L-14
GEK 97310
VOLUME I
ADDENDUM L
Alarm/ Normal
simultaneously
with start initia-
tion. De-ener-
gize ignition, fuel
system and
starter air supply
used) of purge. De-
energize fuel and
ignition systems
and starter air
supply
Power Tur- Failure to Trip 380º - 420ºF 0 -1600ºF Trip if tempera-
bine Inlet Light-Off (193º - 216ºC) (-18º - 871ºC) ture does not
(T5.4) reach 400ºF
Tempera- (204ºC) within
ture (Gas 10 seconds after

L-15
GEK 97310
VOLUME I
ADDENDUM L
Alarm/ Normal
Overtemperature:
Natural Gas Trip 1230ºF (666ºC) 1220ºF (660ºC) Values given are
Max for installations
T5.4 control as
the power limit.
Installations
using constant
power control
mode should
consult the con-
tract documents
or the General
Electric Com-
pany for deter-
mining alarm and
trip settings,
which are unique
to each
application
Vibration Gas Generator Trip 7 mils ± 1 mil DA 0-3 mils DA Avoid continu-
ous operation
above 4 mils
Power Turbine Trip 10 mils ± 1 mil DA 0 - 6 mils DA Avoid continu-
ous operation
above 7 mils
Speed Gas Generator Trip 10,200 ± 50 rpm 0 - 10,100 rpm
Power Turbine Trip 3960 ± 40 rpm 0 - 3600 rpm
valve upon loss
of flame

L-16
GEK 97310
VOLUME I
ADDENDUM L
8-2.5 Gas Turbine and Associated Equip- l. Gas turbine compressor rear _________
checklist. and 10, are open (not
a. Gas Turbine Assembly S/N _________ capped)
b. Mounting base secured to _________ m. Continuous lube supply _________
foundation starter is initially serviced
c. Intake air and exhaust gas _________ n. Lube oil storage tank ser- _________
ducts in place and secured viced to full level
d. Bonding straps in place and _________ o. Lube oil supply valves open _________
secure p. All filters are serviced per _________
e. Gas turbine and exhaust _________ Packager’s manual
duct support mounts and q. Fire alarm/extinguish sys- _________
links in place and secure tem ON and operative
f. All service connections _________ r. T5. 4 thermocouple system _________
made and secure
g. All lines flushed per Pack- _________
ager’s manual
t. Compressor inlet total pres- _________
h. All instrumentation connec- _________
tions made and secure
and free of damage
i. All accessories are secure _________
u. Variable stator system _________
per Packager’s manual
secure
j. Gas turbine assembly free _________
v. Required check and inspec- _________
tions specified in Pack-
lines/electrical leads con-
ager’s manual for gas
nected
k. Gas turbine inlet air area _________ performed.
screen secure

L-17
GEK 97310
VOLUME I
ADDENDUM L
Refer to Packager’s manual BE FOLLOWED.

SARY.
MET:

REQUIRED DURING ENGINE MOTORING THE GAS TUR-
OPERATION, CONTACT GE BINE.
SENTATIVE WHO IS TRAINED a. When entering enclosure at or below
TO ENTER THE ENCLOSURE idle speed, wear proper ear protection.
THE CUSTOMER’S PROCE- d. Perform motoring procedure per
ING OR CLOSING THE
ENCLOSURE DOOR.
paragraph 8-2.12.

L-18
GEK 97310
VOLUME I
ADDENDUM L
j. Check automatic operation per f. If an audible report is not heard on
paragraph 8-2.15. No. 1 and/or No. 2 igniters, check out the sys-
8-2.8 Ignition Check. ate corrective action.
WARNING 8-2.9 Motoring. After all preliminary checks
• ASSURE POWER TO IGNITION have been completed and lines flushed, gas
SYSTEMS IS OFF WHEN DIS- generator can be motored as follows:
CONNECTING AND CONNECT- a. Make ignition and natural-gas supply
ING IGNITION EXCITER INPUT systems inoperative as follows:
SERVICE TO PRECLUDE INAD- (1) Disconnect power supply to igni-
VERTENT ACTIVATION. tion unit.
• ASSURE FUEL VALVES ARE (2) Close natural-gas manual shutoff

CLOSED THROUGHOUT THIS valve to fuel control unit.
PROCEDURE. b. Depress MOTORING pushbutton. Gas
a. To clear combustor of any residual turbine will start to rotate. If it does not, refer
fuel, motor gas turbine for one minute; allow to packager’s manual for supply pressure to
gas turbine to coast down. starter.
b. Disconnect number one ignition exciter c. Hold MOTORING pushbutton closed

input lead at exciter. Temporarily secure input until gas generator speed stabilizes, and check
lead away from the exciter. for oil pressure. If there is no indication of oil
c. Turn on electrical power to the ignition while gas turbine is coasting down, loosen oil
system (No. 2 ignition exciter energized). An fittings at lube pump to bleed air from system.
audible report (approximately two sparks per Starter should motor gas turbine to minimum
second) should be heard when the No. 2 spark of 2200 RPM.
igniter fires. d. Repeat motoring and bleeding proce-
safetywire connector.
e. Repeat steps b, c and d, disconnecting
the No. 2 exciter.

L-19
GEK 97310
VOLUME I
ADDENDUM L

Item Requirement
Fuel valves Closed
Ignition Off
Oil tank level Full
Lube oil temperature 140ºF to 160ºF (60º to 71ºC)
Fuel supply
pressure (at manifold inlet) 350 psig max (2413 kPa)
temperature -65 to 150ºF (-54º to 66ºC)
flow See paragraph 8-1.2, step b
8-2.10 False Start. Perform false start as a. With ignition lead disconnected, but
follows: with manual gas valve open and governing
a. With ignition leads disconnected and turbine per packager’s manual.
manual gas valve closed, make automatic start
of gas turbine per packager’s manual. b. Gas turbine should accelerate to light-
off speed (1100 to 1300 rpm). Fuel valve
b. Gas turbine should go through normal should open 3 psig (21 kPa). Adjust fuel sup-
start cycle and then abort because of lack of ply if required. Start will then abort because of
flame. lack of flame.
8-2.11 Governor Check. Check governor sys- c. Allow gas turbine to coast to stop; then
tem per packager’s manual. motor it to purge any remaining natural gas
from gas turbine. Continue to motor for
follows:

L-20
GEK 97310
VOLUME I
ADDENDUM L
8-2.13 Manual Start and Operation. Perform (2) Immediately after the gas turbine
manual start per packager’s manual with fuel stops rotating, re-start and stabilize at idle
valve open and with ignition lead connected. speed (4950 ± 50 rpm) for 30 seconds.
Refer to Table 5.
CAUTION additional start-up and shutdown cycles.
rotate after accomplishing substeps (1) through
a. The power turbine must rotate by time (5) Immediately after gas turbine
the gas generator speed reaches 7000 rpm rotation stops, re-start and accelerate to
NGG. If power turbine speed indication is not 7000 rpm NGG maximum and stabilize for
obtained and it is determined that a “thermal 30 seconds. If the power turbine still does not
seizure” of the power turbine has occurred, rotate, shut down and investigate/correct the
proceed as follows: cause. During the investigation for the cause of
NOTE blades in stages 4, 5, and 6 for shingling and
Power Turbine, except in a new instal- unlatching. If blades have become unlatched,
lation, will be rotating at gas generator they may be relatched. LPT blades that have
idle speed. encountered shingling may be bent thereby
necessitating power turbine replacement.
NOTE
Thermal seizure of the power turbine 8-2.14 Operation to Maximum Power.
is shut down and is most likely to occur CAUTION
within 30 to 40 minutes following gas MANUAL OPERATION MAY
turbine operation. Thermal seizure is ELIMINATE CERTAIN PROTEC-
the condition where the power turbine TIVE CIRCUITS. OPERATING LIM-
rotor is prevented from rotating by hard ITS SHALL NOT BE EXCEEDED.
shrouds, interstage seals and other a. Slowly increase manual control setting
internal interference. This condition is (refer to packager’s manual) to increase gas
the result of unequal cooling rates of generator speed. After each 500 RPM increase,
the various power turbine components. log all instrument readings, paying particular
The possibility of thermal seizures can attention to variable stator vane position and
be reduced by operating the gas turbine vibration. If variable stator system is not
at idle power for at least five minutes within limits, adjust it per work packages
prior to shutdown to achieve proper 118 00. If vibrations are not within limits, con-
cooling of the power turbine. sult the local General Electric Company repre-
sentative.

L-21
GEK 97310
VOLUME I
ADDENDUM L
1. Assure that prestart checks are com- Automatic shutdown
pleted per Table 4 (trip) at 1230ºF (666ºC).
Refer to Table 3.
CAUTION
IF T5.4 RAPIDLY APPROACHES OR EXCEEDS 1220ºF (660ºC), MAXIMUM,
ABORT START
NOTE
NOTE
3. At 1100 to 1300 rpm NGG
a. Ignition on
(21 kPa). See
paragraph 8-1.1
c. Note time to lightoff (T5.4 above 20 seconds max. Abort start-automatic
400ºF - 204ºC) 1200 rpm shutdown
4. Note time to 4500 ± 200 RPM 90 seconds max. Troubleshoot system
and take corrective
action if rpm stops
accelerating or it takes
longer than 90 sec. to
reach 4300 rpm
5. At 4300 to 4700 rpm NGG
a. Starter shutoff valve, should Valve closed Close fuel valve and
close automatically allow gas generator to
motor for 60 seconds,
then shutoff starter

L-22
GEK 97310
VOLUME I
ADDENDUM L
a. Oil pressure See applicable figure in Alarm at 8 ± 1 psig
Chapter 5 (55 ± 6.9 kPa)
Trip at 6 ± 1 psig
(41 ± 6.9 kPa)
b. NGG 5000 RPM ± 250 RPM Adjust
c. T5.4 1000ºF (538ºC) max Emergency shutdown -
Table 7
e. Gas generator vibration 0 to 3 mils Alarm set at 4 mils.
corrective action
f. Power turbine vibration 0 to 6 mils DA Alarm set at 7 mils.
corrective action
g. Compressor inlet temperature Approximately equal to Troubleshoot sensing
(T2) outside air temperature and indicating system.
Correct as required
h. Check for fuel or oil leaks No leaks allowed Correct as required
i. Maximum NGG with power tur- 7000 RPM NGG maximum Shut down and investi-
bine seizure (thermal seizure) for 30 seconds gate/correct cause per
paragraph 8-2.13
8. Set desired power setting. Observe 1220ºF (660ºC) max. Correct as required.
T5.4 during transient operation Refer to figure 1
a. T5.4 1220ºF (660ºC) *
b. NGG 10,100 RPM max. *
corrected

L-23
GEK 97310
VOLUME I
ADDENDUM L
NOTE
The maximum allowable physical (uncorrected) speed is 10,370 RPM.
c. NPT 3600 RPM max *
e. Scavenge oil temperature 160ºF to 275ºF Alarm at 290-310ºF
71ºC to 135ºC (143-154ºC); Auto-
matic shutdown if above
340°F (171ºC)
f. Gas generator Vibration 3 mils max *
4 mils (alarm) Troubleshoot
7 mils (trip) Emergency or automatic
shutdown
g. Power turbine vibration 6 mils max *
7 mils max (Alarm) Troubleshoot
10 mils max (Trip) Emergency or automatic
shutdown
h. Fuel manifold pressure 305 psig (2103 kPa) **
maximum
(-54º to +66ºC)
l. T2 Approximately equal to **
WP 118 00 WP 118 00
shutdown.

L-24
GEK 97310
VOLUME I
ADDENDUM L

(unloaded)
following:
Trip at 6 ± 1 psig
(41 ± 6.9 kPa)
c. T5.4 1000ºF (538ºC) max. Troubleshoot and take

corrective action
e. Gas generator vibration 3 mils max. Alarm at 4 mils. Automatic

corrective action
f. Power turbine vibration 6 mils max. Alarm at 7 mils. Automatic
g. Fuel inlet temperature -65º to 150ºF (-54 to 66ºC)
erates and stops
4. Observe T5.4 for 3 minutes 700ºF (371ºC) Motor gas turbine and shut-
decreases

L-25
GEK 97310
VOLUME I
ADDENDUM L
CAUTION
1. Conditions permitting, decelerate gas T5.4 drops below 400ºF Manually shut off fuel
turbine to idle and close fuel valves (204ºC) and NGG and supply
NPT decelerate
2. Observe T5.4 for 3 minutes 700ºF (371ºC) max. Motor gas turbine.
after shutdown Continue motoring
until temperature
decreases
(621ºC) has occurred, and a “hot restart”
procedure.
be accomplished.

L-26
GEK 97310
VOLUME I
ADDENDUM L
b. Operate gas turbine up to rated power, d. Decelerate to idle.
perature (T5.4) limit. Hold at this power setting e. Check for fuel or lube oil leaks.
until all temperatures stabilize. If governing f. After a total of five minutes at idle,
system is unstable, adjust per packager’s shut down gas turbine.
manual.
c. Log all instrument readings once they strainers; clean or replace as necessary.
d. Reduce gas turbine speed to idle. After
stabilizing for three minutes, record all instru- i. Remove all temporary instrumentation.
e. Check fail-safe section of control system for loose parts; tighten as necessary.
idle for five minutes, make normal shut-down. 8-3.1 General. Normal operation is the rou-
Refer to Table 6, steps 3 and 4. tine operation of an installed gas turbine. For
8-2.15 Automatic Operation. Check automatic operation for normal operation, refer to pack-
operation per packager’s manual. ager’s manual.
a. Accelerate to idle. 8-3.2 Interlocks. Refer to packager’s manual

for description of interlocks which affect gas
turbine operation.

L-27
GEK 97310
VOLUME I
ADDENDUM L
SARY.
MET: OPERATING.
BINE.
ENTRY SHOULD BE
per Table 7.
DURES. e. Refer to paragraph 5-3.30 and 5-3.31,
5-32B, 5-32E, 5-32F, 5-32J, 5-32L, 5-32N,
and 5-32Q.).
ING OR CLOSING THE
ENCLOSURE DOOR. f. Idle lube oil pressure is 29 psig
(200 kPa) maximum after five minutes
stabilization.
GAS TURBINE IS OPERATING, g. The corrected operating pressure of the
AN OBSERVER SHALL BE STA- lube oil shall be per applicable table in
TIONED AT THE ENCLOSURE Chapter 5 at standard conditions of 9000 rpm
DOOR AND CONFINED SPACE gas generator speed and 150°F (66°C) lube
ENTRY PROCEDURES SHALL pump discharge temperature. Oil pressure
BE FOLLOWED. measured at conditions other than standard
applicable table in Chapter 5.

L-28
GEK 97310
VOLUME I
ADDENDUM L
a. In an emergency, the gas turbine may time gas turbine is coasting to stop, tempera-
ing the fuel valve. However, this should only that combustion is still taking place because of
be done in an emergency, since rapid shutdown a leaking fuel valve. (A slight temperature
will decrease life of gas turbine. increase after rotation stops is normal.) Make
b. Emergency shutdown shall be made certain fuel is shut off, and motor the gas tur-
per Table 7. bine. This will blow out the fire. As soon as
motoring.

L-29
GEK 97310
VOLUME I
ADDENDUM L
Figure 4 and 5. DELETED

Table 8. DELETED

L-30
GEK 97310
VOLUME I
ADDENDUM M
ADDENDUM
7LM2500-PE-MG

GEK 97310
VOLUME I
ADDENDUM M
TABLE OF CONTENTS
1-0 INTRODUCTION....................................................................................... M-3

2-0 REFERENCE DATA .................................................................................. M-3
3-0 INSTALLATION DRAWINGS.................................................................. M-4
4-0 EQUIPMENT DESCRIPTION ................................................................. M-4
5-0 INSTRUMENTATION AND SUPPLY REQUIREMENTS ................... M-4
6-0 SERVICE REQUIREMENTS ................................................................... M-4
6-1.1 Natural Gas ................................................................................................... M-4
7-0 OPTIONAL HARDWARE KITS - 7LM2500-PE-MG............................ M-7
8-0 GAS TURBINE OPERATION .................................................................. M-7
8-1.1 Performance Ratings and Operating Limits.................................................. M-7
8-1.2 Performance Ratings ..................................................................................... M-8
8-1.3 Operating Limits ........................................................................................... M-9
8-2 INITIAL OPERATION .............................................................................. M-9
8-2.1 General .......................................................................................................... M-9
8-2.2 Special Instrumentation Required for Operation .......................................... M-9
8-2.3 Special Instrumentation Required for Monitoring and Troubleshooting ...... M-14
8-2.4 Preparation .................................................................................................... M-14
8-2.5 Gas Turbine and Associated Equipment Check List..................................... M-14
8-2.6 Governor and Manual Control Check........................................................... M-15
8-2.7 Start-Up and Checkout.................................................................................. M-15
8-2.8 Ignition Check............................................................................................... M-16
8-2.9 Motoring........................................................................................................ M-16
8-2.10 False Start...................................................................................................... M-17
8-2.11 Governor Check ............................................................................................ M-17
8-2.12 Wet Prestart ................................................................................................... M-17
8-2.13 Manual Start and Operation .......................................................................... M-18
8-2.14 Operation to Maximum Power...................................................................... M-18
8-2.15 Automatic Operation..................................................................................... M-19
8-3 NORMAL OPERATION............................................................................ M-19
8-3.1 General .......................................................................................................... M-19
8-3.2 Interlocks....................................................................................................... M-19
8-3.3 Operation....................................................................................................... M-26
8-4 EMERGENCY OPERATION ................................................................... M-27
8-4.1 Emergency Shutdown ................................................................................... M-27
8-4.2 Post Shutdown Fire ....................................................................................... M-27
8-5 SPECIAL GAS TURBINE CONSTRAINTS ........................................... M-27
8-5.1 General .......................................................................................................... M-27
8-5.2 Overtemperature............................................................................................ M-27
8-5.3 Lube Oil Supply Pressure ............................................................................. M-27
8-5.4 High Speed Stall............................................................................................ M-28
8-5.5 Starter Duty Cycle - Air or Natural Gas........................................................ M-28

M-1
GEK 97310
VOLUME I
ADDENDUM M
TABLE OF CONTENTS - Continued
8-5.6 Re-Start Following High Power Trip ............................................................ M-28

8-5.7 No Power Turbine Rotation .......................................................................... M-28
8-5.8 Windmilling .................................................................................................. M-28
Figure Title Page
1 Transient Temperature Limits ................................................................................ M-24

2 Deleted
3 Deleted
4 Deleted
5 Deleted
LIST OF TABLES
Table Title Page
1 INSTRUMENTATION CONNECTIONS - 7LM2500-PE-MG............................ M-5

2 SUPPLY CONNECTIONS - 7LM2500-PE-MG................................................... M-6
3 GAS TURBINE OPERATING LIMITS................................................................ M-10
4 PRESTART CHECKS ........................................................................................... M-17
5 START-UP AND OPERATION ............................................................................ M-20
6 GAS TURBINE SHUTDOWN ............................................................................. M-25
7 EMERGENCY SHUTDOWN............................................................................... M-29
8 DELETED
9 DELETED
10 DELETED
11 DELETED

M-2
GEK 97310
VOLUME I
ADDENDUM M
1-0 INTRODUCTION. Combustor 120(54)
High Pressure Turbine Rotor 419(190)
7LM2500-PE-MG model gas turbine basic
configuration and control system differences. High Pressure Turbine Nozzle,
In addition, the coverage of reference data, Stg 1 68(31)
cial servicing requirements, optional hardware Stg 2 127(58)
kits and the complete gas turbine operating Turbine Mid Frame 530(240)
instructions for the 7LM2500-PE-MG model
are included. Low Pressure Turbine Rotor 1095(497)
2-0 REFERENCE DATA.
EQUIPMENT High Speed Coupling Shaft
Gas Turbine Assembly Forward Adapter 91(41)
(General Electric Co., Cincinnati, Ohio) Exhaust Duct Assembly 2741(1243)
Model No. 7LM2500-PE-MG Exhaust Duct 1565(710)
Dwg. No. L31430G10
Outer Cone 410(186)
PERFORMANCE RATING Inner Deflector 255(116)
Refer to paragraph 8-1.1 Ring Seal 49(22)
GAS TURBINE WEIGHTS Ring Support 74(34)
Insulation 269(122)
ponents are: Cover, Insulation 62(28)
Component Wt-Lbs/(Kg) Mech 19(9)
Gas turbine - including inlet Outside Piping and Bracketing 278(126)
fuser, and coupling nut 7396(3355) DRAWING LIST
diffuser 2313(1049) Drawing No.
Gas Generator 4212(1911) Gas Turbine Installation
Power Turbine 2777(1260) Drawing L31705
Inlet Gearbox 38(17) Fuel System Flow Diagram L24327
Transfer Gearbox 245(111) Lubrication System Flow
Compressor Front Frame 517(235) Diagram L24328
Compressor Rotor 552(250) Electrical Diagram L24329
Compressor Stator, Front 307(139) Ignition Units L21454
Compressor Stator, Rear 93(42) Gas Turbine Assembly
Drawing L31430G10
Compressor Rear Frame 421(191)

M-3
GEK 97310
VOLUME I
ADDENDUM M
3-0 INSTALLATION DRAWINGS. b. The temperature of the gas supply at
A complete set of installation drawings have the fuel manifold connection on the gas turbine
been provided. must be in the range of 20°F (-6.7°C) above
the saturated vapor temperature of the gas at
4-0 EQUIPMENT DESCRIPTION. the supply pressure as a minimum, and 350°F
The 7LM2500-PE-MG is a natural gas fueled, (177°C) as a maximum. Based on consider-
marinized gas turbine. ation of control system components however,
it is recommended that the maximum gas sup-
5-0 INSTRUMENTATION AND ply temperature be limited to 150°F (66°C). If
SUPPLY REQUIREMENTS. the supply temperature of the gas is not repeat-
See Tables 1 and 2. able on a day-to-day basis, it will be necessary
to change the control system starting fuel
6-0 SERVICE REQUIREMENTS. adjustment or to adjust the supply pressure to
the gas turbine to maintain a constant BTU-
6-1.1 Natural Gas. per-cubic-foot supply. Once started the gas tur-
bine will accept variations in supply tempera-
a. The required supply pressure to the ture of ±20°F (±11°C). The maximum fuel
natural gas fuel manifold on the gas turbine is flow required, assuming a lower heating value
355 ± 5 psig (2448 ± 35 kPa) maximum. of 19,000 BTU lb is 13,500 pph (6123 kg/h)
for the 7LM2500-PE-MG model gas turbine.

M-4
GEK 97310
VOLUME I
ADDENDUM M
Table 1. INSTRUMENTATION CONNECTIONS - 7LM2500-PE-MG
E1 Vibration pickup, Gas Generator Diagnostic System Corp. Part No. 303-03
temperature
E13 Vibration pickup, power turbine Diagnostic System Corp. Part No. 303-03
(optional)
(optional)
(optional)
NOTE
gas turbine.

M-5
GEK 97310
VOLUME I
ADDENDUM M
Table 2. SUPPLY CONNECTIONS - 7LM2500-PE-MG
CAUTION
Turbine Fuel Manifold
L1 Oil Supply 1-1/2 inch line to Lube Pump on Gas Tur-
bine AN818-24C or MS20819-24C
Turbine AN818-16C or MS20819-16C
L3 Scavenge oil discharge 1-1/4 inch line from Gas Turbine Scavenge
AN818-20C or MS20819-20C
(1.92 inch ID)
arrestor)
manifold on Gas Turbine Inlet Duct
AN818-16C or MS20819-16C
NOTE
turbine.

M-6
GEK 97310
VOLUME I
ADDENDUM M
7LM2500-PE-MG.
a. Refer to Volume II, WP 001 00 for a EXISTS DO NOT OPERATE THE
pany for the 7LM2500-PE-MG Gas Turbine. IN UNDUE STRESS BEING
procedures. When a fault exists, refer to Vol- 8-1.1 Performance Ratings and Operating
ume I, Chapter IV, TROUBLESHOOTING. Limits.
c. It is possible that these instructions NOTE
equipment or contingency to be met in connec- to the gas turbine. The driven unit rat-
tion with the operation of the gas turbine. ings/limits may be lower in some cases
Refer requests for additional information to the and shall take precedence over the gas
General Electric Company; Marine and Indus- turbine manual limits.
trial Engine Department; Cincinnati, Ohio
45215.

M-7
GEK 97310
VOLUME I
ADDENDUM M
8-1.2 Performance Ratings. b. Starting fuel flow for the 7LM2500-
PE-MG model gas turbine is normally set by
a. The rated performance of the the minimum stop on the gas fuel metering
7LM2500-PE-MG gas turbine in the new and valve. The proper fuel flow setting for the min-
clean condition is as follows: imum stop, on a heat consumption basis, is
10. 45 x 106 ± 0. 46 x 106 BTU/hour for ambi-
Power Turbine Speed ent temperatures of -65°F (-54°C) to +130°F
3600 rmp 3000 rpm (54°C), and is based commencing fuel and
ignition at 1200 ± 100 rpm. Where a minimum
• Shaft Horsepower stop is not utilized, acceptable light-offs can be
obtained in the sub-idle region, however dur-
- Base 29,500 28,500 ing such starts, ignition should be initiated at
- Maximum 32,000 30,000 that fuel flow corresponding to the minimum
stop with its associated tolerance. If starts in
• Heat Rate, BTU/HP-Hr the sub-idle region are required, refer to Gas
- Average 6874 7081 Turbine Installation Design Manual
(Base) MID-IDM-2500-9.
- Average 6908 7125 c. Refer to Installation Design Manual
(Maximum) MID-IDM-2500-9 for the 7LM2500-PE-MG
gas turbine model transient fuel flow
Based on the following conditions: requirements.
Inlet Air 59ºF 59ºF d. Acceleration fuel rates greater than

Temperature (l5ºC) (15ºC) those shown will result in over-temperature
Altitude Sea Level Sea Level
Inlet Losses 0" H2O 0" H2O result in "hung" starts in the below idle speed
Exhaust Losses 0" H2O 0" H2O range.
Relative e. Above the idle speed point, low accel-
Humidity 0% 0% eration fuel rates will not harm the gas turbine
Compressor and will only result in slower acceleration
Bleed 0 0 times.
Accessory
Power f. For normal accelerations from idle to
Extraction 0 0 power settings the changes should be made
Power Turbine
Inlet Gas Temperature, T5.4 Avg.
- At Base 1461 1449 g. The fuel rates shown on the curve will
Rating give starting times to 5000 rpm idle of
- At Maximum 1551 1516 maximum power of 15 seconds.
Rating

M-8
GEK 97310
VOLUME I
ADDENDUM M
h. Normal decelerations from maximum 8-2.2 Special Instrumentation Required for
power to idle should be made in approximately Operation.
2 to 3 minutes - this will enhance the time
between hot section repairs and the life of the Gas Generator speed sensor 0-11,000 RPM
gas turbine. Lube oil scavenge tempera- 0-400°F
8-1.3 Operating Limits. Refer to Table 3. ture sensors (A-, B-, C-, (-18 to 204°C)
D-sumps and transfer
NOTE gearbox) . . . . . . . . . . . . .
If any operating limit is exceeded, ver- Lube oil supply temperature 0-400ºF
ify instrumentation accuracy before sensor . . . . . . . . . . . . . . . (-18 to 204ºC)
troubleshooting or inspecting gas Vibration indicators
generator. gas generator. . . . . . . . . . 0-4 in/sec or
0-10 mil DA
Power turbine . . . . . . . . . . 0-2 in/sec
0-15 mil DA
that period of operation immediately following Power turbine speed sensor 0-5000 RPM
gas turbine replacement or major maintenance Power turbine inlet gas 0-2000ºF
on the system. temperature (T5.4) . . . . . . (-18 to
1093ºC)
Lube oil supply pressure . . 0-100 psig
(0-690 kPa)

M-9
GEK 97310
VOLUME I
ADDENDUM M
Normal
Alarm/ Operating
NOTE
System - Lube Supply (55 kPa ± 6.9 kPa) (138 - 413 kPa) rpm
Ranges (103 kPa ± 6.9
kPa) above 8000
rpm
Gas Turbine Trip 6 psig + 1 psig 20 - 60 psig Bypass until 4500
Lube Supply (41 kPa + 6.9 kPa) (135 - 414 kPa) rpm
Pressure
Gas Turbine Alarm 110 psig + 10 psig 10 - 100 psig Scavenge Dis-
Scavenge (759 kPa + 69 kPa) (69 - 690 kPa) charge Pressure
Pressure 180 psig
(1242 kPa)
Lube Supply (82º - 104ºC) (60º - 71ºC) Range reflects
expected during
operation above
idle speed
Lube (166º - 177ºC) (71º - 135ºC) Range reflects
Scavenge temperature
Tempera- Alarm 290°-310°F expected during
tures - Five (143°-154°C) operation above
idle speed
Fuel Fuel Mani- 20 - 355 psig Supply Pressure as
System fold Pressure (138 - reflected at the
(Natural 2448 kPa) fuel manifold inlet
Gas) on the gas turbine

M-10
GEK 97310
VOLUME I
ADDENDUM M
Normal
Alarm/ Operating
Fuel Supply Alarm 150º - 170ºF -65º to Starting Fuel Flow
Temperature (66º - 77ºC) 150ºF Adjustments may
(-54º to be required to
66ºC) compensate for
fuel temperature
variation
Pressure based on gas
turbine starter
torque
requirements
Application 1200 + 100 rpm
of Fuel and
Ignition
Application 1700 + 100 rpm 1700 + 100 rpm
ignition (if purge cycle
purge cycle
is used)
Starting Trip 1200 + 100 rpm Activate 20
Time to seconds time delay
1200 rpm simultaneously
with start initiation
Failure to Trip 380º - 420ºF T5.4 Activate 10 sec-
simultaneously
with application of
fuel and ignition.
Starting Trip 4500 + 200 rpm Activate 90 sec-
Time to onds time delay
4500 rpm simultaneously
with start initia-
tion. De-Energize
ignition, fuel sys-
tem and starter air
supply

M-11
GEK 97310
VOLUME I
ADDENDUM M
Normal
Alarm/ Operating
Starting Trip 4500 + 100 rpm Activate 60 sec-
Time to 4500 onds time delay
rpm (if purge upon completion
gize fuel and igni-
tion systems and
starter air supply
Power Tur- Failure to Trip 380 - 420ºF 0º - 1600ºF Trip if temperature
bine Inlet Light-Off (193º - 216ºC) (0º - 871ºC) does not reach
Tempera- 400ºF (204ºC)
ture within 10 seconds
after fuel and igni-
tion are applied
Overtemper- Trip 1505ºF (818ºC) Values given are
ature @ 3600 NPT for base rating
installations using
1490ºF (810ºC) constant T5.4 con-
@ 3000 NPT trol as the power
limit. Installa-
Alarm 1495ºF (813ºC) tions using con-
@ 3600 NPT stant power
control mode
1480ºF (804ºC) should consult the
@ 3000 NPT contract docu-
ments or the Gen-
eral Electric
Company for
determining alarm
and trip settings,
which are unique
to each
application.
Vibration Gas Trip 7 mils DA 0 - 3 mils DA Avoid continuous
Generator operation over
Alarm 4 mils DA 4 mils
Power Trip 10 mils DA 0-6 mils DA Avoid continuous
Turbine operation over
Alarm 7 mils DA 4 mils

M-12
GEK 97310
VOLUME I
ADDENDUM M
Normal
Alarm/ Operating
Speed Gas Trip 10100 rpm cor- 0 - 9500 rpm
Generator rected
Power Trip 3960 + 40 rpm 0 - 3600 rpm
Turbine
upon loss of flame
Overtemperature:
Power Turbine Speed
3000 rpm 3600 rpm
Natural Gas Trip 1575ºF 1575ºF
(857ºC) (857ºC)
Alarm 1505ºF 1515ºF
(818ºC) (824ºC)
Speed
(For 60 Hz) Gas Trip 10,200 rpm 0 - 10,100 rpm
Generator
(For 60 Hz) Power Trip 3,960 rpm 0 - 3,600 rpm
Turbine
Generator
Turbine
NOTE
• Consult General Electric Company for approval when operating speeds above 3300 rpm
are considered.
• Refer to packager’s manual for specific alarm and trip levels.
upon loss of flame

M-13
GEK 97310
VOLUME I
ADDENDUM M
8-2.3 Special Instrumentation Required for d. Bonding straps in place
Monitoring and Troubleshooting: and secure _________
Fuel manifold pressure . . 0-400 psi e. Gas turbine and exhaust

sensor (0-2758 kPa) duct support mounts and
Compressor inlet total . . . 10-16 psia
pressure sensor (69-110 kPa) f. All service connections
made and secure _________
Power turbine inlet gas . . 0-75 psia
pressure (0-517 kPa) g. All lines have been
Compressor discharge . . . 0-300 psig flushed per Packager’s
pressure (0-2068 kPa) manual _________
Fuel supply pressure. . . . . 0-400 psig h. All instrumentation con-
(0-2758 kPa) nections made and secure _________
Fuel supply temperature. . 0-250ºF i. All accessories are secure
(-18 to 121ºC) per Packager’s manual _________
Gas turbine inlet air . . . . . -65 to 150ºF j. Gas turbine assembly free
temperature (-54 to 66ºC) of loose objects and all
Lube oil scavenge pressure 0-200 psig lines/electrical leads
(0-1377 kPa) connected _________
Remote reading variable . -5º to +45º k. Gas turbine inlet air area
vane indicator free of foreign objects.
Starter air supply pressure 0-50 psig Inlet screen secure _________
(optional) (0-345 kPa) l. Gas turbine compressor
rear frame leakage ports,
8-2.4 Preparation. The gas turbine and asso- struts, 7 and 10, are open
ciated systems must be inspected and checked (not capped). _________
out for proper installation and operation before m. Continuous lube supply
normal operation can commence. starter is initially serviced
per Packager’s manual _________
ment Check List. Complete the following n. Lube oil storage tank
checklist. serviced to full level _________
a. Gas Turbine Assembly open _________
S/N _________ p. All filters are serviced per
b. Mounting base secured to Packager’s manual _________
foundation _________ q. Fire alarm/extinguish sys-
c. Intake air and exhaust gas tem ON and operative _________
ducts in place and secured _________ r. T5.4 thermocouple system

M-14
GEK 97310
VOLUME I
ADDENDUM M
s. Ignition system operative _________ THE CUSTOMER’S PROCE-
DURES.
t. Compressor inlet total
pressure probe aligned • SECONDARY AIR TO THE
properly and free of ENCLOSURE SHALL BE SHUT
damage _________ OFF. HIGH SECONDARY AIR-
u. Variable stator system
ING OR CLOSING THE
secure _________
ENCLOSURE DOOR.
v. Required checks and
inspections specified in • THE ENCLOSURE DOOR
Packager’s manual for gas SHALL BE KEPT OPEN. IF THE
turbine control have been GAS TURBINE IS OPERATING,
performed _________ AN OBSERVER SHALL BE STA-
8-2.6 Governor and Manual Control Check. DOOR AND CONFINED SPACE
Refer to Packager’s manual. ENTRY PROCEDURES SHALL
BE FOLLOWED.
8-2.7 START-UP AND CHECKOUT. • ALLOW THE GAS TURBINE TO
BINE ENCLOSURE, THE FOLLOW- LATED GLOVES AS NECES-
ING REQUIREMENTS SHALL BE SARY.
MET:

a. When entering enclosure during gas
turbine operation, wear proper ear protection.

paragraph 8-2.9.

M-15
GEK 97310
VOLUME I
ADDENDUM M
e. Perform false start per d. Turn off electrical power to the ignition
paragraph 8-2.10. system. Reconnect input lead to exciter and
f. Perform governor check per safety-wire connector.
paragraph 8-2.11. e. Repeat steps b, c and d, disconnecting
g. Perform a wet prestart per the No. 2 exciter.
paragraph 8-2.12. f. If an audible report is not heard on
h. Perform a manual start and operate per No. 1 and/or No. 2 igniters, check out the sys-
paragraph 8-2.13. tem to isolate the problem, and take appropri-
paragraph 8-2.14. 8-2.9 Motoring. After all preliminary checks
j. Check automatic operation per have been completed and lines flushed, gas
paragraph 8-2.15. generator can be motored as follows:
8-2.8 Ignition Check. a. Make ignition and natural-gas supply


tion unit.
SYSTEMS IS OFF WHEN DIS- (2) Close natural-gas manual shutoff
CONNECTING AND CONNECT- valve to fuel control unit.
ING IGNITION EXCITER INPUT b. Depress MOTORING pushbutton. Gas
LEAD. TAG SWITCH OUT OF turbine will start to rotate. If it does not, refer
SERVICE TO PRECLUDE INAD- to Packager's manual for supply pressure to
VERTENT ACTIVATION. starter.
• ASSURE FUEL VALVES ARE c. Hold MOTORING pushbutton closed
CLOSED THROUGHOUT THIS until gas generator speed stabilizes, and check
PROCEDURE. for oil pressure. If there is no indication of oil
a. To clear combustor of any residual while gas turbine is coasting down, loosen oil
fuel, motor gas turbine for one minute; allow fittings at lube pump to bleed air from system.
gas turbine to coast down. Starter should motor gas turbine to minimum
of 2200 RPM.
b. Disconnect number one ignition exciter d. Repeat motoring and bleeding proce-
input lead at exciter. Temporarily secure input dure until an indication of oil pressure appears.
igniter fires.

M-16
GEK 97310
VOLUME I
ADDENDUM M
Item Requirements
Fuel valves Closed
Ignition Off
Oil tank level Full
Lube oil temperature Above +20ºF (+1ºC) for MIL-L-23699
Above -20ºF (-29ºC) for MIL-L-7808
pressure at manifold inlet 50 psig max.
(345 kPa)
(-54º to 66ºC)
flow See paragraph
8-1.2, step b.
8-2.10 False Start. Perform false start as a. With ignition lead disconnected, but
follows: with manual gas valve open and governing
a. With ignition leads disconnected and turbine per Packager's manual.
of gas turbine per Packager's manual. b. Gas generator should accelerate to
b. Gas turbine should go through normal should open and fuel manifold pressure should
start cycle and then abort because of lack of be approximately 3 psig (21 kPa). Adjust fuel
flame. supply if required. Start will then abort
8-2.11 Governor Check. Check governor because of lack of flame.
system per Packager's manual. c. Allow gas turbine to coast to stop; then
8-2.12 Wet Prestart. Perform wet prestart as motor it to purge any remaining natural gas
follows: from gas turbine. Continue to motor for

M-17
GEK 97310
VOLUME I
ADDENDUM M
manual start per Packager's manual with fuel stops rotating, re-start and stabilize at idle
Refer to Table 5.
additional start-up and shutdown cycles.
CAUTION
DO NOT EXCEED 6000 RPM NGG rotate after accomplishing substeps (1) through
AND 30 SECONDS OF GAS TUR- (3), shut down the gas turbine.
POWER TURBINE ROTATION. (5) Immediately after gas turbine
rotation stops, re-start and accelerate to
a. The power turbine must rotate by the 6000 rpm NGG maximum and stabilize for
time the gas generator speed reaches 6000 rpm 30 seconds. If the power turbine still does not
NGG. If power turbine speed indication is not rotate, shut down and investigate/correct the
obtained and it is determined that a "thermal cause. During the investigation for the cause of
seizure" of the power turbine has occurred, a thermally seized rotor, inspect the LPT
proceed as follows: blades in stages 4, 5 and 6 for shingling and
NOTE they may be relatched. LPT blades that have
Power Turbine except in a new installa- necessitating power turbine replacement.
tion will be rotating when gas genera-
tor idle speed is attained. 8-2.14 Operation to Maximum Power.
NOTE
CAUTION
rotor can occur when a hot gas turbine MANUAL OPERATION MAY
is shut down and is most likely to occur ELIMINATE CERTAIN PROTEC-
within 30 to 40 minutes following gas TIVE CIRCUITS. OPERATING LIM-
turbine operation. Thermal seizure is ITS SHALL NOT BE EXCEEDED.
rotor is prevented from rotating by hard a. Slowly increase manual control setting
contact between LPT blades and (refer to Packager's manual) to increase gas
shrouds, interstage seals and other generator speed. After each 500 RPM increase,
internal interference. This condition is log all instrument readings, paying particular
the result of unequal cooling rates of attention to variable stator vane position and
the various power turbine components. vibration. If variable stator system is not
The possibility of thermal seizures can within limits, adjust it per work package
be reduced by operating the gas turbine 118 00. If vibrations are not within limits, con-
at idle power for at least five minutes sult the local General Electric Company
prior to shutdown to achieve proper representative.

M-18
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VOLUME I
ADDENDUM M
b. Operate gas turbine up to rated power, d. Decelerate to idle.
perature (T5.4) limit. Hold at this power setting e. Check for fuel or lube oil leaks.
system is unstable, adjust per Packager's f. After a total of five minutes at idle,
manual. shut down gas turbine.
c. Log all instrument readings once they g. Check lube oil and fuel filters and
stabilize. Refer to Table 5, step 9. strainers: clean or replace as necessary.
d. Reduce gas turbine speed to idle. After h. Correct any leaks observed.
stabilizing for three minutes, record all instru-
ment readings. Refer to Table 6, step 2. i. Remove all temporary instrumentation.
e. Check fail-safe section of control sys- j. Check gas turbine and mounting sys-
tem per Packager's manual. tem for loose parts; tighten as necessary.
f. After gas turbine has been stabilized at 8-3 NORMAL OPERATION.

Refer to Table 6, steps 3 and 4. 8-3.1 General. Normal operation is the rou-
8-2.15 Automatic Operation. Check auto- directions in the use of manual or automatic
matic operation per Packager's manual. operation for normal operation, refer to Pack-
ager's manual.
8-3.2 Interlocks. Refer to Packager's manual
b. Accelerate to rated power. for description of interlocks which affect gas
turbine operation.

M-19
GEK 97310
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ADDENDUM M

1. Assure that prestart checks Investigate cause of condi-

are completed per Table 4 tion. If T5.4 start limit is
exceeded perform over-
temperature inspection.
CAUTION
IF T5.4 RAPIDLY APPROACHES OR EXCEEDS VALUES SHOWN IN FIGURE 1
ABORT START.
NOTE
A start may be aborted at any time by closing fuel valve, allowing gas turbine to motor
NOTE
3. At 1100 to 1300 RPM NGG
a. Ignition on
b. Fuel valve open Fuel manifold pressure approx-
imately 3 psig (21 kPa).
See paragraph 8-1.1
(T5.4 above 400ºF/ shutdown. Investigate/
(204ºC) 1200 RPM correct cause.
4. Note time to 4500 ± 200 90 seconds maximum Troubleshoot system and

RPM stops increasing or it
takes longer than 90 sec. to
reach 4300 RPM
5. At 4300 to 4700 RPM NGG
a. Starter shutoff valve Valve closed Manually close starter air

should close supply
automatically

M-20
GEK 97310
VOLUME I
ADDENDUM M

6. Note time to 5000 RPM 90 seconds maximum
NGG
7. At idle, check the

following:
a. Oil pressure See applicable figures in Alarm at 8 + 1 psig
Chapter 5 (55 + 6.9 kPa)
Trip at 6 + 1 psig
(41 + 6.9 kPa)
b. NGG 5000 RPM + 250 RPM Adjust
c. T5.4 1000ºF (538ºC) max. Emergency shutdown -

Table 7
d. NPT (unloaded) 1600 - 1900 rpm Troubleshoot and take
corrective action
e. Gas generator vibration 0 to 3 mils DA Alarm set at 4 mils. Auto-
f. Power turbine vibration 0 to 6 mils DA Alarm set at 7 mils. Auto-
action
g. Compressor inlet tem- Approximately equal to Troubleshoot sensing and
perature (T2) outside air temperature indicating system. Correct
as required
leaks
i. Maximum NGG with 6000 RPM NGG maximum for Shut down and investigate/
power turbine seizure 30 seconds correct cause per
(thermal seizure) paragraph 8-2.13

M-21
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ADDENDUM M

8. Set desired power setting. Less than alarm limit Correct as required. Refer
sient operation
a. T5.4 Less than alarm limit *
b. NGG *
NOTE
The maximum allowable corrected speed is 10,100 rpm.
c. NPT 0-3960 RPM *
d. Oil pressure See applicable table and figure Emergency or automatic

in Chapter 5 shutdown if 5 psig
e. Scavenge oil 160ºF to 275ºF Alarm at 290-310ºF
temperature (71ºC to 135ºC) (143-154ºC); automatic
shutdown if above 340ºF
(171ºC)
f. Gas generator vibration 3 mils max. *
shutdown
g. Power turbine vibration 6 mils max. *
7 mils max. (Alarm) Emergency or automatic
10 mils max. (Trip) shutdown
h. Fuel manifold pressure 355 psig (2448 kPa) max. **
(-54º to +66ºC)
filter ∆P

M-22
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VOLUME I
ADDENDUM M


WP 118 00 WP 118 00
limits, shutdown.

M-23
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ADDENDUM M

M-24
GEK 97310
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ADDENDUM M
(unloaded)
following:
a. Oil pressure See applicable figure in Alarm at 8 + 1 psig
Chapter 5 (55 + 6.9 kPa)
Trip at 6 + 1 psig
(41 + 6.9 kPa)
b. NGG 4950 - 5050 RPM Adjust
c. T5.4 approximately 1000ºF Troubleshoot and take
(538ºC) corrective action
d. NPT (unloaded) 1200 - 1900 RPM
e. Gas generator 3 mils max. Alarm set at 4 mils. Auto-
f. Power turbine 6 mils max. Alarm set at 7 mils. Auto-
action
g. Fuel inlet temperature -65º to 150ºF (-54º to 66ºC)
3. After stabilizing at idle for T5.4 drops below 400ºF Manually shut off fuel
5 minutes, close fuel valves (204ºC) NGG and NPT supply
decelerates and stops
4. Observe T5.4 for 3 minutes 700ºF (371ºC) Motor gas turbine. Con-
after shutdown tinue motoring until

M-25
GEK 97310
VOLUME I
ADDENDUM M
8-3.3 Operation. ENTRY PROCEDURES SHALL
BE FOLLOWED.
WARNING
MET: LATED GLOVES AS NECES-
SARY.
FIELD SERVICE FOR A REPRE- MOTORING THE GAS TUR-
SENTATIVE WHO IS TRAINED BINE.
UNDER SUCH CONDITIONS. WARNING

SYSTEM SHALL BE MADE a. When entering enclosure during gas
INACTIVE ACCORDING TO turbine operation, wear proper ear protection.
DURES.
Table 3.
ENCLOSURE SHALL BE SHUT c. Shut down the gas turbine per Table 6.
OFF. HIGH SECONDARY AIR- d. Emergency shut down the gas turbine
FLOW MAY PREVENT OPEN- per table 7.
ING OR CLOSING THE
ENCLOSURE DOOR. e. Refer to paragraph 5-3.30 and 5-3.31,
• THE ENCLOSURE DOOR pressure characteristics. (See tables V-21A,
SHALL BE KEPT OPEN. IF THE V-21B, V-21E, and V-21F, and figures 5-32A,
GAS TURBINE IS OPERATING, 5-32B, 5-32E, 5-32F, 5-32J, 5-32L, 5-32N,
AN OBSERVER SHALL BE STA- and 5-32Q.)
TIONED AT THE ENCLOSURE f. Idle lube oil pressure is 29 psig
(200 kPa) maximum after five minutes
stabilization.

M-26
GEK 97310
VOLUME I
ADDENDUM M
g. The corrected operating pressure of the These events are either not detected or not pre-
lube oil shall be per applicable table in Chapter vented by the customary protective devices of
5 at standard conditions of 9000 rpm gas gen- control systems.
erator speed and 150° F (66°C) lube pump dis-
charge temperature. Oil pressure measured at • Overtemperature During Starting
conditions other than standard shall be cor-
rected to standard conditions using applicable • Lube Oil Pressure
table in Chapter 5.
8-4 EMERGENCY OPERATION. • High Speed Stalls
8-4.1 Emergency Shutdown. • Starter Duty Cycle

be shut down from any power setting by clos- • Re-Start Following High Power Trip
be done in an emergency, since rapid shutdown • No Power Turbine Rotation
will decrease life of gas turbine.
• Gas Generator Windmilling
b. Emergency shutdown shall be made
per Table 7. 8-5.2 Overtemperature. During starting and
8-4.2 Post Shutdown Fire. acceleration to idle, cooling flows to compo-
nents of the engine hot section are not suffi-
cient to protect the metals at T5.4 alarm and
trip levels specified in the limits table. A lower
time gas turbine is coasting to stop, tempera-
T5.4 limit is therefore established, with higher
levels acceptable provided they exist for lim-
ited times as depicted on the curve titled
increase after rotation stops is normal.) Make "Transient Temperature Limits for Starts".
certain fuel is shut off, and motor the gas tur- This must be monitored by the operator. The
bine. This will blow out the fire. As soon as overtemperature inspection called for by entry
temperature decreases to normal, discontinue into area B requires hot section disassembly
motoring. and inspection in a qualified facility.
8-5 SPECIAL GAS TURBINE 8-5.3 Lube Oil Supply Pressure. The lube oil
CONSTRAINTS. supply pressure limits given in the limit table
8-5.1 General. Under normal operating con- are "distress" limits. Protective devices cannot
ditions, the gas turbines are constrained by the reliably monitor supply pressure because the
operating limits published in the limits table. proper pressure is dependent on engine speed,
Continuous operation between the alarm and oil type, oil temperature, and number of oil
shutdown or "trip" level should not be jets. An operator must therefore derive a cor-
practiced. rected oil pressure as directed on the appropri-
ate pressure correction table in Chapter 5 to
In the event that any of the following situations
determine if the lube system is performing
or events occur, the associated special action or
within the high-low limits stated on each table.
limitation must be followed in order to assure
the gas turbines continued normal operation.

M-27
GEK 97310
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ADDENDUM M
8-5.4 High Speed Stall. Stalls incurred at gas 8-5.7 No Power Turbine Rotation. A ther-
generator rotational speeds above 7500 rpm mally bound power turbine rotor could occur
can result in high pressure compressor blade under extreme conditions following a rapid
fracture. The gas turbine can be operated after shutdown from high power. Power turbine
an inspection of the compressor stages 3 rotation should initiate during gas turbine
through 6 verifies that blade tip clanging has acceleration to idle. If rotation does not occur,
not occurred. If tip clanging has occurred, fur- the following procedure should be used:
ther inspection and stress relief of the blades is
required, which necessitates blade removal a. Remain at idle for 30 seconds and shut
from the spool. down.
b. Refire and repeat Item a.
8-5.5 Starter Duty Cycle - Air or Natural
Gas. c. Refire and repeat Item a.
a. With starter inlet air pressure set at d. Refire and accel to 6000 rpm. Do not
40 psig (276 kPa): exceed 6000. Power turbine should break
away. If not, shut down and investigate for
• 45 seconds on, 2 minutes off for any
unlatched or shingled blades, or other cause.
number of cycles,
or, 8-5.8 Windmilling.
• 2 minutes on, 5 minutes off with two
a. Unlimited windmilling or cranking of
such cycles in any 30 minute period.
the gas turbine is allowed at gas generator
b. With starter inlet air pressure set at speeds above 1000 rpm provided the lube oil
15 psig (103 kPa): temperature limits are not exceeded. At these
speeds, the lube supply and scavenge systems
are in normal operation.
such cycles in any 30 minute period,
or, b. Below 1000 rpm gas generator speeds,
windmilling is allowed up to five (5) minutes,
• 10 minutes on, 20 minutes off for any
with successive periods allowed if preceded by
number of cycles.
normal gas turbine operation.
c. There is no duty cycle limit on the
hydraulic starter.
8-5.6 Re-Start Following High Power Trip.

In the event that re-start of the gas turbine is
required within two (2) hours following a trip
or rapid shutdown from high power, a five (5)
minute cranking at 2400 rpm should precede
the fire up. The objective is to cool the high
pressure turbine rotor, so that blade tips main-
tain clearance with the more rapidly cooling
case.

M-28
GEK 97310
VOLUME I
ADDENDUM M
CAUTION
GENCY SHUTDOWN FROM HIGH POWER SETTINGS. SEIZURE OF GAS
TURBINE ROTOR MAY OCCUR DUE TO TIGHT CLEARANCES. NOR-
MALLY THE ROTOR WILL FREE ITSELF AFTER A COOLING PERIOD OF 3
TO 4 HOURS. CHECK FOR FREEDOM OF ROTATION BY TURNING ROTOR
BY HAND.
1. Conditions permitting, T5.4 drops below 400ºF Manually shut off fuel
decelerate gas turbine to idle (204ºC) and NGG and NPT supply
2. Observe T5.4 for 3 minutes 700ºF (371ºC) max Motor gas turbine. Con-
ature decreases
(T5.4) greater than 1150ºF
(621ºC) has occurred, and a
ceed as follows:
a. If the fault detection
and sequencing sys-
tem can be cleared
and the gas turbine
can be restarted
within 1 minute fol-
lowing coastdown of
the HPC rotor,
acceptable restarts
can be made using
the normal starting
procedure.

M-29
GEK 97310
VOLUME I
ADDENDUM M
b. If a “hot restart” is to
be performed
between 1 minute
and 2 hours follow-
ing the emergency
shutdown, motor the
gas turbine at 2000-
2500 rpm NGG for 5
minutes. At the end
of the 5 minute
motoring/purge
cycle, perform nor-
mal restart and accel-
erate to idle.
Acceleration to the
desired power set-
ting can then be
accomplished.
c. After 2 hours follow-
HPC rotor, restart
can be made using
the normal starting
procedure.

M-30
GEK 97310
VOLUME I
ADDENDUM M

TABLES 8 thru 11. Deleted

M-31/(M-32 Blank)
GEK 97310
VOLUME I
ADDENDUM N
ADDENDUM
7LM2500-PE-ND

GEK 97310
VOLUME I
ADDENDUM N
TABLE OF CONTENTS
1-0 INTRODUCTION....................................................................................... N-3

2-0 REFERENCE DATA .................................................................................. N-3
3-0 INSTALLATION DRAWINGS.................................................................. N-3
4-0 EQUIPMENT DESCRIPTION ................................................................. N-3
5-0 GAS TURBINE CONTROL ...................................................................... N-3
6-0 INSTRUMENTATION AND SUPPLY REQUIREMENTS ................... N-4
7-0 SERVICE REQUIREMENTS ................................................................... N-7
7-1.1 Natural Gas ................................................................................................... N-7
7-1.2 Liquid Fuel.................................................................................................... N-7
8-0 OPTIONAL HARDWARE KITS .............................................................. N-7
9-0 GAS TURBINE OPERATION .................................................................. N-7
9-1 PERFORMANCE RATINGS AND OPERATING LIMITS .................. N-8
9-1.1 Performance Ratings ..................................................................................... N-8
9-1.2 Operating Limits ........................................................................................... N-10
9-2 INITIAL OPERATION .............................................................................. N-16
9-2.1 General .......................................................................................................... N-16
9-2.2 Special Instrumentation Required for Operation .......................................... N-16
9-2.3 Special Instrumentation Required for Monitoring and Troubleshooting ...... N-16
9-2.4 Preparation .................................................................................................... N-17
9-2.5 Gas Turbine and Associated Equipment Check List..................................... N-17
9-2.6 Governor and Manual Control Check........................................................... N-18
9-2.7 Start-up and Checkout................................................................................... N-18
9-2.8 Ignition Check............................................................................................... N-19
9-2.9 Motoring........................................................................................................ N-20
9-2.10 False Start...................................................................................................... N-20
9-2.11 Governor Check ............................................................................................ N-20
9-2.12 Wet Prestart ................................................................................................... N-20
9-2.13 Manual Start and Operation .......................................................................... N-20
9-2.14 Operation to Maximum Power...................................................................... N-21
9-2.15 Automatic Operation..................................................................................... N-22
9-3 NORMAL OPERATION............................................................................ N-37
9-3.1 General .......................................................................................................... N-37
9-3.2 Interlocks....................................................................................................... N-37
9-3.3 Operation....................................................................................................... N-37
9-4 EMERGENCY OPERATION ................................................................... N-38
9-4.1 Emergency Shutdown ................................................................................... N-38
9-4.2 Post Shutdown Fire ....................................................................................... N-38
9-5 SPECIAL GAS TURBINE CONSTRAINTS ........................................... N-38
9-5.1 General .......................................................................................................... N-38
9-5.2 Overtemperature............................................................................................ N-38
9-5.3 Lube Oil Supply Pressure ............................................................................. N-39

N-1
GEK 97310
VOLUME I
ADDENDUM N
9-5.4 High Speed Stall............................................................................................ N-39

9-5.5 Starter Duty Cycle - Air or Natural Gas........................................................ N-39
9-5.6 Re-Start Following High Power Trip ............................................................ N-39
9-5.7 No Power Turbine Rotation .......................................................................... N-39
9-5.8 Windmilling .................................................................................................. N-39
Figure Title Page
1 Deleted
2 Deleted
3 Deleted
4 Deleted
5 Dual Fuel System Flow vs. Pressure Drop Characteristic ............................ N-29
6 Dual Fuel System - Flow Divider Inlet Pressure vs. Total Liquid Fuel Flow N-30
7 Dual Fuel System - Primary Manifold Pressure vs. Total Liquid Fuel Flow N-31
8 Dual Fuel System - Secondary Manifold Pressure vs. Total Liquid Fuel FlowN-32
9 Dual Fuel System - Gas Flow Rate vs. Manifold Pressure ........................... N-33
10 Transient Temperature Limits ....................................................................... N-34
LIST OF TABLES
Table Title Page
1 INSTRUMENTATION CONNECTIONS .................................................... N-4

2 SUPPLY CONNECTIONS ........................................................................... N-5
3 GAS TURBINE OPERATING LIMITS....................................................... N-11
4 PRESTART CHECK..................................................................................... N-19
5 START-UP AND OPERATION.................................................................... N-23
6 GAS TURBINE SHUTDOWN .................................................................... N-35
7 EMERGENCY SHUTDOWN...................................................................... N-40
8 DELETED
9 DELETED
10 DELETED
11 DELETED

N-2
GEK 97310
VOLUME I
ADDENDUM N
1-0 INTRODUCTION. 4-0 EQUIPMENT DESCRIPTION.
The information contained herein describes the The 7LM2500-PE-ND is a dual-fueled (natural
7LM2500-PE-ND model gas turbine basic gas and liquid fuel) nonmarinized gas turbine.
configuration and control system differences. The on-engine mounted dual fuel system con-
In addition, the coverage of reference data, sists of a natural gas manifold, two liquid fuel
instrumentation and supply connections, spe- manifolds, 30 dual fuel nozzles, and a single
cial servicing requirements, optional hardware liquid fuel off-gas turbine mounted flow
kits and the complete gas turbine operating divider valve. The 7LM2500-PE-ND gas tur-
instructions for the 7LM2500-PE-ND model bine is designed to operate on 100 percent nat-
are included. ural gas, 100 percent liquid fuel or a
combination of the two. The minimum fuel
2-0 REFERENCE DATA. flow for each fuel, when operating on dual
fuel, should be selected so that if one fuel is
EQUIPMENT cut off, the gas generator speed will not
decrease below 5000 rpm before the governor
Gas Turbine Assembly action restores the gas turbine to normal
(General Electric Co., Cincinnati OH) operation.
Model No. 7LM2500-PE-ND
Dwg. No. L31430G13 5-0 GAS TURBINE CONTROL.
PERFORMANCE RATING a. The transition from natural gas to liq-

Refer to paragraph 9-1 shall not result in abrupt changes in gas gener-
DRAWING LIST from natural gas to liquid fuel or vice versa is a
function of the operator’s control system, so
Drawing No. long as the change in total fuel flow does not
Gas Turbine Installation L31705 exceed that shown on the maximum accelera-
Drawing tion fuel flow curves.
Fuel System Installation 682L310
Diagram
Ignition Units L21454
Drawing
3-0 INSTALLATION DRAWINGS.

been provided.

N-3
GEK 97310
VOLUME I
ADDENDUM N
See Tables 1 and 2.
E3A “A” Sump T/C (optional equipment) MS3106R-12S-3SW except pin A iron and pin B
constantan
E4A “B” sump T/C (optional equipment) MS3106R-12S-3SW except pin A iron and pin B
constantan
E5A “C” sump T/C (optional equipment) MS3106R-12S-3SW except pin A iron and pin B
constantan
E6 Accessory gearbox scavenge oil MS3106Rl2S-3S
temperature
E6A Accessory gearbox T/C (optional MS3106R-12S-3SW except pin A iron and pin B
equipment) constantan
E11A Inlet T/C (optional equipment) MS3106R-12S-3SW except pin A iron and pin B
constantan
E18A “D” sump T/C (optional equipment) MS3106R-12S-3SW except pin A iron and pin B
constantan
(optional)

N-4
GEK 97310
VOLUME I
ADDENDUM N
A18 CIT sensor (part of fuel control
system)
F3 Natural gas fuel manifold pressure MS20819-4C or AN818-4C
tap (optional)
F5 Fuel inlet liquid pressure tap No. 1 AN818-6C or MS20819-6C
L7 Lube scavenge pressure tap AN818-4C or MS9197-04
(optional)
NOTE
turbine.

CAUTION
REQUIRED.
F1 Fuel manifold inlet, gas 2 inch line from fuel control unit to gas generator
fuel manifold
F2 Fuel manifold inlet No. 1 Fuel manifold inlet liquid, mates with AN818-10C
or MS20819-10C or equivalent
F6 Fuel manifold inlet No. 2 Fuel manifold inlet liquid, mates with AN818-12C
or MS20819-12C or equivalent.
L1 Oil supply 1-1/2 inch line to lube pump on gas generator,
AN818-24C or MS20819-24C

N-5
GEK 97310
VOLUME I
ADDENDUM N
L2 Lube pump discharge 1 inch line from lube pump to oil supply filters,
AN819-16C or MS20819-16C
L4 Lube supply inlet port 1 inch line from oil supply filters to gas generator,
AN818-16C or MS20819-16C
L3 Scavenge oil discharge 1-1/4 inch line from gas generator scavenge pump to
oil scavenge filter and cooler, AN818-20C or
MS20819-20C
A1 Bleed air port 8th stage Shipped with cover that must remain in place if port
if not used
D5 Oil Drain, aft AN818-6C or MS20819-6C
S1 or Waterwash manifold 1 inch line - hot water line to waterwash manifold on
S1A gas generator inlet duct AN818-16C or
MS20819-16C
NOTE

N-6
GEK 97310
VOLUME I
ADDENDUM N
7-0 SERVICE REQUIREMENTS. 7-1.2 Liquid Fuel.
7-1.1 Natural Gas. a. The maximum required supply pres-

sure to the flow divider is 720 psia (4964 kPa).
natural gas fuel manifold on the gas turbine is b. The fuel temperature supplied to the
355 ± 5 psig (2448 ± 35 kPa) maximum. gas turbine shall be a minimum of 20°F
(-6.7°C) above the wax point of the fuel and a
b. The temperature of the gas supply at maximum of 150°F (66°C). The fuel shall be
the fuel manifold connection on the gas turbine filtered to 20 microns absolute. The maximum
must be in the range of 20°F (-6.7°C) above total fuel flow required is 14,000 pph
the saturated vapor temperature of the gas at (6350 kg/h) with a lower heating value of
the supply pressure as a minimum, and 350°F 18,400 BTU/1b.
(177°C) as a maximum. Based on consider-
ation of control system components however, 8-0 OPTIONAL HARDWARE
it is recommended that the maximum gas sup- KITS - 7LM2500-PE-ND.
ply temperature be limited to 150°F (66°C). If
the supply temperature of the gas is not repeat- a. Refer to Volume II, WP 001 00 for a
able on a day-to-day basis, It will be necessary detailed list of optional kits available for this
to change the control system starting fuel particular gas turbine model.
adjustment or to adjust the supply pressure to
the gas turbine to maintain a constant BTU- 9-0 GAS TURBINE OPERATION.
per-cubic-foot supply. Once started the gas tur-
bine will accept variations in supply tempera- a. These instructions contain the detailed
ture of ± 20°F (± 11°C). The maximum fuel gas turbine operating procedures and limits
flow required, assuming a lower heating value recommended by the General Electric Com-
of 19,000 BTU/lb is 13,500 pph (6123 kg/h) pany for the 7LM2500-PE-ND gas turbine.
for the 7LM2500-PE-ND model gas turbine.
tain to routine and emergency condition and
procedures. When a fault exists, refer to Chap-
ter 4 entitled, TROUBLESHOOTING.

N-7
GEK 97310
VOLUME I
ADDENDUM N
c. It is possible that these instructions 9-1 PERFORMANCE RATINGS AND
may not provide for every possible variation in OPERATING LIMITS.
tion with the operation of the gas turbine. NOTE
Refer requests for additional information to the Ratings published in this manual apply
General Electric Company, Marine and Indus- to the gas turbine. The driven unit rat-
trial Engine Department, Cincinnati, Ohio ings/limits may be lower in some cases
45215. and shall take precedence over the gas
WARNING
GAS TURBINE UNTIL A THOR- a. The performance of the
7LM2500-PE-ND gas turbine operating on
either natural gas or liquid fuel is given in
MID-TD-2500-9. The actual performance of
the dual fueled 7LM2500-PE-ND gas turbine
will be a function of the ratio of natural gas
and liquid fuel used. The time between on-site
maintenance and repair of the hot section will
also change as a function of the ratio of the
natural gas and liquid fuels used, with the
longest times being associated with 100% nat-
ural gas. For condition monitoring purposes it
is recommended that the Buyer or Customer
maintain a record of the accumulated gas tur-
bine operating time on different fuels.
NOTE

N-8
GEK 97310
VOLUME I
ADDENDUM N
b. The rated performance of the Natural Gas Fuel per GE Specification
7LM2500-PE-ND gas turbine in the new and MID-TD-0000-1
clean condition is as follows:
Liquid Fuel per GE Specification
Power Turbine Speed
MID-TD-0000-2
3600 rpm 3000 rpm
Shaft Horsepower
c. The gas turbine is designed to operate
-Base 29,500 28,500 on 100% natural gas fuel, 100% liquid fuel, or
-Maximum 32,000 30,000 combinations of the two with no limit on natu-
Heat Rate, Gas ral gas/liquid fuel ratios. The gas turbine can
be started on either natural gas or liquid fuel
-Average (Base) 6874 BTU 7081 BTU but not on a combination of the two. Starting
/hp-hr /hp-hr fuel flow for the 7LM2500-PD-ND model gas
-Average (Maximum) 6908 BTU 7125 BTU turbine is normally set by the minimum stop
/hp-hr /hp-hr on the gas fuel metering valve. For ambient
Heat Rate, Liquid temperatures of -65°F (-54°C) to +130°F
(54°C) the proper fuel flow setting for the min-
-Average (Base) 6920 BTU 7125 BTU
imum stop on a heat consumption basis, is
/hp-hr /hp-hr
10.45x106±0.46x106 BTU/hour for natural gas
-Average (Maximum) 6955 BTU 7211 BTU
/hp-hr /hp-hr fuel, and 11.96x106±0.72x106 BTU/hour for
liquid fuel, and is based upon commencing
Based on the following conditions: fuel and ignition at 1200 ± 100 rpm. Where a
Inlet Air Temperature 59°F 59°F minimum stop is not utilized, acceptable light-
Altitude Sea Level Sea Level offs can be obtained in the sub-idle region,
however, during such starts, ignition should be
Exhaust Losses 0” H2O 0” H2O minimum stop with its associated tolerance. If
Relative Humidity 0% 0% starts in the sub-idle region are required, refer
Compressor Bleed 0 0 MID-IDM-2500-9.
Accessory Power 0 0
Extraction d. The minimum fuel flow for each fuel,
when operating on dual fuel, should be
Power Turbine Inlet Gas
selected so that if one fuel is cut off the gas
Temperature, T5.4 Avg. generator speed will not decrease below 5000
Gas: rpm before the governor action restores the
engine to normal operation.
-At Base Rating 1461 1449
-At Maximum Rating 1551 1516
Liquid:
-At Maximum Rating 1575 1538

N-9
GEK 97310
VOLUME I
ADDENDUM N
e. Refer to Installation Design Manual j. Normal decelerations from maximum
MID-IDM-2500-9 for the LM2500-PE-ND power to idle should be made in approximately
gas turbine model transient fuel flow 2 to 3 minutes. This will enhance the time
requirements. between hot section repairs and the life of the
gas turbine.
f. Acceleration fuel rates greater than
those shown will result in over-temperature k. The transition from natural gas to liq-
and possible stall of the gas turbine. Accelera- uid fuel and vice versa shall be smooth and
tion fuel rates lower than those shown can shall not result in abrupt changes in gas gener-
result in “hung” starts in the below idle speed ator speed or temperature. Transfers from nat-
range. ural gas to liquid fuel or vice versa can be
achieved within 10 seconds. The actual
g. Above the idle speed point, low accel- switchover time is established by the control
eration fuel rates will not harm the gas turbine system response.
times. l. The actual performance of the
7LM2500-PE-ND gas turbine will be a func-
h. For normal accelerations from idle to tion of the ratio of natural gas fuel and liquid
power settings the changes should be made fuel used. The time between repairs of the hot
more slowly to enhance the time between hot section will also change as a function of the
section repairs and the life of the gas turbine; a ratio of the natural gas and liquid fuels used
time of 2 to 3 minutes is reasonable. with the longest times being associated with
100% natural gas.
i. The fuel rates shown on the curves will
give starting times to 5000 rpm idle of 60 to 90 9-1.2 Operating Limits. Refer to Table 3.
mum power of 15 seconds. NOTE
turbine.

N-10
GEK 97310
VOLUME I
ADDENDUM N
Normal
Alarm/ Operating
NOTE
above 8000 rpm
(41 kPa ± 6.9 kPa) (138 - 414 kPa) 4500 rpm
Pressure 180 psig
(1241 kPa)
Gas Turbine Alarm 180° - 220°F 140° - 160°F Normal Operating
Lube Pump (82° - 140°C) (60° - 71°C) Range reflects tem-
above idle speed

N-11
GEK 97310
VOLUME I
ADDENDUM N
Normal
Alarm/ Operating
Lube Scav- (166° - 17°C) (71° - 135°C) Range reflects tem-
enge Temper- perature expected
atures - Five during operation
above idle speed
Alarm 290° - 310°F
(143° - 154°C)
Fuel Fuel
System Manifold
Pressure
Natural Gas 20 - 355 psig Supply Pressure as
(138 - 2448 kPa) reflected at the fuel
manifold inlet on
the gas turbine
Liquid Fuel
Flow Divider 0 - 705 psig Supply Pressure as
Inlet (0 - 4861 kPa) reflected at the
Fuel Flow Divider
Valve Inlet on the
gas turbine
Primary 0 - 615 psig Supply Pressure as
(0 - 4240 kPa) reflected at the
Primary Fuel
Manifold Inlet on
the gas turbine
Secondary 0 - 365 psig Supply Pressure as
(0 - 2517 kPa) reflected at the
Secondary Fuel
Manifold Inlet on
the gas turbine

N-12
GEK 97310
VOLUME I
ADDENDUM N
Normal
Alarm/ Operating
Fuel Supply
Temperature
Natural Gas Alarm 150° - 170°F -65° to 150°F Starting Fuel Flow
(66° - 77°C) (-54° to 66°C) Adjustments may
be required to com-
Liquid Fuel 20°F (-7°C) pensate for fuel
above wax point temperature
of fuel to variation
150°F (66°C)
maximum
on gas turbine
starter torque
requirements
of Fuel and
Ignition
Ignition (If cycle
purge cycle is
used)
simultaneously
Failure to Trip 380° - 420°F (T5.4) Activate 10 sec-
simultaneously
with application of
fuel and ignition

N-13
GEK 97310
VOLUME I
ADDENDUM N
Normal
Alarm/ Operating
simultaneously
with start initiation.
De-energize igni-
tion, fuel system
and starter air
supply
(If purge upon completion of
fuel and ignition
systems and starter
air supply
Power Tur- Failure to Trip 380° - 420°F 0 - 1600°F Trip if temperature
bine Inlet Light-Off (193° - 216°C) (-18°C - 871°C) does not reach
(T5.4) Tem- 400°F (204°C)
perature within 10 seconds
(Gas Gener- after fuel and igni-
ator tion are applied
Exhaust)
Overtemperature:
Power Turbine Speed
3000 rpm 3600 rpm
Natural Gas Trip 1575°F 1575°F
(857°C) (857°C)
Alarm 1505°F 1515°

(818°C) (824°C)
Liquid Fuel Trip 1575°F 1575°F

(857°C) (857°C)

N-14
GEK 97310
VOLUME I
ADDENDUM N
Normal
Alarm/ Operating
Alarm 1530°F 1540°F
(832°C) (837°C)
Vibration Gas Genera- Trip 7 mils DA 0 - 3 mils DA Avoid continuous

tor operation above 4
mils
Alarm 4 mils DA
Power Tur- Trip 10 mils DA 0 - 6 mils DA Avoid continuous
bine operation above
7 mils
Alarm 7 mils DA
Speed
Generator
Turbine
Generator
Turbine
NOTE
are considered.
upon loss of flame

N-15
GEK 97310
VOLUME I
ADDENDUM N
that period of operation immediately following Fuel manifold pressure sensor:
gas turbine replacement or major maintenance liquid fuel:
on the system.
primary 0-1200 psig
9-2.2 Special Instrumentation Required for (0-8280 kPa)
Operation. secondary 0-600 psig
(0-4139 kPa)
Gas generator speed sensor 0-11,000 rpm fuel flow divider inlet 0-1200 psig
Lube oil scavenge temperature 0-400°F (0-8274 kPa)
sensors (A-, B-, C-, D-sumps (-18°C-205°C) natural gas 0-400 psig
and transfer gearbox) (0-2760 kPa)
Lube pump discharge temper- 0-400°F
pressure sensor (69-110.4 kPa)
ature sensor (-18°C-205°C)
Vibration indicators: pressure (0-517.5 kPa)
0-10 mil DA Fuel supply temperature:
power turbine 0-2 in/sec or liquid fuel 0-250°F
0-15 mil DA (-18°C-121°C)
Power turbine speed sensor 0-5000 rpm natural gas 0-250°F
(-18°C-121°C)
perature (T5.4) Fuel Supply Pressure:
(-18°C -
1093°C) liquid fuel 0-1000 psig
(0-6895 kPa)
Lube pump discharge pressure 0-100 psig
(0-690 kPa) natural gas 0-400 psig
(0-2760 kPa)
Remote reading variable -5° to +45°
vane indicator
Scavenge oil pressure 0-200 psig
(0-1379 kPa)
Gas turbine inlet air -65°F-150°F
temperature (-54°C -66°C)
(0-345 kPa)

N-16
GEK 97310
VOLUME I
ADDENDUM N
9-2.4 Preparation. The gas turbine and asso- j. Gas turbine inlet air area free _________
ciated systems must be inspected and checked of foreign objects. Inlet
out for proper installation and operation before screen secure
k. Gas turbine compressor rear _________
and 10, are open (not capped)
check list. l. Starter is serviced per pack- _________
ager’s manual
a. Gas Turbine Assembly S/N _________ m. Lube oil storage tank ser- _________
b. Mounting base secured to _________ viced to full level
foundation n. Lube oil supply valves open _________
c. Intake air and exhaust gas _________ o. All filters serviced per pack- _________
ducts in place and secured ager’s manual
d. Gas turbine and exhaust duct _________ p. T5.4 thermocouple system _________
support mounts and links in functioning properly
place and secure
q. Ignition system operative _________
e. All service connections made _________
r. Compressor inlet total pres- _________
and secure
f. All lines have been flushed _________ and free of damage
s. Variable stator system secure _________
g. All instrumentation connec- _________
t. Required checks and inspec- _________
tions made and secure
tions specified in packager’s
h. All accessories are secure per _________ manual for gas turbine con-
packager’s manual trol have been performed
i. Gas turbine assembly free of _________
electrical leads connected

N-17
GEK 97310
VOLUME I
ADDENDUM N
9-2.6 Governor and Manual Control Check. DOOR AND CONFINED SPACE
Refer to packager’s manual. ENTRY PROCEDURES SHALL
BE FOLLOWED.
9-2.7 Start-up and Checkout.
WARNING
BINE ENCLOSURE, THE FOLLOW- LATED GLOVES AS NECES-
ING REQUIREMENTS SHALL BE SARY.
MET:

SENTATIVE WHO IS TRAINED a. When entering enclosure during gas
TO ENTER THE ENCLOSURE turbine operation, wear proper ear protection.
SYSTEM SHALL BE MADE c. Perform ignition check out per
DURES. d. Perform motoring procedure per
paragraph 9-2.9.
ENCLOSURE SHALL BE SHUT e. Perform false start per
FLOW MAY PREVENT OPEN- f. Perform governor check per packager’s
ING OR CLOSING THE manual.
ENCLOSURE DOOR.
GAS TURBINE IS OPERATING, h. Perform a manual start and operate per

N-18
GEK 97310
VOLUME I
ADDENDUM N
Table 4. PRESTART CHECK
Item Requirements
Fuel Valves Closed
Ignition Off
Oil tank level Full
Lube oil temperature +20°F (+1°C) for MIL-L-23699
-20°F (-29°C) for MIL-L-7808
temperature -65° to 150°F
(-54° to 66°C)
liquid fuel temperature 20°F (-7°C)
above wax point of fuel to 150°F
(66°C) maximum
i. Operate to maximum power per b. Disconnect number one ignition exciter

paragraph 9-2.14. input lead at exciter. Temporarily secure input
paragraph 9-2.15. c. Turn on electrical power to the ignition
9-2.8 Ignition Check. audible report (approximately two sparks per
WARNING igniter fires.
• ASSURE POWER TO IGNITION d. Turn off electrical power to the ignition
SYSTEMS IS OFF WHEN DIS- system. Reconnect input lead to exciter and
CONNECTING AND CONNECT- safetywire connector.
LEAD. TAG SWITCH OUT OF e. Repeat steps b, c and d, disconnecting
SERVICE TO PRECLUDE INAD- the No. 2 exciter.
VERTENT ACTIVATION.
• ASSURE THAT FUEL VALVES No. 1 and/or No. 2 igniters, check out the sys-
ARE CLOSED THROUGHOUT tem to isolate the problem, and take appropri-
THIS PROCEDURE. ate corrective action.
a. To clear combustor of any residual

N-19
GEK 97310
VOLUME I
ADDENDUM N
9-2.9 Motoring. After all preliminary checks 9-2.12 Wet Prestart. Perform wet prestart as
have been completed and lines flushed, motor follows:
gas generator as follows:
a. With ignition lead disconnected, but
a. Make ignition, liquid fuel and natural with either manual natural gas or liquid fuel
gas supply systems inoperative as follows: valve open and governing system operating,
make automatic start of gas generator per
(1) Disconnect power supply to igni- packager’s manual.
tion units.
(2) Close liquid fuel and natural gas light-off speed (1100 to 1300 rpm). Fuel valve
manual shutoff valves to fuel control unit. should open and fuel manifold pressure should
b. Depress MOTORING pushbutton. Gas supply if required. Start will then abort
generator will start to rotate. If it does not, because of lack of flame.
to starter. c. Allow gas turbine to coast to a stop.
Motor it to purge any remaining natural gas
c. Hold MOTORING pushbutton closed from the gas turbine or drain liquid fuel from
until gas generator speed stabilizes, and check manifold if liquid fuel was used in the wet pre-
for oil pressure. If there is no indication of oil start. Purge fuel nozzles of liquid fuel with nat-
pressure, release MOTORING pushbutton. ural gas or compressed air at 200 psig
While gas turbine is coasting down, loosen oil (1380 kPa) maximum. Remain on starter for
fittings at lube pump to bleed air from system. 60 seconds to purge fuel from gas turbine.
Starter should motor gas turbine to minimum
of 2200 RPM. 9-2.13 Manual Start and Operation. Perform
manual start per packager’s manual with fuel
d. Repeat motoring and bleeding proce- system normal and with ignition lead con-
dure until an indication of oil pressure appears. nected. Refer to Table 5.
9-2.10 False Start. Perform false start as NOTE

follows: Power Turbine, except in a new instal-
lation, will be rotating when gas gener-
a. With ignition leads disconnected and ator idle speed is attained.
manual liquid fuel and natural gas shutoff
valves closed, make automatic start of gas tur- CAUTION
b. Gas generator should go through nor- AND 30 SECONDS OF GAS TUR-
mal start cycle and then abort because of lack BINE OPERATION WITHOUT
of flame. POWER TURBINE ROTATION.
9-2.11 Governor Check. Check governor sys- a. The power turbine must rotate by the
tem per packager’s manual. time the gas generator speed reaches 6000 rpm

N-20
GEK 97310
VOLUME I
ADDENDUM N
NGG. If power turbine speed indication is not blades in stages 4, 5 and 6 for shingling and
obtained and it is determined that a “thermal unlatching. If blades have become unlatched,
seizure” of the power turbine has occurred, they may be relatched. LPT blades that have
proceed as follows: encountered shingling may be bent thereby
NOTE turbine.
CAUTION
turbine operation. Thermal seizure is MANUAL OPERATION MAY
the condition where the power turbine ELIMINATE CERTAIN PROTEC-
rotor is prevented from rotating by hard TIVE CIRCUITS. OPERATING LIM-
contact between LPT blades and ITS SHALL NOT BE EXCEEDED.
shrouds interstage seals and other inter-
nal interference. This condition is the a. Slowly increase manual control setting
result of unequal cooling rates of the (refer to packager’s manual) to increase gas
various power turbine components. generator speed. After each 500 rpm increase,
The possibility of thermal seizures can log all instrument readings, paying particular
be reduced by operating the gas turbine attention to variable stator vane position and
at idle power for at least five minutes vibration. If variable stator system is not
prior to shutdown to achieve proper within limits, adjust it per work package
cooling of the power turbine. 118 00. If vibrations are not within limits, con-
sult the local General Electric Company
(1) Shutdown gas turbine. representative.
(2) Immediately after the gas turbine b. Operate gas turbine up to rated power,
stops rotating, re-start and stabilize at idle if possible, but do not exceed exhaust gas tem-
speed (4950 ± 50 rpm) for 30 seconds. perature (T5.4) limit. Hold at this power setting
(3) Repeat steps (1) and (2) for two system is unstable, adjust per packager’s man-
additional start-up and shutdown cycles. ual.
(4) If the power turbine does not c. Log all instrument readings once they
rotate after accomplishing substeps (1) through stabilize. Refer to Table 5, step 10.
(5) Immediately after gas turbine stabilizing for three minutes, record all instru-
rotation stops, re-start and accelerate to ment readings. Refer to Table 6, step 2.
6000 rpm NGG maximum and stabilize for
30 seconds. If the power turbine still does not e. Check fail-safe section of control sys-
rotate, shut down and investigate/correct the tem per packager’s manual.
N-21
GEK 97310
VOLUME I
ADDENDUM N
f. After gas turbine has been stabilized at f. After a total of five minutes at idle,
idle for five minutes, make normal shut down. shut down gas turbine.
9-2.15 Automatic Operation. Check auto- strainers; clean or replace as necessary.
c. Log all instrument readings. tem for loose parts; tighten as necessary.

N-22
GEK 97310
VOLUME I
ADDENDUM N

1. Assure that prestart checks are
completed per Table 4
CAUTION
• IF T5.4 RAPIDLY APPROACHES OR EXCEEDS VALUES SHOWN IN FIGURE 11,
ABORT START. INVESTIGATE CAUSE OF CONDITION. IF T5.4 START LIMIT IS
EXCEEDED PERFORM OVERTEMPERATURE INSPECTION
• THE GAS TURBINE IS DESIGNED TO OPERATE ON 100% NATURAL GAS FUEL,

100% LIQUID FUEL, OR ON A COMBINATION OF THE TWO. THE GAS TURBINE
CAN BE STARTED ON EITHER NATURAL GAS FUEL OR LIQUID FUEL BUT
NOT ON A COMBINATION OF THE TWO. WHEN OPERATING ON BOTH FUELS,
NEITHER FUEL FLOW SHOULD BE LESS THAN THE IDLE FUEL FLOW; I.E., IF
OPERATING ON BOTH FUELS, THE MINIMUM FLOW TO THE GAS TURBINE
WILL BE LIQUID FUEL IDLE FLOW PLUS NATURAL GAS IDLE FLOW.
• WHEN OPERATING ON 100% LIQUID FUEL OR A RATIO OF LIQUID AND NAT-

URAL GAS, IT IS NECESSARY TO DRAIN THE LIQUID FUEL MANIFOLD WHEN
THE GAS TURBINE IS SHUTDOWN. APPROXIMATELY 250 CUBIC INCHES
(4098 CC) OF LIQUID FUEL AT A MAXIMUM TEMPERATURE OF 200°F (94°C)
WILL DRAIN EACH TIME THE GAS TURBINE IS SHUTDOWN. REFER TO
OPERATOR’S MANUAL FOR PROCEDURE.
NOTE
• Immediately after switching from liquid fuel burning or duel fuel burning to natural gas
burning, it is necessary to initiate purging of the liquid fuel portion (feed tubes, manifolds,
and nozzles) of the dual fuel system, and to maintain this purging action on a continuous
basis during the following period of natural gas operation.
Either natural gas or compressed air may be used as the purge medium. Refer to the opera-
tor’s manual.

N-23
GEK 97310
VOLUME I
ADDENDUM N

4. At 1100 to 1300 rpm NGG
a. Ignition on
b. Natural gas fuel valve- Fuel manifold pressure Troubleshoot fuel control
open Approx 3 psig (21 kPa) system
Liquid fuel valve- (natural gas) 90-150 psig
closed (621 - 1035 kPa)
or (Liquid fuel)
Natural gas fuel valve-
closed
[T5.4 above 400° F shutdown
(204°C)]
to reach 4300 rpm
6. At 4300 to 4500 rpm NGG
closes automatically supply valve

7. Note time to 5000 rpm NGG 90 seconds maximum
Chapter 5 (41 kPa)
b. Fuel manifold Troubleshoot system and
pressure: take corrective action. See
Figures 5 - 9
Natural gas Approx 25 psig (173 kPa)

N-24
GEK 97310
VOLUME I
ADDENDUM N

Liquid fuel
Primary- Approx 150 psig
(1035 kPa)
Secondary- Approx 30 psig (207 kPa)
Flow divider valve Approximately 185 psig
inlet pressure (1276 kPa)
power turbine seizure for 30 seconds correct cause per
e. T5.4 1000°F (538°C) maximum Emergency shutdown
Table 7
f. NPT (unloaded) 1200 - 1900 rpm Troubleshoot and take cor-
rective action
action
i. Compressor inlet tem- Approximately equal to Troubleshoot sensing and in-
perature (T2) outside air temperature dicating system. Correct as
required
leaks
9. Set desired power setting. Less than alarm limit Correct as required. Refer to
Observe T5.4 during transient transient temperature limits
operation contained in figure 10

N-25
GEK 97310
VOLUME I
ADDENDUM N

power setting, read and record
the following:
b. NGG The maximum allowable *
speed is 10,100 rpm
corrected
c. NPT 0 - 3960 rpm *
figure in Chapter 5 shutdown if 5 psig (34 kPa)
out of limits
e. Scavenge oil 160°F to 275°F Automatic shutdown if
temperature (71° to 135°C) above 340°F ± 10°F
(171° C ± 6°C)
shutdown
g. Power turbine 6 mils maximum *
vibration 7 mils maximum (Alarm) *
10 mils maximum (Trip) Emergency or automatic
shutdown
h. Fuel manifold inlet
pressure
Natural gas 350 psig maximum **
(2413 kPa)
Liquid fuel - Primary 0-615 psig **
(0-4240 kPa)
-Secondary 0-365 psig **
(0-2517 kPa)
-Flow Divider 0-705 psig **
Valve Inlet (0-4861 kPa)

N-26
GEK 97310
VOLUME I
ADDENDUM N

(-54° to 66°C)
Liquid fuel 20°F (11°C) above wax **
point of fuel minimum, to
manual
k. Lube oil supply filter Refer to packager’s
∆P manual
m. VSV schedule See applicable figure in Correct as required per
WP 118 00 WP 118 00
shut down.

N-27
GEK 97310
VOLUME I
ADDENDUM N

N-28
GEK 97310
VOLUME I
ADDENDUM N
Figure 5. Dual Fuel System Flow vs. Pressure Drop Characteristic

N-29
GEK 97310
VOLUME I
ADDENDUM N
Figure 6. Dual Fuel System - Flow Divider Inlet Pressure vs. Total Liquid Fuel Flow

N-30
GEK 97310
VOLUME I
ADDENDUM N
Figure 7. Dual Fuel System - Primary Manifold Pressure vs. Total Liquid Fuel Flow

N-31
GEK 97310
VOLUME I
ADDENDUM N
Figure 8. Dual Fuel System - Secondary Manifold Pressure vs. Total Liquid Fuel Flow

N-32
GEK 97310
VOLUME I
ADDENDUM N
Figure 9. Dual Fuel System - Gas Flow Rate vs. Manifold Pressure

N-33
GEK 97310
VOLUME I
ADDENDUM N

N-34
GEK 97310
VOLUME I
ADDENDUM N

1. Set gas turbine at idle power Gas generator decelerates Emergency shut down
(unloaded)
2. After stabilizing for 3 minutes,
read and record the following:
(55 kPa)
Natural gas See figure 9
Liquid fuel See figures 5 through 8
c. NGG 4950 - 5050 rpm Adjust
d. T5.4 Approximately 1000°F Troubleshoot and take cor-
(538°C) rective action
e. NPT 1200 - 1900 rpm
matic shutdown if above 7
mils. Troubleshoot and
(-54° C to +66° C)
Liquid fuel 20°F (11°C) above wax
manual
manual

N-35
GEK 97310
VOLUME I
ADDENDUM N

3. After stabilizing at idle for T5.4 drops below 400°F Manually shut off fuel
5 minutes, close fuel valves (204°C) NGG and NPT supply
decelerate and stop
4. Observe T5.4 for 3 minutes after 700°F (371°C) Motor gas turbine. Con-
shutdown tinue motoring until tem-
perature decreases

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ager’s manual.
9-3.2 Interlocks. Refer to packager’s manual SHALL BE KEPT OPEN. IF THE
for description of interlocks which affect gas GAS TURBINE IS OPERATING,
turbine operation. AN OBSERVER SHALL BE STA-
BE FOLLOWED.
WARNING
MET:
SARY.
FIELD SERVICE FOR A REPRE- MOTORING THE GAS TUR-
SENTATIVE WHO IS TRAINED BINE.
UNDER SUCH CONDITIONS. a. When entering enclosure during gas
SYSTEM SHALL BE MADE b. Start and operate the gas turbine per
INACTIVE ACCORDING TO Table 5. Do not exceed operating limits of
THE CUSTOMER’S PROCE- Table 3.
DURES.

per Table 7.

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e. Refer to paragraph 5-3.30 and 5-3.31, 9-5 SPECIAL GAS TURBINE
for lube correction factors and lube supply CONSTRAINTS.
V-21B, V-21E, and V-21F, and figures 5-32A, 9-5.1 General. Under normal operating con-
5-32B, 5-32E, 5-32F, 5-32J, 5-32L, 5-32N, ditions, the gas turbines are constrained by the
and 5-32Q.) operating limits published in the limits table.
Continuous operation between the alarm and
NOTE shutdown or “trip” level should not be
practiced.
Refer to figures 5 through 9 for fuel
system requirements when operating In the event that any of the following situations
on natural gas, liquid fuel or a combi- or events occur, the associated special action
nation of the two. or limitation must be followed in order to
assure the gas turbines continued normal oper-
9-4 EMERGENCY OPERATION. ation. These events are either not detected or
not prevented by the customary protective
9-4.1 Emergency Shutdown. devices of control systems.
a. In an emergency, the gas turbine may • Overtemperature During Starting

ing the natural gas and/or liquid fuel valve. • Lube Oil Pressure
However, this should only be done in an emer-
gency, since rapid shutdown will decrease life • High Speed Stalls
of gas turbine.
• Starter Duty Cycle
per Table 7. • Re-Start Following High Power Trip
9-4.2 Post Shutdown Fire. • No Power Turbine Rotation
a. During a normal shutdown, exhaust • Gas Generator Windmilling

time gas turbine is coasting to stop, tempera- 9-5.2 Overtemperature. During starting and
ture increases instead of decreases, it indicates acceleration to idle, cooling flows to compo-
that combustion is still taking place because of nents of the gas turbine hot section are not suf-
a leaking fuel valve. (A slight temperature ficient to protect the metals at T5.4 alarm and
increase after rotation stops is normal.) Make trip levels specified in the limits table. A lower
certain fuel is shut off, and motor the gas gen- T5.4 limit is therefore established, with higher
erator. This will blow out the fire. As soon as levels acceptable provided they exist for lim-
temperature decreases to normal, discontinue ited times as depicted on the curve titled
motoring. “Transient Temperature Limits for Starts”.
This must be monitored by the operator. The
overtemperature inspection called for by entry
into area B requires hot section disassembly
and inspection in a qualified facility.
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9-5.3 Lube Oil Supply Pressure. The lube c. There is no duty cycle limit on the
oil supply pressure limits given in the limit hydraulic starter.
table are “distress” limits. Protective devices
cannot reliably monitor supply pressure 9-5.6 Re-Start Following High Power Trip.
because the proper pressure is dependent on In the event that re-start of the gas turbine is
gas generator speed, oil type, oil temperature, required within two (2) hours following a trip
and number of oil jets. An operator must there- or rapid shutdown from high power, a five (5)
fore derive a corrected oil pressure as directed minute cranking at 2400 rpm should precede
on the appropriate pressure correction table in the fire up. The objective is to cool the high
Chapter 5 to determine if the lube system is pressure turbine rotor, so that blade tips main-
performing within the high-low limits stated tain clearance with the more rapidly cooling
on each table. case.
generator rotational speeds above 7500 rpm mally bound power turbine rotor could occur
can result in high pressure compressor blade under extreme conditions following a rapid
fracture. The gas turbine can be operated after shutdown from high power. Power turbine
an inspection of the compressor stages 3 rotation should initiate during gas turbine
through 6 verifies that blade tip clanging has acceleration to idle. If rotation does not occur,
not occurred. If tip clanging has occurred, fur- the following procedure should be used:
required, which necessitates blade removal a. Remain at idle for 30 seconds and shut
from the spool. down.
9-5.5 Starter Duty Cycle - Air or Natural b. Refire and repeat Item a.
Gas.
c. Refire and repeat Item a.
a. With starter inlet air pressure set at
40 psig (276 kPa): d. Refire and accel to 6000 rpm. Do not
• 45 Seconds, on 2 minutes off for any exceed 6000 rpm. Power turbine should break
number of cycles, away. If not, shut down and investigate for
or,
9-5.8 Windmilling.
such cycles in any 30 minute period. a. Unlimited windmilling or cranking of
• 5 minutes on, 2 minutes off with two speeds, the lube supply and scavenge systems
such cycles in any 30 minute period, are in normal operation.

• 10 minutes on, 20 minutes off for any with successive periods allowed if preceded by
number of cycles. normal gas turbine operation.
N-39
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CAUTION
1. Conditions permitting, T5.4 drops below 400°F Manually shut off fuel
decelerate gas turbine to idle and close (204°C) and NGG and supply
fuel valves NPT decelerate
2. Observe T5.4 for 3 minutes after shut- 700°F (371°C) max. Motor gas turbine.
down Continue motor until
a If the fault detection and sequencing
procedure.
b If a “hot restart” is to be performed
motor the gas turbine at 2000-2500
rpm NGG for 5 minutes. At the end
of the 5 minute motoring/purge
cycle, perform normal restart and
accelerate to idle. Acceleration to the
desired power setting can then be
accomplished.
c After 2 hours following coastdown of

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TABLES 8 and 9. Deleted

N-41/(N-42 Blank)
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ADDENDUM
7LM2500-PE-MD

GEK 97310
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TABLE OF CONTENTS
1-0 INTRODUCTION....................................................................................... O-3

2-0 REFERENCE DATA .................................................................................. O-3
3-0 INSTALLATION DRAWINGS.................................................................. O-3
4-0 EQUIPMENT DESCRIPTION ................................................................. O-3
5-0 GAS TURBINE CONTROL ...................................................................... O-3
6-0 INSTRUMENTATION AND SUPPLY REQUIREMENTS ................... O-5
7-0 SERVICE REQUIREMENTS ................................................................... O-9
7-1.1 Natural Gas ................................................................................................... O-9
7-1.2 Liquid Fuel.................................................................................................... O-9
8-0 OPTIONAL HARDWARE KITS - 7LM2500-PE-MD ............................ O-9
9-0 GAS TURBINE OPERATION .................................................................. O-9
9-1 PERFORMANCE RATINGS AND OPERATING LIMITS .................. O-10
9-1.1 Performance Ratings ..................................................................................... O-10
9-1.2 Operating Limits ........................................................................................... O-12
9-2 INITIAL OPERATION .............................................................................. O-17
9-2.1 General .......................................................................................................... O-17
9-2.2 Special Instrumentation Required for Operation .......................................... O-17
9-2.3 Special Instrumentation Required for Monitoring and Troubleshooting ...... O-17
9-2.4 Preparation .................................................................................................... O-18
9-2.5 Gas Turbine and Associated Equipment Check List..................................... O-18
9-2.6 Governor and Manual Control Check........................................................... O-19
9-2.7 Start-up and Checkout................................................................................... O-19
9-2.8 Ignition Check............................................................................................... O-20
9-2.9 Motoring........................................................................................................ O-21
9-2.10 False Start...................................................................................................... O-21
9-2.11 Governor Check ............................................................................................ O-21
9-2.12 Wet Prestart ................................................................................................... O-21
9-2.13 Manual Start and Operation .......................................................................... O-22
9-2.14 Operation to Maximum Power...................................................................... O-22
9-2.15 Automatic Operation..................................................................................... O-23
9-3 NORMAL OPERATION............................................................................ O-31
9-3.1 General .......................................................................................................... O-31
9-3.2 Interlocks....................................................................................................... O-31
9-3.3 Operation....................................................................................................... O-31
9-4 EMERGENCY OPERATION ................................................................... O-32
9-4.1 Emergency Shutdown ................................................................................... O-32
9-4.2 Post Shutdown Fire ....................................................................................... O-32
9-5 SPECIAL GAS TURBINE CONSTRAINTS ........................................... O-32
9-5.1 General .......................................................................................................... O-32
9-5.2 Overtemperature............................................................................................ O-32
9-5.3 Lube Oil Supply Pressure ............................................................................. O-38

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9-5.4 High Speed Stall............................................................................................ O-38

9-5.5 Starter Duty Cycle - Air or Natural Gas........................................................ O-38
9-5.6 Re-Start Following High Power Trip ............................................................ O-38
9-5.7 No Power Turbine Rotation .......................................................................... O-38
9-5.8 Windmilling .................................................................................................. O-38
Figure Title Page
1 Deleted
2 Deleted
3 Deleted
4 Deleted
5 Dual Fuel System Flow Versus Pressure Drop Characteristic ............................... O-33
6 Dual Fuel System - Flow Divider Pressure vs. Total Liquid Fuel Flow................ O-34
7 Dual Fuel System - Primary Manifold Pressure vs. Total Liquid Fuel Flow ........ O-35
8 Dual Fuel System - Secondary Manifold Pressure vs. Total Liquid Fuel Flow .... O-36
9 Dual Fuel System - Gas Flow Rate vs. Manifold Pressure.................................... O-37
10 Transient Temperature Limits ................................................................................ O-41
LIST OF TABLES
Table Title Page
1 INSTRUMENTATION CONNECTIONS............................................................. O-5

2 SUPPLY CONNECTIONS.................................................................................... O-7
3 GAS TURBINE OPERATING LIMITS................................................................ O-13
4 PRESTART CHECKS ........................................................................................... O-20
5 START-UP AND OPERATION ............................................................................ O-24
6 GAS TURBINE SHUTDOWN ............................................................................. O-29
7 EMERGENCY SHUTDOWN............................................................................... O-39
8 DELETED
9 DELETED
10 DELETED
11 DELETED

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1-0 INTRODUCTION. 3-0 INSTALLATION DRAWINGS.
The information contained herein describes the A complete set of installation drawings have
7LM2500-PE-MD model gas turbine basic been provided.
configuration and control system differences.
In addition, the coverage of reference data, 4-0 EQUIPMENT DESCRIPTION.
instrumentation and supply connections, spe- The 7LM2500-PE-MD is a dual-fueled (natu-
cial servicing requirements, optional hardware ral gas and liquid fuel) marinized gas turbine.
kits and the complete gas turbine operating The on-engine mounted dual fuel system con-
instructions for the 7LM2500-PE-MD model sists of a natural gas manifold, two liquid fuel
are included. manifolds, 30 dual fuel nozzles, and a single
liquid fuel off-gas turbine mounted flow
2-0 REFERENCE DATA. divider valve. The 7LM2500-PE-MD gas tur-
bine is designed to operate on 100 percent nat-
EQUIPMENT ural gas, 100 percent liquid fuel or a
combination of the two. The minimum fuel
Gas Turbine Assembly flow for each fuel, when operating on dual
(General Electric Co., Cincinnati OH) fuel, should be selected so that if one fuel is
Model No. 7LM2500-PE-MD cut off, the gas generator speed will not
Dwg. No. L31430G12 decrease below 5000 rpm before the governor
action restores the gas turbine to normal
PERFORMANCE RATING operation.
Refer to paragraph 9-1 5-0 GAS TURBINE CONTROL.
DRAWING LIST a. The transition from natural gas to liq-

Drawing No. shall not result in abrupt changes in gas gener-
Gas Turbine Installation from natural gas to liquid fuel or vice versa is a
Drawing L31705 function of the operator’s control system, so
Fuel System Installation 682L310 long as the change in total fuel flow does not
Lubrication System Flow exceed that shown on the maximum accelera-
Diagram L24328 tion fuel flow curves.
Drawing L31430G12

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Figure 1. Deleted

O-4
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ADDENDUM O
pin B constantan
pin B constantan
pin B constantan
E6 Accessory gearbox scavenge MS3106Rl2S-3S
oil temperature
E6A Accessory gearbox T/C MS3106R-12S-3SW except pin A iron and
(optional equipment) pin B constantan
pin B constantan
pin B constantan
(optional)

O-5
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ADDENDUM O

F3 Natural gas fuel manifold pressure tap MS20819-4C or AN818-4C
(optional)

NOTE
For all other instrumentation connections, refer to Installation Draw-
ings provided with gas turbine.

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CAUTION
ON GAS GENERATOR. IF EXCESSIVE FORCE IS REQUIRED TO COMPLETE
A CONNECTION, LOOSEN ALL CONNECTIONS AND CHECK/ADJUST
F1 Fuel manifold inlet, gas 2 inch line from fuel control unit to
gas generator fuel manifold
F2 Fuel manifold inlet No. 1 Fuel manifold inlet liquid, mates with
AN818-10C or MS20819-10C or equivalent
F6 Fuel manifold inlet No. 2 Fuel manifold inlet liquid, mates with
AN818-12C or MS20819-12C
or equivalent
L1 Oil supply 1-1/2 inch line to lube pump on gas genera-
tor, AN818-24C or MS20819-24C
L2 Lube pump discharge 1 inch line from lube pump to oil supply fil-
ters, AN819-16C or MS20819-16C
L4 Lube supply inlet port 1 inch line from oil supply filters to gas gen-
erator, AN818-16C or MS20819-16C
L3 Scavenge oil discharge 1-1/4 inch line from gas generator scavenge
pump to oil scavenge filter and cooler,
AN818-20C or MS20819-20C
A1 Bleed air port 8th stage Shipped with cover that must remain in
place if port is not used

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ADDENDUM O

arrestor)
D3 Oil Drain, forward AN818-6C or MS20819-6C
D5 Oil Drain, aft AN818-6C or MS20819-6C
S1 or Waterwash manifold 1 inch line - hot water line to waterwash
S1A manifold on gas generator inlet duct,
AN818-16C or MS20819-16C
NOTE
For all other supply connections, refer to Installation Drawings

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7-0 SERVICE REQUIREMENTS. 8-0 OPTIONAL HARDWARE KITS -
7LM2500-PE-MD.
7-1.1 Natural Gas.
a. The required supply pressure to the detailed list of optional kits available for this
natural gas fuel manifold on the gas turbine is particular gas turbine model.
355 ± 5 psig (2448 ± 35 kPa) maximum.
b. The temperature of the gas supply at
the fuel manifold connection on the gas turbine a. These instructions contain the detailed
must be in the range of 20ºF (-6.7ºC) above the gas turbine operating procedures and limits
saturated vapor temperature of the gas at the recommended by the General Electric Com-
supply pressure as a minimum, and 350ºF pany for the 7LM2500-PE-MD gas turbine.
(177ºC) as a maximum. Based on consider-
ation of control system components however, b. The instructions are intended to pro-
it is recommended that the maximum gas sup- vide operating personnel with the information
ply temperature be limited to 150ºF (66ºC). If required to operate the gas turbine. They per-
the supply temperature of the gas is not repeat- tain to routine and emergency condition and
able on a day-to-day basis, it will be necessary procedures. When a fault exists, refer to Chap-
to change the control system starting fuel ter 4 entitled, TROUBLESHOOTING.
adjustment or to adjust the supply pressure to
the gas turbine to maintain a constant BTU- c. It is possible that these instructions
per-cubic-foot supply. Once started the gas tur- may not provide for every possible variation in
bine will accept variations in supply tempera- equipment or contingency to be met in connec-
ture of ± 20ºF (± 11ºC). The maximum fuel tion with the operation of the gas turbine.
flow required, assuming a lower heating value Refer requests for additional information to the
of 19,000 BTU/lb is 13,500 pph (6123 kg/h) General Electric Company, Marine and Indus-
for the 7LM2500-PE-MD model gas turbine. trial Engine Department, Cincinnati, Ohio
45215.
7-1.2 Liquid Fuel.
a. The maximum required supply pres-

sure to the flow divider is 720 psia (4964 kPa).
b. The fuel temperature supplied to the

gas turbine shall be a minimum of 20ºF
(-6.7ºC) above the wax point of the fuel and a
filtered to 20 microns absolute. The maximum
total fuel flow required is 14000 pph
(6350 kg/h) with a lower heating value of
18,400 BTU/1b.

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WARNING OPERATING LIMITS.
NOTE
GAS TURBINE UNTIL A THOR- Ratings published in this manual apply
OUGH INVESTIGATION HAS to the gas turbine. The driven unit rat-
BEEN MADE. DO NOT REPEAT ings/limits may be lower in some cases
HOT STARTS, COMPRESSOR and shall take precedence over the gas
STALLS, OR OTHER RECOGNIZED turbine manual limits.
THOROUGH INVESTIGATION. 9-1.1 Performance Ratings.
IN UNDUE STRESS BEING a. The performance of the 7LM2500-PE-
IMPOSED ON GAS TURBINE COM- MD gas turbine operating on either natural gas
PONENTS, WITH IMMEDIATE OR or liquid fuel is given in MID-TD-2500-9. The
SUBSEQUENT DESTRUCTIVE actual performance of the dual fueled
FAILURE OF THE GAS TURBINE 7LM2500-PE-MD gas turbine will be a func-
AND INJURY TO PERSONNEL. tion of the ratio of natural gas and liquid fuel
used. The time between on-site maintenance
NOTE and repair of the hot section will also change
as a function of the ratio of the natural gas and
liquid fuels used, with the longest times being
associated with 100% natural gas. For condi-
tion monitoring purposes it is recommended
that the Buyer or Customer maintain a record
of the accumulated gas turbine operating time
on different fuels.

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b. The rated performance of the Power Turbine Speed
7LM2500-PE-MD gas turbine in the new and Liquid:
clean condition is as follows:
Power Turbine Speed -At Maximum 1575 1538
3600 rpm 3000 rpm Rating
Shaft Horsepower
Natural Gas Fuel per GE Specification
-Base 29,500 28,500 MID-TD-0000-1
-Maximum 32,000 30,000
Heat Rate, Gas Liquid Fuel per GE Specification
MID-TD-0000-2
/hp-hr /hp-hr c. The gas turbine is designed to operate
-Average (Max- 6908 BTU 7125 BTU on 100% natural gas fuel, 100% liquid fuel, or
imum) /hp-hr /hp-hr combinations of the two with no limit on natu-
Heat Rate, Liquid ral gas/liquid fuel ratios. The gas turbine can
be started on either natural gas or liquid fuel
but not on a combination of the two. Starting
/hp-hr /hp-hr
fuel flow for the 7LM2500-PE-MD model gas
-Average (Max- 6955 BTU 7211 BTU turbine is normally set by the minimum stop
imum) /hp-hr /hp-hr on the gas fuel metering valve. For ambient
Based on the following conditions: temperatures of -65ºF (-54ºC) to +130ºF
Inlet Air 59ºF 59ºF (54ºC) the proper fuel flow setting for the min-
Temperature imum stop on a heat consumption basis, is
10.45xl06 ± 0.46xl06 BTU/ hour for natural gas
fuel, and 11.96xl06 ± 0.72xl06 BTU/hour for
Inlet Losses 0”H2O 0”H2O liquid fuel, and is based upon commencing
Exhaust Losses 0”H2O 0”H2O fuel and ignition at 1200 ± 100 rpm. Where a
Relative Humidity 0% 0% minimum stop is not utilized, acceptable light-
offs can be obtained in the sub-idle region,
Compressor Bleed 0 0 however, during such starts, ignition should be
Accessory Power 0 0 initiated at that fuel flow corresponding to the
Extraction minimum stop with its associated tolerance. If
Power Turbine Inlet starts in the sub-idle region are required, refer
Gas Temperature, to Gas Turbine Installation Design Manual
T5.4 Avg. MID-IDM-2500-9.
Gas: d. The minimum fuel flow for each fuel,
-At Base Rating 1461 1449 when operating on dual fuel, should be
-At Maximum 1551 1516 selected so that if one fuel is cut off the gas
Rating generator speed will not decrease below
5000 rpm before the governor action restores
the engine to normal operation.

O-11
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ADDENDUM O
e. Refer to Installation Design Manual k. The transition from natural gas to liq-
MID-IDM-2500-9 for the 7LM2500-PE-MD uid fuel and vice versa shall be smooth and
gas turbine model transient fuel flow shall not result in abrupt changes in gas gener-
requirements. ator speed or temperature. Transfers from nat-
ural gas to liquid fuel or vice versa can be
f. Acceleration fuel rates greater than achieved within 10 seconds. The actual
those shown will result in over-temperature switchover time is established by the control
and possible stall of the gas turbine. Accelera- system response.
result in “hung” starts in the below idle speed l. The actual performance of the
range. 7LM2500-PE-MD gas turbine will be a func-
tion of the ratio of natural gas fuel and liquid
g. Above the idle speed point, low accel- fuel used. The time between repairs of the hot
eration fuel rates will not harm the gas turbine section will also change as a function of the
and will only result in slower acceleration ratio of the natural gas and liquid fuels used
times. with the longest times being associated with
100% natural gas.
h. For normal accelerations from idle to
power settings the changes should be made 9-1.2 Operating Limits. Refer to Table 3.
section repairs and the life of the gas turbine; a NOTE
time of 2 to 3 minutes is reasonable. If any operating limit is exceeded, ver-
i. The fuel rates shown on the curves will troubleshooting or inspecting gas
give starting times to 5000 rpm idle of 60 to 90 turbine.
j. Normal decelerations from maximum

power to idle should be made in approximately
2 to 3 minutes. This will enhance the time
gas turbine.

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.
Alarm/ Normal
NOTE
Lubrication Gas Turbine Alarm 8 psig ± 1 psig 20 - 60 psig Bypass until 4500 rpm
System - Lube Pump (55 kPa ± 6.9 kPa) (138 - 414 kPa)
Ranges (103 kPa ±
6.9 kPa) above
8000 rpm
Trip 6 psig ± 1 psig 20 - 60 psig Bypass until 4500 rpm
(41 kPa ± 6.9 kPa) (138 - 414 kPa)
Gas Turbine Alarm 110 psig ± 10 psig 10 - 100 psig Scavenge Discharge
Scavenge Dis- (758 kPa ± 69 kPa) (69 - 689 kPa) Pressure shall not
charge Pressure exceed
180 psig (1241 kPa)
Lube Pump (82º - 140ºC) (60º - 71ºC) Range reflects temper-
Discharge ature expected during
Temperature operation above idle
speed
Lube Scav- (166º - 177ºC) (71º - 135ºC) Range reflects temper-
enge Tempera- ature expected during
tures - Five operation above idle
speed
(143º - 154ºC)

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Alarm/ Normal
Fuel Fuel Manifold

System Pressure
Natural Gas 20 - 355 psig Supply Pressure as
(138 - 2448 kPa) reflected at the fuel
manifold inlet on the
gas turbine
Liquid Fuel
Flow Divider 0 - 705 psig Supply Pressure as
Inlet (0 - 4861 kPa) reflected at the Fuel
Flow Divider Valve
Inlet on the gas turbine
Primary 0 - 615 psig Supply Pressure as
(0 - 4240 kPa) reflected at the Primary
Fuel Manifold Inlet on
the gas turbine
Secondary 0 - 365 psig Supply Pressure as
(0 - 2517 kPa) reflected at the Sec-
ondary Fuel Manifold
Inlet on the gas turbine
Fuel Supply
Temperature
Natural Gas Alarm 150º - 170ºF -65º to 150ºF Starting Fuel Flow
(66º - 77ºC) (-54º to 66ºC) Adjustment may be
required to compensate
for fuel temperature
variation
Liquid Fuel 20ºF (-7ºC)
above wax point
of fuel to
150º (66ºC)
maximum
System Pressure (276 kPa) Requirement based on
gas turbine starter
torque requirements

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Alarm/ Normal

Fuel and
Ignition
Fuel and Igni- start after purge cycle
tion (If purge
cycle is used)
neously with start
initiation
Failure to Trip 380º - 420ºF (T5.4) Activate 10 seconds
Light-Off (193º - 216ºC) time delay simulta-
tion of fuel and
ignition
neously with start initi-
ation. De-energize
and starter air
supply
to 4500 rpm time delay upon com-
(If purge cycle pletion of purge. De-
is used) energize fuel and igni-
tion systems and starter
air supply
bine Inlet Light-Off (193º - 216ºC) (-18ºC - 871ºC) does not reach 400ºF
(T5.4) (204ºC) within 10 sec-
Tempera- onds after fuel and
ture (Gas ignition are applied
Generator
Exhaust)

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Alarm/ Normal
Overtempera-
ture:
Power Turbine Speed
3000 rpm 3600 rpm
Natural Gas Trip 1575ºF 1575ºF
(857ºC) (857ºC)
(818ºC) (824ºC)
Liquid Fuel Trip 1575ºF 1575ºF
(857ºC) (857ºC)
(832ºC) (838ºC)
Vibration Gas Generator Trip 7 mils DA 0 - 3 mils DA Avoid continuous
operation above 4 mils
Alarm 4 mils DA
Power Turbine Trip 10 mils DA 0 - 6 mils DA Avoid continuous
operation above 7 mils
Alarm 7 mils DA
Speed
(For 60 Hz) Gas Generator Trip 10,200 rpm 0 - 10,100 rpm
(For 60 Hz) Power Turbine Trip 3,960 rpm 0 - 3,600 rpm
(For 50 Hz) Gas Generator Trip 10,200 rpm 0 - 10,100 rpm
NOTE
• Consult General Electric Company for approval when operating speeds above 3300 rpm are
considered.
Loss of Combustor Close and lock out fuel
Flame Flame shutoff valve upon loss
of flame

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ADDENDUM O
that period of operation immediately following Fuel manifold pressure sensor:
gas turbine replacement or major maintenance liquid fuel:
on the system.
primary 0-1200 psig
9-2.2 Special Instrumentation Required for (0-8280 kPa)
Operation. secondary 0-600 psig
(0-4139 kPa)
Gas generator speed 0-11,000 rpm
fuel flow divider inlet 0-1200 psig
sensor
(0-8274 kPa)
Lube oil scavenge 0-400°F
temperature sensors (-18º-205ºC) natural gas 0-400 psig
(A-, B-, C-, D-sumps (0-2760 kPa)
and transfer gearbox) Compressor inlet total pres- 10-16 psia
Lube pump discharge 0-400°F sure sensor (69-110.4 kPa)
temperature sensor (-18ºC-205ºC) Power turbine inlet gas 0-75 psia
Vibration indicators: pressure (0-517.5 kPa)
gas generator 0-4 in/sec or Fuel supply temperature:
0-10 mil DA liquid fuel 0-250ºF
power turbine 0-2 in/sec or (-18ºC-121ºC)
0-15 mil DA natural gas 0-250ºF
Power turbine speed 0-5000 rpm (-18ºC-121ºC)
sensor Fuel Supply Pressure:
Power turbine inlet gas 0-2000°F liquid fuel 0-1000 psig
temperature (T5.4) (-18ºC-1093ºC) (0-6895 kPa)
Lube pump discharge 0-100 psig natural gas 0-400 psig
pressure (0-690 kPa) (0-2760 kPa)
Remote reading variable vane -5º to +45º
indicator
Scavenge oil pressure 0-200 psig
(0-1379 kPa)
Gas turbine inlet air -65ºF-150ºF
temperature (-54ºC-66ºC)
(0-345 kPa)

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ADDENDUM O
9-2.4 Preparation. The gas turbine and asso- i. Gas turbine assembly free of
ciated systems must be inspected and checked loose objects and all lines/
out for proper installation and operation before electrical leads connected _______
9-2.5 Gas Turbine and Associated Equip- of foreign objects. Inlet screen
ment Check List. Complete the following secure _______
check list.
a. Gas Turbine Assembly S/N _______ and 10, are open (not capped) _______
b. Mounting base secured to l. Starter is serviced per pack-
foundation _______ ager’s manual _______
c. Intake air and exhaust gas m. Lube oil storage tank serviced
ducts in place and secured _______ to full level _______
d. Gas turbine and exhaust duct n. Lube oil supply valves open _______
support mounts and links in
place and secure _______ o. All filters serviced per pack-
and secure _______ p. T5.4 thermocouple system
functioning properly _______
packager’s manual _______ q. Ignition system operative _______
g. All instrumentation connec- r. Compressor inlet total pres-
tions made and secure _______ sure probe aligned properly
and free of damage _______
packager’s manual _______ s. Variable stator system secure _______
tions specified in packager’s
have been performed _______

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GEK 97310
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ADDENDUM O
Refer to packager’s manual. BE FOLLOWED.

WHEN ENTERING THE GAS TUR- SARY.
ING REQUIREMENTS SHALL BE • EAR PROTECTION SHALL BE
MET: WORN IF GAS TURBINE IS
OPERATING.
ENCLOSURE OR IN THE
• ENCLOSURE ENTRY DURING PLANE OF ROTATION OF THE
ENGINE OPERATION IS PRO- STARTER WHEN STARTING OR
HIBITED IN GENERAL. IF MOTORING THE GAS TUR-
ENTRY SHOULD BE BINE.
OPERATION, CONTACT GE a. When entering enclosure during gas
FIELD SERVICE FOR A REPRE- turbine operation, wear proper ear protection.
c. Perform ignition check out per
THE CUSTOMER’S PROCE- paragraph 9-2.9.
DURES.
OFF. HIGH SECONDARY AIR- f. Perform governor check per packager’s
FLOW MAY PREVENT OPEN- manual.
ING OR CLOSING THE
paragraph 9-2.12.
TIONED AT THE ENCLOSURE i. Operate to maximum power per
DOOR AND CONFINED SPACE paragraph 9-2.14.

O-19
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ADDENDUM O
j. Check automatic operation per b. Disconnect number one ignition exciter
paragraph 9-2.15. input lead at exciter. Temporarily secure input
WARNING audible report (approximately two sparks per
• ASSURE POWER TO IGNITION igniter fires.
CONNECTING AND CONNECT- d. Turn off electrical power to the ignition
ING IGNITION EXCITER INPUT system. Reconnect input lead to exciter and
LEAD. TAG SWITCH OUT OF safety-wire connector.
VERTENT ACTIVATION. e. Repeat steps b, c and d, disconnecting
the No. 2 exciter.
• ASSURE THAT FUEL VALVES
ARE CLOSED THROUGHOUT f. If an audible report is not heard on
THIS PROCEDURE. No. 1 and/or No. 2 igniters, check out the sys-
a. To clear combustor of any residual ate corrective action.
Item Requirement
Maintenance requirements and Cleared
discrepancies
Fuel valves Closed
Ignition Off
Oil tank level Full
Lube oil supply Open
valves
Lube oil temperature +20ºF (+1ºC) for MIL-L-23699
-20ºF (-29ºC) for MIL-L-7808
Fuel supply
natural gas temperature -65°F to 150°F
(-54° to 66°C)
liquid fuel temperature 20ºF (-7ºC) above wax point of fuel to 150ºF
(66ºC) maximum

O-20
GEK 97310
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ADDENDUM O
9-2.9 Motoring. After all preliminary checks b. Gas generator should go through nor-
have been completed and lines flushed, motor mal start cycle and then abort because of lack
gas generator as follows: of flame.
a. Make ignition, liquid fuel and natural 9-2.11 Governor Check. Check governor sys-
gas supply systems inoperative as follows: tem per packager’s manual.
(1) Disconnect power supply to igni- 9-2.12 Wet Prestart. Perform wet prestart as
tion units. follows:
(2) Close liquid fuel and natural gas a. With ignition lead disconnected, but
manual shutoff valves to fuel control unit. with either manual natural gas or liquid fuel
valve open and governing system operating,
b. Depress MOTORING pushbutton. Gas make automatic start of gas generator per
generator will start to rotate. If it does not, packager’s manual.
to starter. b. Gas generator should accelerate to
c. Hold MOTORING pushbutton closed should open and fuel manifold pressure should
until gas generator speed stabilizes, and check be approximately 3 psig (21 kPa). Adjust fuel
for oil pressure. If there is no indication of oil supply if required. Start will then abort
pressure, release MOTORING pushbutton. because of lack of flame.
While gas turbine is coasting down, loosen oil
fittings at lube pump to bleed air from system. c. Allow gas turbine to coast to a stop.
Starter should motor gas turbine to minimum Motor it to purge any remaining natural gas
of 2200 RPM. from the gas turbine or drain liquid fuel from
manifold if liquid fuel was used in the wet pre-
d. Repeat motoring and bleeding proce- start. Purge fuel nozzles of liquid fuel with nat-
dure until an indication of oil pressure appears. ural gas or compressed air at 200 psig
(1380 kPa) maximum. Remain on starter for
9-2.10 False Start. Perform false start as 60 seconds to purge fuel from gas turbine.
follows:

manual liquid fuel and natural gas shutoff
valves closed, make automatic start of gas tur-

O-21
GEK 97310
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ADDENDUM O
system normal and with ignition lead con- speed (4950 ± 50 rpm) for 30 seconds.
NOTE additional start-up and shutdown cycles.
Power Turbine, except in a new instal-
lation, will be rotating when gas gener- (4) If the power turbine does not
ator idle speed is attained. rotate after accomplishing substeps (1) through
CAUTION
DO NOT EXCEED 6000 RPM NGG rotation stops, re-start and accelerate to
AND 30 SECONDS OF GAS TUR- 6000 rpm NGG maximum and stabilize for 30
BINE OPERATION WITHOUT seconds. If the power turbine still does not
POWER TURBINE ROTATION. rotate, shut down and investigate/correct the
a. The power turbine must rotate by the a thermally seized rotor, inspect the LPT
time the gas generator speed reaches 6000 rpm blades in stages 4, 5 and 6 for shingling and
NGG. If power turbine speed indication is not unlatching. If blades have become unlatched,
obtained and it is determined that a “thermal they may be relatched. LPT blades that have
seizure” of the power turbine has occurred, encountered shingling may be bent thereby
proceed as follows: necessitating replacement of the power
turbine.
NOTE
CAUTION
within 30 to 40 minutes following gas MANUAL OPERATION MAY
turbine operation. Thermal seizure is ELIMINATE CERTAIN PROTEC-
the condition where the power turbine TIVE CIRCUITS. OPERATING LIM-
rotor is prevented from rotating by hard ITS SHALL NOT BE EXCEEDED.
shrouds, interstage seals and other a. Slowly increase manual control setting
internal interference. This condition is (refer to packager’s manual) to increase gas
the result of unequal cooling rates of generator speed. After each 500 rpm increase,
the various power turbine components. log all instrument readings, paying particular
The possibility of thermal seizures can attention to variable stator vane position and
be reduced by operating the gas turbine vibration. If variable stator system is not
at idle power for at least five minutes within limits, adjust it per work package
prior to shutdown to achieve proper 118 00. If vibrations are not within limits, con-
cooling of the power turbine. sult the local General Electric Company
representative.
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GEK 97310
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ADDENDUM O
b. Operate gas turbine up to rated power, 9-2.15 Automatic Operation. Check automatic
if possible, but do not exceed exhaust gas tem- operation per packager’s manual.
until all temperatures stabilize. If governing a. Accelerate to idle.
manual. b. Accelerate to rated power.
c. Log all instrument readings once they c. Log all instrument readings.
stabilizing for three minutes, record all instru- e. Check for fuel or lube oil leaks.
e. Check fail-safe section of control sys- shut down gas turbine.
f. After gas turbine has been stabilized at strainers; clean or replace as necessary.
idle for five minutes, make normal shut down.
Refer to Table 6, steps 3 and 4. h. Correct any leaks observed.


O-23
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ADDENDUM O

1. Assure that prestart checks are Investigate cause of condi-
completed per Table 4. tion. If T5.4 start limit is
exceeded perform overtem-
perature inspection.
CAUTION
• IF T5.4 RAPIDLY APPROACHES OR EXCEEDS VALUES SHOWN IN
FIGURE 10, ABORT START.
• THE GAS TURBINE IS DESIGNED TO OPERATE ON 100% NATURAL GAS

FUEL, 100% LIQUID FUEL, OR ON A COMBINATION OF THE TWO. THE
GAS TURBINE CAN BE STARTED ON EITHER NATURAL GAS FUEL OR
LIQUID FUEL BUT NOT ON A COMBINATION OF THE TWO. WHEN OPER-
ATING ON BOTH FUELS, NEITHER FUEL FLOW SHOULD BE LESS THAN
THE IDLE FUEL FLOW; I.E., IF OPERATING ON BOTH FUELS, THE MINI-
MUM FLOW TO THE GAS TURBINE WILL BE LIQUID FUEL IDLE FLOW
PLUS NATURAL GAS IDLE FLOW.
• WHEN OPERATING ON 100% LIQUID FUEL OR A RATIO OF LIQUID AND
NATURAL GAS, IT IS NECESSARY TO DRAIN THE LIQUID FUEL MANI-
FOLD WHEN THE GAS TURBINE IS SHUTDOWN. APPROXIMATELY
250 CUBIC INCHES (4098 CC) OF LIQUID FUEL AT A MAXIMUM TEMPER-
ATURE OF 200°F (94°C) WILL DRAIN EACH TIME THE GAS TURBINE IS
SHUTDOWN. REFER TO OPERATOR’S MANUAL FOR PROCEDURE.
NOTE
• Immediately after switching from liquid fuel burning or dual fuel burning to natural gas
burning, it is necessary to initiate purging of the liquid fuel portion (feed tubes, manifolds,
and nozzles) of the dual fuel system, and to maintain this purging action on a continuous
basis during the following period of natural gas operation. Either natural gas or com-
pressed air may be used to purge the fuel nozzles. Refer to the operator’s manual.
rotation

O-24
GEK 97310
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ADDENDUM O

4. At 1100 to 1300 rpm NGG
a. Ignition on
b. Natural gas fuel valve-open Fuel manifold pres- Troubleshoot fuel control
Liquid fuel valve-closed sure: Approx 3 psig system.
or (21 kPa) (natural gas)
Natural gas fuel valve-closed 90-150 psig
Liquid fuel valve-open (621-1035 kPa)
(Liquid fuel)
takes longer than 90 sec-
onds to reach 4300 rpm
6. At 4300 to 4500 rpm NGG
a. Starter shutoff valve closes Valve closed Manually close starter air
automatically supply valve.
a. Oil pressure See applicable figures Shutdown if below 6 psig
in Chapter 5 (41 kPa)
b. Fuel manifold pressure: Troubleshoot system and
take corrective action.
See figures 5 - 9
Natural gas Approx 25 psig
(173 kPa)
Liquid fuel
Primary- Approx 150 psig
(1035 kPa)

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GEK 97310
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ADDENDUM O

Secondary- Approx 30 psig
(207 kPa)
Flow divider valve inlet pressure Approximately
185 psig (1276 kPa)
d. Maximum NGG with power tur- 6000 rpm NGG maxi- Shut down and investigate/
bine seizure (thermal seizure) mum for 30 seconds correct cause per
paragraph 9-2.13
e. T5.4 1000°F (538°C) Emergency shutdown
maximum Table 7
f. NPT (unloaded) 1200-1900 rpm Troubleshoot and take cor-
rective action
action
action
i. Compressor inlet Approximately equal Troubleshoot sensing and
temperature (T2) to outside air indicating system. Correct
temperature as required
9. Set desired power setting. Observe Less than alarm limit Correct as required. Refer
T5.4 during transient operation to transient temperature
limits contained in figure 10

O-26
GEK 97310
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ADDENDUM O

b. NGG The maximum allow- *
able speed is 10,100
rpm corrected
c. NPT 0-3960 rpm *
d. Oil pressure See applicable table Emergency or automatic
and figure in shutdown if 5 psig (34 kPa)
Chapter 5 out of limits
(71° to 135°C) above 340°F ± 10°F
(171°C ± 6°C)
shutdown
7 mils maximum *
(Alarm)
10 mils maximum Emergency or automatic
(Trip) shutdown
h. Fuel manifold inlet pressure
Natural gas 350 psig maximum **
(2413 kPa)
Liquid fuel - Primary 0-615 psig **
(0-4240 kPa)
-Secondary 0-365 psig **
(0-2517 kPa)
-Flow Divider 0-705 psig **
Valve Inlet (0-4861 kPa)
(-54° to 66°C)

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ADDENDUM O

Liquid fuel 20°F (11°C) above **
wax point of fuel
minimum, to 150°F
(66°C) maximum
manual
manual
to outside air
temperature
m. VSV schedule See applicable Correct as required per
figure in WP 118 00 WP 118 00
shut down.

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ADDENDUM O

1. Set gas turbine at idle power Gas generator decel- Emergency shut down
(unloaded) erates
2. After stabilizing for 3 minutes, read
and record the following:
a. Oil pressure See applicable figure Automatic normal shut-
in Chapter 5 down if below 8 psig
(55 kPa)
Natural gas See figure 10
Liquid fuel See figures 6
through 9
d. T5.4 Approximately Troubleshoot and take
1000ºF (538ºC) corrective action
e. NPT 1200 - 1900 rpm
(-54ºC to +66ºC)
Liquid fuel 20ºF (11ºC) above
wax point of fuel
minimum to 150ºF
(66ºC) maximum
manual

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ADDENDUM O

manual
3. After stabilizing at idle for T5.4 drops below Manually shut off fuel
5 minutes, close fuel valves 400ºF (204ºC) NGG supply
and NPT decelerate
and stop
4. Observe T5.4 for 3 minutes after 700ºF (371ºC) Motor gas turbine. Con-
shutdown tinue motoring until tem-
perature decreases

O-30
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ADDENDUM O
ager’s manual.
9-3.2 Interlocks. Refer to packager’s manual SHALL BE KEPT OPEN. IF THE
9-3.3 Operation. TIONED AT THE ENCLOSURE
WARNING BE FOLLOWED.
• THE GAS TURBINE SHALL BE LATED GLOVES AS
SHUT DOWN. NECESSARY.

• THE FIRE EXTINGUISHING a. When entering enclosure during gas
SYSTEM SHALL BE MADE turbine operation, wear proper ear protection.
THE CUSTOMER’S b. Start and operate the gas turbine per
PROCEDURES. Table 5. Do not exceed operating limits of
Table 3.

per Table 7.

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ADDENDUM O
e. Refer to paragraph 5-3.30 and 5-3.31, 9-5 SPECIAL GAS TURBINE
V-21B, V-21E, and V-21F, and figures 5-32A, 9-5.1 General. Under normal operating con-
5-32B, 5-32E, 5-32F, 5-32J, 5-32L, 5-32N, ditions, the gas turbines are constrained by the
and 5-32Q.) operating limits published in the limits table.
NOTE shutdown or “trip” level should not be
Refer to figures 5 through 9 for fuel practiced.
system requirements when operating In the event that any of the following situations
on natural gas, liquid gas or a combina- or events occur, the associated special action
tion of the two. or limitation must be followed in order to
9-4 EMERGENCY OPERATION. assure the gas turbines continued normal oper-
ation. These events are either not detected or
9-4.1 Emergency Shutdown. not prevented by the customary protective
devices of control systems.
be shut down from any power setting by clos- • Overtemperature During Starting
ing the natural gas and/or liquid fuel valve.
However, this should only be done in an emer- • Lube Oil Pressure
gency, since rapid shutdown will decrease life • High Speed Stalls
of gas turbine.
per Table 7. • Re-Start Following High Power Trip
9-4.2 Post Shutdown Fire. • No Power Turbine Rotation
a. During a normal shutdown, exhaust • Gas Generator Windmilling
time gas turbine is coasting to stop, tempera- 9-5.2 Overtemperature. During starting and
ture increases instead of decreases, it indicates acceleration to idle, cooling flows to compo-
that combustion is still taking place because of nents of the gas turbine hot section are not suf-
a leaking fuel valve. (A slight temperature ficient to protect the metals at T5.4 alarm and
increase after rotation stops is normal.) Make trip levels specified in the limits table. A lower
certain fuel is shut off, and motor the gas gen- T5.4 limit is therefore established, with higher
erator. This will blow out the fire. As soon as levels acceptable provided they exist for lim-
temperature decreases to normal, discontinue ited times as depicted on the curve titled
motoring. “Transient Temperature Limits for Starts”.

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ADDENDUM O
Figure 5. Dual Fuel System Flow Versus Pressure Drop Characteristic

O-33
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ADDENDUM O
Figure 6. Dual Fuel System - Flow Divider Pressure vs. Total Liquid Fuel Flow

O-34
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ADDENDUM O
Figure 7. Dual Fuel System - Primary Manifold Pressure vs. Total Liquid Fuel Flow

O-35
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ADDENDUM O
Figure 8. Dual Fuel System - Secondary Manifold Pressure vs. Total Liquid Fuel Flow

O-36
GEK 97310
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ADDENDUM O
Figure 9. Dual Fuel System - Gas Flow Rate vs. Manifold Pressure

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GEK 97310
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ADDENDUM O
9-5.3 Lube Oil Supply Pressure. The lube oil c. There is no duty cycle limit on the
supply pressure limits given in the limit table hydraulic starter.
are “distress” limits. Protective devices cannot
reliably monitor supply pressure because the 9-5.6 Re-Start Following High Power Trip.
proper pressure is dependent on gas generator In the event that re-start of the gas turbine is
speed, oil type, oil temperature, and number of required within two (2) hours following a trip
oil jets. An operator must therefore derive a or rapid shutdown from high power, a five (5)
corrected oil pressure as directed on the appro- minute cranking at 2400 rpm should precede
priate pressure correction table in Chapter 5 to the fire up. The objective is to cool the high
determine if the lube system is performing pressure turbine rotor, so that blade tips main-
within the high-low limits stated on each table. tain clearance with the more rapidly cooling
case.
9-5.4 High Speed Stall. Stalls incurred at gas
generator rotational speeds above 7500 rpm 9-5.7 No Power Turbine Rotation. A ther-
can result in high pressure compressor blade mally bound power turbine rotor could occur
fracture. The gas turbine can be operated after under extreme conditions following a rapid
an inspection of the compressor stages 3 shutdown from high power. Power turbine
through 6 verifies that blade tip clanging has rotation should initiate during gas turbine
not occurred. If tip clanging has occurred, fur- acceleration to idle. If rotation does not occur,
ther inspection and stress relief of the blades is the following procedure should be used:
required, which necessitates blade removal
from the spool. a. Remain at idle for 30 seconds and shut
down.
Gas.
40 psig (276 kPa): d. Refire and accel to 6000 rpm. Do not
• 45 Seconds, on 2 minutes off for any exceed 6000 rpm. Power turbine should break
number of cycles, away. If not, shut down and investigate for
or,
9-5.8 Windmilling.
• 5 minutes on, 2 minutes off with two speeds, the lube supply and scavenge systems
such cycles in any 30 minute period, are in normal operation.

• 10 minutes on, 20 minutes off for any with successive periods allowed if preceded by
number of cycles. normal gas turbine operation.
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GEK 97310
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ADDENDUM O
CAUTION
1. Conditions permitting, decelerate gas T5.4 drops below Manually shut off fuel
turbine to idle and close fuel valves 400ºF (204ºC) and supply
NGG and NPT
decelerate
2. Observe T5.4 for 3 minutes after 700ºF (371ºC) max. Motor gas turbine. Con-
shutdown tinue motoring until
(621ºC) has occurred, and a “hot restart”
turbine can be restarted within
1 minute following coastdown of the
procedure.
rpm NGG for 5 minutes. At the end of
the 5 minute motoring/purge cycle,
perform normal restart and accelerate
to idle. Acceleration to the desired
accomplished.

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ADDENDUM O
Tables 8 through 11. DELETED

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O-41/(O-42 Blank)
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ADDENDUM
7LM2500-PE-NG

GEK 97310
VOLUME I
ADDENDUM P
TABLE OF CONTENTS
1-0 INTRODUCTION....................................................................................... P-3

2-0 REFERENCE DATA .................................................................................. P-3
3-0 INSTALLATION DRAWINGS.................................................................. P-4
4-0 EQUIPMENT DESCRIPTION ................................................................. P-4
5-0 INSTRUMENTATION AND SUPPLY REQUIREMENTS ................... P-4
6-0 SERVICE REQUIREMENTS ................................................................... P-4
6-1.1 Natural Gas ................................................................................................... P-4
7-0 OPTIONAL HARDWARE KITS - 7LM2500-PE-NG............................. P-7
8-0 GAS TURBINE OPERATION .................................................................. P-7
8-1.1 Performance Ratings and Operating Limits.................................................. P-7
8-1.2 Performance Ratings ..................................................................................... P-8
8-1.3 Operating Limits ........................................................................................... P-9
8-2 INITIAL OPERATION .............................................................................. P-9
8-2.1 General .......................................................................................................... P-9
8-2.2 Special Instrumentation Required for Operation .......................................... P-9
8-2.3 Special Instrumentation Required for Monitoring and Troubleshooting ...... P-13
8-2.4 Preparation .................................................................................................... P-13
8-2.5 Gas Turbine and Associated Equipment Check List..................................... P-13
8-2.6 Governor and Manual Control Check........................................................... P-14
8-2.7 Start-up and checkout.................................................................................... P-14
8-2.8 Ignition Check............................................................................................... P-15
8-2.9 Motoring........................................................................................................ P-16
8-2.10 False Start...................................................................................................... P-16
8-2.11 Governor Check ............................................................................................ P-16
8-2.12 Wet Prestart ................................................................................................... P-16
8-2.13 Manual Start and Operation .......................................................................... P-16
8-2.14 Operation to Maximum Power...................................................................... P-22
8-2.15 Automatic Operation..................................................................................... P-22
8-3 NORMAL OPERATION............................................................................ P-24
8-3.1 General .......................................................................................................... P-24
8-3.2 Interlocks....................................................................................................... P-24
8-3.3 Operation....................................................................................................... P-24
8-4 EMERGENCY OPERATION ................................................................... P-25
8-4.1 Emergency Shutdown ................................................................................... P-25
8-4.2 Post Shutdown Fire ....................................................................................... P-25
8-5 SPECIAL GAS TURBINE CONSTRAINTS ........................................... P-27
8-5.1 General .......................................................................................................... P-27
8-5.2 Overtemperature............................................................................................ P-27
8-5.3 Lube Oil Supply Pressure ............................................................................. P-27
8-5.4 High Speed Stall............................................................................................ P-27
8-5.5 Starter Duty Cycle - Air or Natural Gas........................................................ P-28

P-1
GEK 97310
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ADDENDUM P
8-5.6 Re-Start Following High Power Trip ............................................................ P-28

8-5.7 No Power Turbine Rotation .......................................................................... P-28
8-5.8 Windmilling .................................................................................................. P-28
Figure Title Page
1 Transient Temperature Limits ....................................................................... P-21

2 Deleted
3 Deleted
4 Deleted
5 Deleted
LIST OF TABLES
Table Title Page
1 INSTRUMENTATION CONNECTIONS - 7LM2500-PE-NG.................... P-5

2 SUPPLY CONNECTIONS-7LM2500-PE-NG............................................. P-6
3 GAS TURBINE OPERATING LIMITS....................................................... P-9
4 PRESTART CHECKS .................................................................................. P-15
5 START-UP AND OPERATION.................................................................... P-17
6 GAS TURBINE SHUTDOWN .................................................................... P-23
7 EMERGENCY SHUTDOWN...................................................................... P-25
8 DELETED
9 DELETED
10 DELETED
11 DELETED

P-2
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ADDENDUM P
The information contained herein describes the Compressor Rotor 552 (250)
7LM2500-PE-NG model gas turbine basic Compressor Stator, Front 307 (139)
configuration and control system differences. Compressor Stator, Rear 93 (42)
instrumentation and supply connections, spe- Compressor Rear Frame 421 (191)
instructions for the 7LM2500-PE-NG model
are included.
Stg 1 68 (31)
2-0 REFERENCE DATA. High Pressure Turbine Nozzle,
Stg 2 127 (58)
(General Electric Co., Cincinnati, Ohio) Low Pressure Turbine Stator 601 (273)
Model No. 7LM2500-PE-NG Turbine Rear Frame 1071 (486)
Dwg. No. L31430G11 High Speed Coupling Shaft
Forward Adapter 91 (41)
PERFORMANCE RATING
Exhaust Duct Assembly 2741 (1243)
Refer to paragraph 8-1.1 Exhaust Duct 1565 (710)
Outer Cone 410 (186)
GAS TURBINE WEIGHTS Inner Deflector 255 (116)
The average weights of the major gas turbine Ring Seal 49 (62)
components are: Ring Support 74 (34)
Component Wt-Lbs/(Kg) Cover, Insulation 62 (28)
Gas turbine - including inlet Variable Stator Actuating
duct, centerbody, exhaust dif- Mech 19 (9)
fuser, and coupling nut 7396 (3355) Outside Piping and Bracketing 278 (126)

P-3
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ADDENDUM P
DRAWING LIST 6-0 SERVICE REQUIREMENTS.
Drawing No. 6-1.1 Natural Gas.

Gas Turbine Installation L31705 a. The required supply pressure to the
Drawing natural gas fuel manifold on the gas turbine is
Fuel System Flow Diagram L24327 355 ± 5 psig (2448 ± 35 kPa) maximum.
Diagram b. The temperature of the gas supply at
must be in the range of 20°F (-6.7°C) above
Ignition Units L21454 the saturated vapor temperature of the gas at
Gas Turbine Assembly L31430G11 the supply pressure as a minimum, and 350°F
Drawing (177°C) as a maximum. Based on consider-
3-0 INSTALLATION DRAWINGS. it is recommended that the maximum gas sup-
A complete set of installation drawings have ply temperature be limited to 150°F (66°C). If
been provided. the supply temperature of the gas is not repeat-
able on a day-to-day basis, it will be necessary
4-0 EQUIPMENT DESCRIPTION. to change the control system starting fuel
The 7LM2500-PE-NG is a natural gas fueled, adjustment or to adjust the supply pressure to
non-marinized gas turbine. the gas turbine to maintain a constant
BTU-per-cubic-foot supply. Once started the
5-0 INSTRUMENTATION AND SUP- gas turbine will accept variations in supply
PLY REQUIREMENTS. temperature of ±20°F (±11°C). The maximum
(See Tables 1 and 2.) fuel flow required, assuming a lower heating
value of 19, 000 BTU/lb is 13, 500 pph
(6123 kg/h) for the 7LM2500-PE-NG model
gas turbine.

P-4
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Table 1. INSTRUMENTATION CONNECTIONS - 7LM2500-PE-NG

E1 Vibration pickup, Gas Generator Diagnostic System Corp.
Part No. 303-03
E13 Vibration pickup, power turbine Diagnostic System Corp.
Part No. 303-03
A9 Compressor inlet total pressure probe (optional) MS33656-6
(optional)
NOTE
turbine.

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ADDENDUM P
Table 2. SUPPLY CONNECTIONS-7LM2500-PE-NG
Mechanical Interface Connections Mates with:
CAUTION
F1 Natural gas supply 2 inch line from Fuel Control Unit to Gas Turbine Fuel
Manifold
L1 Oil Supply 1-1/2 inch line to Lube Pump on Gas Turbine AN818-24C or
MS20819-24C
AN818-16C or MS20819-16C
L4 Lube supply inlet port 1 inch line from Oil Supply Filters to Gas Turbine
AN818-16C or MS20819-16C
L3 Scavenge oil discharge 1-1/4 inch line from Gas Turbine Scavenge Pump to Oil
A6 Starter Air or Gas Inlet Port
A7 Starter Air or Gas Outlet
Port
A12 Air/Oil Separator 3 inch line from air/oil separator to atmospheric vent or to
Turbine Inlet Duct AN818-16C or MS20819-16C
NOTE
turbine.

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ADDENDUM P
7LM2500-PE-NG.
pany for the 7LM2500-PE-NG Gas Turbine. IN UNDUE STRESS BEING
ume I, Chapter 4, TROUBLESHOOTING. 8-1.1 Performance Ratings and Operating
Limits.
trial Engine Department; Cincinnati, Ohio turbine manual limits.
45215.

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8-1.2 Performance Ratings. b. Starting fuel flow for the
7LM2500-PE-NG model gas turbine is nor-
a. The rated performance of the mally set by the minimum stop on the gas fuel
7LM2500-PE-NG gas turbine in the new and metering valve. The proper fuel flow setting
clean condition is as follows: for the minimum stop, on a heat consumption
basis, is 10.45 x 106 ± 0. 46 x 106 BTU/hour
Power Turbine Speed for ambient temperatures of -65°F (-54°C) to
+130°F (54°C), and is based commencing fuel
3600 rpm 3000 rpm
and ignition at 1200 ± 100 rpm. Where a mini-
• Shaft Horsepower mum stop is not utilized, acceptable light-offs
can be obtained in the sub-idle region, how-
-Base 29,500 28,500
ever during such starts, ignition should be ini-
-Maximum 32,000 30,000 tiated at that fuel flow corresponding to the
• Heat Rate, BTU/HP-Hr
-Average (Base) 6874 7081 to Gas Turbine Installation Design Manual
MID-IDM-2500-9.
-Average 6908 7125
(Maximum) c. Refer to Installation Design Manual
MID-IDM-2500-9 for the LM2500-PE-NG
Based on the following conditions: gas turbine model transient fuel flow
requirements.
Inlet Air Temperature 59°F 59°F (15°C)
(15°C) d. Acceleration fuel rates greater than
Altitude Sea Level Sea Level and possible stall of the gas turbine. Accelera-
Inlet Losses 0” H2O 0” H2O tion fuel rates lower than those shown can
result in “hung” starts in the below idle speed
Exhaust Losses 0” H2O 0” H2O
range.
e. Above the idle speed point, low accel-
Compressor Bleed 0 0
Accessory Power 0 0 and will only result in slower acceleration
Extraction times.
Power Turbine Inlet
Gas Temperature, f. For normal accelerations from idle to
T5.4 Avg. power settings the changes should be made
- At Base Rating 1461 1449 section repairs and the life of the gas turbine; a
- At Maximum 1551 1516 time of 2 to 3 minutes is reasonable.
Rating

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ADDENDUM P
h. Normal decelerations from maximum 8-2.2 Special Instrumentation Required for
power to idle should be made in approximately Operation.
Gas Generator speed.............. 0-11,000 RPM
sensor
gas turbine.
Lube oil scavenge temper-..... 0-400°F
8-1.3 Operating Limits. Refer to Table 3. ature sensors (A-, B-, C-, D- (-18 to 204°C)
sumps and transfer gearbox)
NOTE
Lube oil supply temper-......... 0-400°F
If any operating limit is exceeded, ver- ature sensor (-18 to 204°C)
Vibration indicators ...............
0-4 in/sec or
generator.
Power turbine.........................
0-2 in/sec
8-2 INITIAL OPERATION. 0-15 mil DA
8-2.1 General. Initial operational period is Power turbine speed sensor ... 0-5000 RPM
that period of operation immediately following Power turbine inlet gas .......... 0-2000°F
gas turbine replacement or major maintenance temperature (T5.4) (-18 to 1093°C)
on the system. Lube oil supply pressure........ 0-100 psig
(0-690 kPa)

Alarm/ Normal
NOTE
above 8000 rpm
Pressure

P-9
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VOLUME I
ADDENDUM P
Alarm/ Normal
Scavenge Dis- (759 kPa ± 69 kPa) (69 - 690 kPa) charge Pressure
180 psig
(1242 kPa)
Gas Turbine Alarm 180° - 220°F 140° - 160°F Normal Operating
Lube Supply (82° - 104°C) (60° - 71°C) Range reflects
expected during
operation above
idle speed
Lube Scavenge (166° - 177°C) (71° - 135°C) Range reflects
Temperatures - temperature
Five expected during
operation above
Alarm 290° - 310°F
idle speed
(143° - 154°C)
Fuel System Fuel 0 - 355 psig Supply Pressure as
(Natural Manifold (0 - 2448 kPa) reflected at the
Gas) Pressure fuel manifold inlet
on the gas turbine
Fuel Supply Alarm 150° - 170°F -65° to 150°F Starting Fuel Flow
Temperature (66° - 77°C) (-54° to 66°C) Adjustments may
be required to
compensate for
fuel temperature
variation
Pressure based on gas tur-
bine starter torque
requirements
Fuel and Ignition

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ADDENDUM P
Alarm/ Normal
Fuel and ignition for start after
used)
simultaneously
with start initia-
tion
Failure to Trip 380° - 420°F T5.4 Activate 10 sec-
simultaneously
with application of
fuel and ignition.
simultaneously
with start initia-
tion. De-Energize
ignition, fuel sys-
tem and starter air
supply
gize fuel and igni-
tion systems and
starter air supply
Power Tur- Failure to Trip 380°- 420°F 0° - 1600°F Trip if temperature
bine Inlet Light-Off (193° - 216°C) (0°- 871°C) does not reach
Temperature 400°F (204°C)
within 10 seconds
tion are applied

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ADDENDUM P
Alarm/ Normal
Overtemperature:
Power Turbine Speed
3000 rpm 3600 rpm
(857°C) (857°C)
Alarm 1525°F 1540°F
(829°C) (838°C)
Vibration Gas Generator Trip 7 mils DA 0 - 3 mils DA Avoid continuous
operation above 4
mils
Alarm 4 mils DA
Power Turbine Trip 10 mils DA 0 - 6 mils DA Avoid continuous
operation above 7
mils
Alarm 7 mils DA
Speed
(For 60 Hz) Gas Generator Trip 10,200 rpm 0 - 10, 100 rpm
(For 50 Hz) Gas Generator Trip 10,200 rpm 0 - 10,100
upon loss of flame
NOTE
considered.

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8-2.3 Special Instrumentation Required for f. All service connections _________
Monitoring and Troubleshooting: made and secure
Fuel manifold pressure .......... 0-400 psi g. All lines have been flushed _________
sensor (0-2758 kPa) per Packager’s manual
Compressor inlet total pres-... 10-16 psia h. All instrumentation connec- _________
sure sensor (69-110 kPa) tions made and secure
Power turbine inlet gas .......... 0-75 psia i. All accessories are secure _________
pressure (0-517 kPa) per Packager’s manual
Compressor discharge............ 0-300 psig j. Gas turbine assembly free of _________
pressure (0-2068 kPa) loose objects and all lines/
Fuel supply pressure .............. 0-400 psig electrical leads connected
(0-2758 kPa) k. Gas turbine inlet air area _________
Fuel supply temperature ........ 0-250°F free of foreign objects. Inlet
(-18 to 121°C) screen secure
Gas turbine inlet air ............... -65 to 150°F l. Gas turbine compressor rear _________
temperature (-54 to 66°C) frame leakage ports, struts,
Lube oil scavenge pressure.... 0-200 psig 7 and 10, are open (not
(0-1377 kPa) capped)
Remote reading variable........ -5° to +45° m. Continuous lube supply _________
vane indicator starter is initially serviced
Starter air supply pressure ..... 0-50 psig per Packager’s manual
(optional) (0-345 kPa) n. Lube oil storage tank ser- _________
viced to full level
ciated systems must be inspected and checked o. Lube oil supply valves open _________
out for proper installation and operation before p. All filters serviced per Pack- _________
normal operation can commence. ager’s manual
8-2.5 Gas Turbine and Associated Equip- q. Fire alarm/extinguish sys- _________
ment Check List. Complete the following tem ON and operative
checklist. r. T5. 4 thermocouple system _________
a. Gas Turbine Assembly S/N _________
b. Mounting base secured to _________
foundation t. Compressor inlet total pres- _________
c. Intake air and exhaust gas _________ and free of damage
ducts in place and secured
u. Variable stator system _________
d. Bonding straps in place and _________ secure
secure
v. Required checks and inspec- _________
e. Gas turbine and exhaust _________ tions specified in Packager’s
duct support mounts and manual for gas turbine con-
links in place and secure trol have been performed

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ADDENDUM P
8-2.7 Start-up and checkout.
LATED GLOVES AS
WARNING
NECESSARY.
MET: OPERATING.
MOTORING THE GAS
TURBINE.
ENTRY SHOULD BE
PROCEDURES.
ING OR CLOSING THE
paragraph 8-2.12.
paragraph 8-2.13.
paragraph 8-2.15.

P-14
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ADDENDUM P
Item Requirements
Fuel valves Closed
Ignition Off
Ventilation inlet air (secondary cooling air) Off - air temp. below 70°F (21°C)
Oil tank level Full
Lube oil temperature Above +20°F (+1°C) for MIL-L-23699
Above -20°F (-29°C) for MIL-L-7808
pressure at manifold inlet 50 psig max. (345 kPa)
temperature -65° to 150°F (-54° to 66°C)
flow See paragraph 8-1.2, step b.
8-2.8 Ignition Check. b. Disconnect number one ignition exciter

WARNING
• ASSURE POWER TO IGNITION c. Turn on electrical power to the ignition
SYSTEMS IS OFF WHEN DIS- system (No. 2 ignition exciter energized). An
CONNECTING AND CONNECT- audible report (approximately two sparks per
ING IGNITION EXCITER INPUT second) should be heard when the No. 2 spark
LEAD. TAG SWITCH OUT OF igniter fires.
VERTENT ACTIVATION. d. Turn off electrical power to the ignition
• ASSURE FUEL VALVES ARE safety-wire connector.
PROCEDURE. e. Repeat steps b, c and d, disconnecting
the No. 2 exciter.
fuel, motor gas turbine for one minute; allow f. If an audible report is not heard on No.
gas turbine to coast down. 1 and/or No. 2 igniters, check out the system to
rective action.

P-15
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ADDENDUM P
8-2.9 Motoring. After all preliminary checks a. With ignition lead disconnected, but
have been completed and lines flushed, gas with manual gas valve open and governing
generator can be motored as follows: system operating, make automatic start of gas
turbine per Packager’s manual.
systems inoperative as follows: b. Gas generator should accelerate to
tion unit.
(2) Close natural-gas manual shutoff supply if required. Start will then abort
valve to fuel control unit. because of lack of flame.
b. Depress MOTORING pushbutton. Gas c. Allow gas turbine to coast to stop; then
turbine will start to rotate. If it does not, refer motor it to purge any remaining natural gas
to Packager’s manual for supply pressure to from gas turbine. Continue to motor for
starter. 60 seconds to purge fuel from the gas turbine.
c. Hold MOTORING pushbutton closed 8-2.13 Manual Start and Operation. Perform
until gas generator speed stabilizes, and check manual start per Packager’s manual with fuel
for oil pressure. If there is no indication of oil valve open and with ignition lead connected.
pressure, release MOTORING pushbutton; Refer to Table 5.
while gas turbine is coasting down, loosen oil
fittings at lube pump to bleed air from system. CAUTION
of 2200 RPM. DO NOT EXCEED 6000 RPM NGG
d. Repeat motoring and bleeding proce- BINE OPERATION WITHOUT
dure until an indication of oil pressure appears. POWER TURBINE ROTATION.
8-2.10 False Start. Perform false start as a. The power turbine must rotate by the
NGG. If Power turbine speed indication is not
a. With ignition leads disconnected and obtained and it is determined that a “thermal
manual gas valve closed, make automatic start seizure” of the power turbine has occurred,
of gas turbine per Packager’s manual. proceed as follows:
b. Gas turbine should go through normal NOTE
start cycle and then abort because of lack of
flame. Power Turbine except in a new installa-
tion will be rotating when gas genera-
8-2.11 Governor Check. Check governor sys- tor idle speed is attained.
tem per Packager’s manual.

follows:

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ADDENDUM P
NOTE the various power turbine components.
Thermal seizure of the power turbine The possibility of thermal seizures can
rotor can occur when a hot gas turbine be reduced by operating the gas turbine
is shut down and is most likely to occur at idle power for at least five minutes
within 30 to 40 minutes following gas prior to shutdown to achieve proper
turbine operation. Thermal seizure is cooling of the power turbine.
rotor is prevented from rotating by hard (1) Shutdown gas turbine.
shrouds, interstage seals and other (2) Immediately after the gas turbine
internal interference. This condition is stops rotating, re-start and stabilize at idle
the result of unequal cooling rates of speed (4950 ± 50 rpm) for 30 seconds.

CAUTION
IF T5.4 RAPIDLY APPROACHES OR EXCEEDS VALUES SHOWN IN FIGURE 1,
EXCEEDED PERFORM OVERTEMPERATURE INSPECTION.
NOTE
NOTE
3. At 1100 to 1300 RPM NGG
a. Ignition on
(21 kPa). See paragraph 8-1. 1
c. Note time to lightoff 10 seconds max. Abort start-automatic shut-
(T5.4 above 400°F/ down. Investigate/correct
204°C) 1200 RPM cause.

P-17
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ADDENDUM P
reach 4300 RPM
5. At 4300 to 4700 RPM NGG
should close supply.
automatically
6. Note time to 5000 RPM NGG 90 seconds maximum
a. Oil pressure See applicable figures in Alarm at 8 ± 1 psig
Trip at 6 ± 1 psig
(41 ± 6.9 kPa)
c. T5.4 1000°F (538°C) max. Emergency shutdown -
Table 7
d. NPT (unloaded) 1200 - 1900 RPM Troubleshoot and correct as
required
action
action
g. Compressor inlet tem- Approximately equal to out- Troubleshoot sensing and
perature (T2) side air temperature indicating system. Correct
as required

P-18
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ADDENDUM P
leaks
i. Maximum NGG with 6000 RPM NGG maximum Shut down and investigate/
8. Set desired power setting. Less than alarm limit Correct as required. Refer
sient operation
b. NGG *
NOTE
c. NPT 0 - 3960 RPM *
d. Oil Pressure See applicable table and fig- Emergency or automatic
out of limits
e. Scavenge oil temperature 160°F to 275°F Alarm at 290-310°F
(71°C to 135°C) (143-154°C); automatic
shutdown if above 340°F
(171°C)
shutdown
7 mils max (Alarm) Emergency or automatic
10 mils max. (Trip) shutdown
h. Fuel manifold pressure 355 psig (2448 kPa) max. **
i. Fuel inlet temperature -65° to 150°F (-54° to +66°C) **

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ADDENDUM P
WP 118 00 WP 118 00
shutdown.

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ADDENDUM P

P-21
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ADDENDUM P
(3) Repeat steps (1) and (2) for two b. Operate gas turbine up to rated power,
additional start-up and shutdown cycles. if possible, but do not exceed exhaust gas tem-
(4) If the power turbine does not until all temperatures stabilize. If governing
rotate after accomplishing substeps (1) through system is unstable, adjust per Packager’s
(3), shut down the gas turbine. manual.
(5) Immediately after gas turbine c. Log all instrument readings once they
rotation stops, re-start and accelerate to stabilize. Refer to Table 5, step 9.
30 seconds. If the power turbine still does not d. Reduce gas turbine speed to idle. After
rotate, shut down and investigate/correct the stabilizing for three minutes, record all instru-
cause. During the investigation for the cause of ment readings. Refer to Table 6, step 2.
blades in stages 4, 5 and 6 for shingling and e. Check fail-safe section of control sys-
unlatching. If blades have become unlatched, tem per Packager’s manual.
encountered shingling may be bent thereby f. After gas turbine has been stabilized at
necessitating power turbine replacement. idle for five minutes, make normal shut-down.
8-2.15 Automatic Operation. Check automatic
CAUTION operation per Packager’s manual.
MANUAL OPERATION MAY a. Accelerate to idle.
TIVE CIRCUITS. OPERATING LIM- b. Accelerate to rated power.
(refer to Packager’s manual) to increase gas d. Decelerate to idle.
within limits, adjust it per work package
118 00. If vibrations are not within limits, con- g. Check lube oil and fuel filters and
sult the local General Electric Company repre- strainers; clean or replace as necessary.
sentative.


P-22
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ADDENDUM P

(unloaded)
following:
Trip at 6 ± 1 psig
(41 ± 6.9 kPa)
c. T5.4 Approximately 1000°F Troubleshoot and take cor-

e. Gas generator vibration 3 mils max. Alarm set at 4 mils Auto-

f. Power turbine vibration 6 mils max. Alarm set at 7 mils Auto-
g. Fuel inlet temperature -65° to 150°F (-54° to 66°C)
5 minutes, close fuel valves (204°C) NGG and NPT supply
4. Observe T5.4 for 3 minutes 700°F (371°C) Motor gas turbine. Con-
ature decreases

P-23
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ADDENDUM P
operation for normal operation, refer to Pack- DOOR AND CONFINED SPACE
BE FOLLOWED.
8-3.2 Interlocks. Refer to Packager’s manual
8-3.3 Operation.
WARNING SARY.
MET: OPERATING.

ENTRY SHOULD BE
REQUIRED DURING ENGINE a. When entering enclosure during gas
OPERATION, CONTACT GE turbine operation, wear proper ear protection.
FIELD SERVICE FOR A REPRE- b. Start and operate the gas turbine per
SYSTEM SHALL BE MADE d. Emergency shut down the gas turbine
INACTIVE ACCORDING TO per Table 7.
• SECONDARY AIR TO THE pressure characteristics. (See tables V-21A,
ENCLOSURE SHALL BE SHUT V-21B, V-21E, and V-21F, and figures 5-32A,
OFF. HIGH SECONDARY AIR- 5-32B, 5-32E, 5-32F, 5-32J, 5-32L, 5-32N,
FLOW MAY PREVENT OPEN- and 5-32Q.)
ING OR CLOSING THE
ENCLOSURE DOOR.

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ADDENDUM P
f. Idle lube oil pressure is 29 psig be done in an emergency, since rapid shutdown
(200 kPa) maximum after five minutes will decrease life of gas turbine.
stabilization.
g. The corrected operating pressure of the per Table 7.
Chapter 5 at standard conditions of 9000 rpm 8-4.2 Post Shutdown Fire.
gas generator speed and 150° F (66° C) lube
pump discharge temperature. Oil pressure a. During a normal shutdown, exhaust
measured at conditions other than standard gas temperature should decrease. If during
shall be corrected to standard conditions using time gas turbine is coasting to stop, tempera-
applicable table in Chapter 5. ture increases instead of decreases, it indicates
8-4 EMERGENCY OPERATION. a leaking fuel valve. (A slight temperature
certain fuel is shut off, and motor the gas tur-
a. In an emergency, the gas turbine may bine. This will blow out the fire. As soon as
be shut down from any power setting by clos- temperature decreases to normal, discontinue
ing the fuel valve. However, this should only motoring.

No. Normal Results Abnormal Results
CAUTION
1. Conditions permitting, decelerate gas T5.4 drops below 400°F Manually shut off
turbine to idle and close fuel valves (204°C) and NGG and fuel supply
NPT decelerate
2. Observe T5.4 for 3 minutes after shut- 700°F (371°C) max. Motor gas turbine.
down Continue motoring
until temperature
decreases

P-25
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VOLUME I
ADDENDUM P
Table 7. EMERGENCY SHUTDOWN (Cont.)

No. Normal Results Abnormal Results
procedure.
be accomplished.
using the normal starting procedure

P-26
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ADDENDUM P
8-5 SPECIAL GAS TURBINE 8-5.2 Overtemperature. During starting and
CONSTRAINTS. acceleration to idle, cooling flows to compo-
nents of the gas turbine hot section are not suf-
8-5.1 General. Under normal operating con- ficient to protect the metals at T5.4 alarm and
ditions, the gas turbines are constrained by the trip levels specified in the limits table. A lower
operating limits published in the limits table. T5.4 limit is therefore established, with higher
Continuous operation between the alarm and levels acceptable provided they exist for lim-
shutdown or “trip” level should not be ited times as depicted on the curve titled
practiced. “Transient Temperature Limits for Starts”.
In the event that any of the following situations overtemperature inspection called for by entry
or events occur, the associated special action into area B requires hot section disassembly
or limitation must be followed in order to and inspection in a qualified facility.
ation. These events are either not detected or 8-5.3 Lube Oil Supply Pressure. The lube oil
not prevented by the customary protective supply pressure limits given in the limit table
devices of control systems. are “distress” limits. Protective devices cannot
reliably monitor supply pressure because the
• Overtemperature During Starting proper pressure is dependent on engine speed,
oil type, oil temperature, and number of oil
• Lube Oil Pressure jets. An operator must therefore derive a cor-
rected oil pressure as directed on the appropri-
• High Speed Stalls ate pressure correction table in Chapter 5 to
• Starter Duty Cycle within the high-low limits stated on each table.
• Re-Start Following High Power Trip 8-5.4 High Speed Stall. Stalls incurred at gas
generator rotational speeds above 7500 rpm
• No Power Turbine Rotation can result in high pressure compressor blade
fracture. The gas turbine can be operated after
• Gas Generator Windmilling an inspection of the compressor stages 3
through 6 verifies that blade tip clanging has
not occurred. If tip clanging has occurred, fur-
from the spool.

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ADDENDUM P
8-5.5 Starter Duty Cycle - Air or Natural 8-5.7 No Power Turbine Rotation. A ther-
Gas. mally bound power turbine rotor could occur
under extreme conditions following a rapid
a. With starter inlet air pressure set at shutdown from high power. Power turbine
40 psig (276 kPa). rotation should initiate during gas turbine
acceleration to idle. If rotation does not occur,
• 45 seconds on, 2 minutes off for any the following procedure should be used:
number of cycles,
a. Remain at idle for 30 seconds and shut
or, down.
• 2 minutes on, 5 minutes off with b. Refire and repeat Item a.

two such cycles in any 30 minute
period. c. Refire and repeat Item a.
b. With starter inlet air pressure set at d. Refire and accel to 6000 rpm. Do not
15 psig (103 kPa). exceed 6000. Power turbine should break
• 5 minutes on, 2 minutes off with unlatched or shingled blades, or other cause.
two such cycles in any 30 minute
period, 8-5.8 Windmilling.
or, a. Unlimited windmilling or cranking of

• 10 minutes on, 20 minutes off for speeds above 1000 rpm provided the lube oil
any number of cycles. temperature limits are not exceeded. At these
c. There is no duty cycle limit on the are in normal operation.
hydraulic starter.
b. Below 1000 rpm gas generator speeds,
8-5.6 Re-Start Following High Power Trip. windmilling is allowed up to five (5) minutes,
In the event that re-start of the gas turbine is with successive periods allowed if preceded by
required within two (2) hours following a trip normal gas turbine operation.
minute cranking at 2400 rpm should precede
the fire up. The objective is to cool the high
tain clearance with the more rapidly cooling
case.

P-28
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TABLES 8 through 11. Deleted

P-30
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ADDENDUM Q
ADDENDUM
7LM2500-PE-NGX

GEK 97310
VOLUME I
ADDENDUM Q
TABLE OF CONTENTS
1-0 INTRODUCTION....................................................................................... Q-3

2-0 REFERENCE DATA .................................................................................. Q-3
3-0 INSTALLATION DRAWINGS.................................................................. Q-4
4-0 EQUIPMENT DESCRIPTION ................................................................. Q-4
5-0 NOX SUPPRESSION (STEAM INJECTION SYSTEM)....................... Q-4
6-0 INSTRUMENTATION AND SUPPLY REQUIREMENTS ................... Q-5
7-0 SERVICE REQUIREMENTS ................................................................... Q-7
7-1.1 Natural Gas ................................................................................................... Q-7
7-1.2 Steam Servicing Requirements (NOX Suppression) .................................... Q-7
8-0 OPTIONAL HARDWARE KITS - 7LM2500-PE-NGX.......................... Q-7
9-0 GAS TURBINE OPERATION .................................................................. Q-7
9-1 PERFORMANCE RATINGS AND OPERATING LIMITS .................. Q-8
9-1.1 Performance Ratings ..................................................................................... Q-8
9-1.2 Steam Scheduling Requirements During Operations (NOX Suppression)... Q-9
9-1.3 Operating Limits ........................................................................................... Q-15
9-2 INITIAL OPERATION .............................................................................. Q-19
9-2.1 General .......................................................................................................... Q-19
9-2.2 Special Instrumentation Required for Operation .......................................... Q-19
9-2.3 Special Instrumentation Required for Monitoring and Troubleshooting ...... Q-19
9-2.4 Preparation .................................................................................................... Q-19
9-2.5 Gas Turbine and Associated Equipment Check List..................................... Q-20
9-2.6 Governor and Manual Control Check........................................................... Q-20
9-2.7 Start-Up and Checkout.................................................................................. Q-21
9-2.8 Ignition Check............................................................................................... Q-23
9-2.9 Motoring........................................................................................................ Q-23
9-2.10 False Start...................................................................................................... Q-23
9-2.11 Governor Check ............................................................................................ Q-23
9-2.12 Wet Prestart ................................................................................................... Q-24
9-2.13 Manual Start and Operation .......................................................................... Q-24
9-2.14 Operation to Maximum Power...................................................................... Q-30
9-2.15 Automatic Operation..................................................................................... Q-30
9-3 NORMAL OPERATION............................................................................ Q-31
9-3.1 General .......................................................................................................... Q-31
9-3.2 Interlocks....................................................................................................... Q-31
9-3.3 Operation....................................................................................................... Q-31
9-4 EMERGENCY OPERATION ................................................................... Q-32
9-4.1 Emergency Shutdown ................................................................................... Q-32
9-4.2 Post Shutdown Fire ....................................................................................... Q-32
9-5 SPECIAL GAS TURBINE CONSTRAINTS ........................................... Q-32
9-5.1 General .......................................................................................................... Q-32
9-5.2 Overtemperature............................................................................................ Q-32

Q-1
GEK 97310
VOLUME I
ADDENDUM Q
9-5.3 Lube Oil Supply Pressure ............................................................................. Q-33

9-5.4 High Speed Stall............................................................................................ Q-33
9-5.5 Starter Duty Cycle - Air or Natural Gas........................................................ Q-33
9-5.6 Re-Start Following High Power Trip ............................................................ Q-33
9-5.7 No Power Turbine Rotation .......................................................................... Q-33
9-5.8 Windmilling .................................................................................................. Q-33
Figure Title Page
1 Natural Gas Fuel System with Steam Injection ............................................ Q-4

2 Deleted
3 Deleted
4 Deleted
5 Steam/Fuel Ratio Requirement when Operating on Natural Gas Fuel ......... Q-11
6 Steam/Fuel Premix Manifold Pressure vs. Fuel Flow Requirement at
Various Steam/Fuel Ratios............................................................................ Q-12
7 Recommended Minimum Steam/Gas Mixture Temperature vs. Steam/Fuel
Ratio Requirement to Prevent Condensation ................................................ Q-13
8 Transient Temperature Limits ....................................................................... Q-14
LIST OF TABLES
Table Title Page
1 INSTRUMENTATION CONNECTION, 7LM2500-PE-NGX .................... Q-5

2 SUPPLY CONNECTIONS - 7LM2500-PE-NGX........................................ Q-6
3 GAS TURBINE OPERATING LIMITS....................................................... Q-15
4 PRESTART CHECKS .................................................................................. Q-22
5 START-UP AND OPERATION.................................................................... Q-25
6 GAS TURBINE SHUTDOWN .................................................................... Q-29
7 EMERGENCY SHUTDOWN...................................................................... Q-34
8 DELETED
9 DELETED

Q-2
GEK 97310
VOLUME I
ADDENDUM Q
The information contained herein describes the Compressor Stator, Rear 93(42)
7LM2500-PE-NGX model gas turbine basic Compressor Rear Frame 421(191)
configuration and control system differences. Combustor 120(54)
cial servicing requirements, optional hardware High Pressure Turbine Nozzle, 68(31)
kits and the complete gas turbine operating Stage-1
instructions for the 7LM2500-PE-NGX model High Pressure Turbine Nozzle, 127(58)
are included. Stage-2
2-0 REFERENCE DATA.
EQUIPMENT Low Pressure Turbine Stator 601(273)
(General Electric Co., Cincinnati, Ohio) High Speed Coupling Shaft 91(41)
Model No. 7LM2500-PE-NGX Forward Adapter
Dwg. No. L31430G15 Variable Stator Actuating 19(9)
Mech
PERFORMANCE RATING Outside Piping and Bracketing 278(126)

DRAWING LIST Drawing No.
GAS TURBINE WEIGHTS Industrial Installation Dwg. L31705
The average weights of the major gas
Lubrication System Flow Dia. L24328
turbine components are:
Component Wt-Lbs/(Kg) Ignition Units L21454P02
Gas Turbine - including inlet Gas Turbine Assembly Dwg. L31430G15

Q-3
GEK 97310
VOLUME I
ADDENDUM Q
3-0 INSTALLATION DRAWINGS. system upstream of the fuel manifold and the
use of larger flow area fuel nozzles. The steam
A complete set of installation drawings have and natural gas are mixed prior to introduction
been provided. into the fuel manifold by means of a “tee” con-
nection exiting into a static mixer to ensure
4-0 EQUIPMENT DESCRIPTION. complete mixing of the steam and gas. The
mixer itself may have appropriate connections
The 7LM2500-PE-NGX is a natural gas fired which will delete the need for a separate tee
gas turbine with NOX suppression capability. (see figure 1). The LM2500 NOX suppression
system has been designed to meet the require-
5-0 NOX SUPPRESSION (STEAM ments of the U.S.E.P.A. standard for NOX
INJECTION SYSTEM). emissions for stationary gas turbines and
includes a conservative margin for meeting the
a. As an option, the 7LM2500-PE-NGX requirements of other, possibly more restric-
gas turbine can be equipped for suppression of tive, local codes where applicable.
oxides of nitrogen (NOX) in the gas generator
exhaust gases. This is accomplished by intro-
duction of steam into the natural gas delivery
Figure 1. Natural Gas Fuel System with Steam Injection

Q-4
GEK 97310
VOLUME I
ADDENDUM Q
SUPPLY REQUIREMENTS. (See
Tables 1 and 2.)
Table 1. INSTRUMENTATION CONNECTION, 7LM2500-PE-NGX
E1 Gas Generator Accelerometer Diagnostic System Corp. Part No. 303-03
E2 Power turbine inlet gas temperature MS3106R14S-9S
E3 A-sump RTD MS3106R12S-3S
E4 B-sump RTD MS3106R12S-3S
E5 C-sump RTD MS3106R12S-3S
E6 Accessory gearbox RTD MS3106R12S-3S
E10 Starter speed switch (optional) MS3106R10SL-4S
E11 Oil Supply RTD MS3106R12S-3S
E13 Gas Turbine Accelerometer Diagnostic System Corp. Part No. 303-03
E14 Power turbine speed pickup No. 1 MS3106R10SL-4S
A9 Compressor inlet total pressure probe
(optional) MS33656-6
A13 Power turbine inlet pressure probe
(optional) AN818-4C or MS9197-04
A23 CDP pressure tap .500-20UNJF
A18 CIT sensor pad .190-32UNJF
F3 Natural gas fuel manifold pressure tap
(optional) MS33656-4

Q-5
GEK 97310
VOLUME I
ADDENDUM Q
Table 1. INSTRUMENTATION CONNECTION, 7LM2500-PE-NGX - Continued
NOTE
turbine.
Table 2. SUPPLY CONNECTIONS - 7LM2500-PE-NGX

CAUTION
MAL GROWTH OF GAS GENERATOR WITHOUT PLACING STRAIN ON LINES OR
ON GAS GENERATOR.
F1 Natural gas supply 2 inch line from Fuel Control Unit to Gas Turbine
Fuel Manifold
L1 Inlet port lube pump 1-1/2 inch line to Lube Pump on Gas Turbine
AN818-24C or MS9197-24
L2 Discharge port lube pump 1 inch line from Lube Pump to Oil Supply Filters
AN818-16C or MS9197-16
L3 Lube pump scavenge oil discharge 1-1/4 inch line from Gas Turbine Scavenge Pump
to Oil Scavenge Filter and Cooler AN818-20C or
MS9197-20
L4 Inlet port lube supply line 1 inch line from Oil Supply Filters to Gas Turbine
AN818-16C or MS9197-16
A2 Bleed air 16th stage 16th stage compressor bleed air lines if used
(1.92 inch ID)
A3 Attachment flange exhaust duct
A4 Inlet duct seal flange (if required)
A6 Starter Air or Gas Inlet Port
A7 Starter Air or Gas Outlet Port
A10 CDP seal leakage No.1 (if required) 2-inch line
A12 Air/Oil Separator Discharge Port 3 inch line from air/oil separator to atmospheric

Q-6
GEK 97310
VOLUME I
ADDENDUM Q
Table 2. SUPPLY CONNECTIONS - 7LM2500-PE-NGX
D3 Fwd lube manifold drain AN818-6C or MS9197-06
D5 Aft lube drain manifold port AN818-6C or MS9197-06
S1 Waterwash manifold 3/4 inch line - hot water line to waterwash mani-
fold on Gas Turbine Inlet Duct AN818-12C or
MS9197-12
NOTE
7-0 SERVICE REQUIREMENTS. lated gas generator steam flow required to

meet the requirement of the applicable EPA
7-1.1 Natural Gas. standard or other local codes, corresponding
pressure level may be obtained from the tabu-
lar performance data sheets.
(2448 ± 35 kPa) maximum.
b. The temperature of the gas must be in 8-0 OPTIONAL HARDWARE KITS -
the range of 20°F (-6.7°C) above the saturated 7LM2500-PE-NGX.
vapor temperature as a minimum, and 350°F
(177°C) as a maximum. If the temperature is a. Refer to Volume II, WP 001 00 for a
not repeatable on a day-to-day basis it will be detailed list of optional kits available for this
necessary to change the starting fuel adjust- particular gas turbine model.
ment to adjust the supply pressure to the 9-0 GAS TURBINE OPERATION.
engine to maintain a constant Btu-per-cubic-
foot supply. The maximum fuel flow required a. These instructions contain the gas tur-
is 13,500 pph (6123 kg/h) with a lower heating bine operating procedures and limits recom-
value of 19,000 Btu/lb. mended by the General Electric Company for
the 7LM2500-PE-NGX Gas Turbine.
7-1.2 Steam Servicing Requirements (NOX
Suppression). b. The instructions are intended to pro-
a. The steam delivery pressure at the required to operate the gas turbine. They per-
manifold connection shall be 400 psig tain to routine and emergency conditions and
(2758 kPa) nominal. The temperature of the procedures. When a fault exists, refer to Vol-
steam supplied to the manifold shall be 600°F ume I, Chapter IV, TROUBLESHOOTING.
nominal, and shall be free of pressure pulsa-
tions in the 0 to 300 Hz range. The steam must
be controlled in a manner to prevent any sud-
den pressure spikes which could momentarily
displace the fuel. Other criteria, such as calcu-
Q-7
GEK 97310
VOLUME I
ADDENDUM Q
c. It is possible that these instructions 9-1.1 Performance Ratings.
equipment or contingency to be met in connec- a. The rated performance of the
tion with the operation of the gas turbine. 7LM2500-PE-NGX gas turbine in the new and
Refer requests for additional information to the clean condition as compared to gas turbine
General Electric Company; Marine and Indus- performance with steam injection, is as
trial Engine Division; Cincinnati, Ohio 45215. follows:
NOTE
WARNING
The use of steam injection to control
NOX emissions results in a change in gas
EXISTS, DO NOT OPERATE THE GAS
turbine performance. Unless specifically
TURBINE UNTIL A THOROUGH
agreed to in the applicable contract docu-
INVESTIGATION HAS BEEN MADE.
ments, all performance guarantees are
DO NOT REPEAT HOT STARTS,
based upon “dry” operation with no steam
COMPRESSOR STALLS, OR OTHER
injection.
RECOGNIZED PROBLEMS WITH-
OUT PRIOR THOROUGH INVESTI- With NOX
GATION. FAILURE TO DO SO CAN Normal Steam
RESULT IN UNDUE STRESS BEING (Dry) Suppression
IMPOSED ON GAS TURBINE COM- Brake 29,500 29,500
PONENTS, WITH IMMEDIATE OR Horsepower
SUBSEQUENT DESTRUCTIVE FAIL- Inlet Air 59°F(15°C) 59°F(15°C)
URE OF THE GAS TURBINE AND Temperature
INJURY TO PERSONNEL. Inlet Losses 0” H2O 0” H2O
NOTE Exhaust Back 0” H2O 0” H2O
Pressure
direct mathematical conversions and may Relative 60% 60%
be rounded off in most instances at the Humidity
users discretion. Examples of units that Altitude 0 Ft. 0 Ft.
may be rounded off are those utilized for Compressor 0 Lbs/Sec 0 Lbs/Sec
temperatures, torque values, pressures, Bleed
etc. Examples where S.I. units may not be Accessory 0 0
rounded off are those utilized for drop Horsepower
checks, rigging adjustments, runouts, etc. Extraction
9-1 PERFORMANCE RATINGS AND Power Turbine 3600 RPM 3600 RPM
OPERATING LIMITS. Speed
Heat Rate, Max6885 BTU/ 6822 BTU/
NOTE hp-hr hp-hr
Ratings published in this manual apply to Power Turbine 1458°F 1437°F
the gas turbine. The driven unit ratings/ Inlet Gas (792°C) (781°C)
limits may be lower in some cases and Temperature
shall take precedence over the gas turbine
manual limits.

Q-8
GEK 97310
VOLUME I
ADDENDUM Q
With NOX e. For normal accelerations from idle to
Normal Steam power settings the changes should be made
(Dry) Suppression more slowly to enhance the time between hot
Steam Injection 0 Lbs/Hr 3538 Lbs/Hr
(1605 kg/hr)
Fuel Flow 10690 Lbs/Hr 10592 Lbs/Hr f. The fuel rate shown on the curve will
(4849 kg/hr) (4805 kg/hr) give starting times to 5000 rpm (idle) of 60 to
NOX 184 *112 90 seconds and accelerations from idle to max-
Emissions imum power of 15 seconds.
(ppm at 15%
O2) g. Normal decelerations from maximum
*Limit is per US-EPA and is based upon power to idle should be made in approximately
29,500 BHP at 4-1 ISO or standard day condi- 2 to 3 minutes; this will enhance the time
tions for an electric utility application. between hot section repairs and the life of the
gas turbine.
b. Starting fuel flow for the
7LM2500-PE-NGX model gas turbine is nor- 9-1.2 Steam Scheduling Requirements Dur-
mally set by the minimum stop on the gas fuel ing Operations (NOX Suppression). (See
metering valve. The proper fuel flow setting Figures 5, 6, and 7.)
basis, is 10.45 x 106 ± 0.46 x 106 BTU/hour a. Steam flow must be scheduled as a
for ambient temperatures of -65°F (-54°C) to function of fuel flow and must be shut off dur-
+130°F (54°C), and is based on commencing ing starting and acceleration to idle. Steam
ignition and fuel at 1200 ± 100 rpm. Where a flow should be initiated at a fuel flow of
minimum stop is not utilized, acceptable light- 5700 pph ± 450 pph on acceleration when
offs can be obtained in the sub-idle region, operating on natural gas. Subsequently, the
however during such starts, ignition should be steam should be shut off at these points on a
initiated at that fuel flow corresponding to the deceleration. During initiation of steam flow,
minimum stop with its associated tolerance. If the gas turbine should be operating at a stabi-
starts in the sub-idle region are required, refer lized steady-state condition. Refer to figures
to Gas Turbine Installation Design Manual 5, 6, and 7 for steam/fuel ratios, manifold pres-
MID-IDM-2500-9. sure/flow requirements and temperature/ratio
requirements. During gas turbine accelera-
c. Acceleration fuel rates greater than tions adjust steam flow after gas turbine is on
those shown will result in overtemperature and point. Conversely during decelerations steam
possible stall of the gas turbine. Acceleration flow should be adjusted downward before gas
fuel rates lower than those shown can result in turbine decels. To avoid flame-out during rapid
“hung” starts in the below idle speed range. decelerations, it is recommended that transient
steam/fuel ratios in excess of 2.2 (lbs/lb) be
d. Above the idle speed point, low accel- avoided.
times.

Q-9
GEK 97310
VOLUME I
ADDENDUM Q

Q-10
GEK 97310
VOLUME I
ADDENDUM Q
Figure 5. Steam/Fuel Ratio Requirement when Operating on Natural Gas Fuel

Q-11
GEK 97310
VOLUME I
ADDENDUM Q
Figure 6. Steam/Fuel Premix Manifold Pressure vs. Fuel Flow Requirement at

Various Steam/Fuel Ratios

Q-12
GEK 97310
VOLUME I
ADDENDUM Q
Figure 7. Recommended Minimum Steam/Gas Mixture Temperature vs. Steam/Fuel

Ratio Requirement to Prevent Condensation

Q-13
GEK 97310
VOLUME I
ADDENDUM Q

Q-14
GEK 97310
VOLUME I
ADDENDUM Q
9-1.3 Operating Limits. Refer to table 3.
NOTE
troubleshooting or inspecting gas gen-
erator.
Alarm/ Normal
NOTE
Ranges (103 kPa ±
6.9 kPa) above
8000 rpm
(41 kPa ± 6.9 kPa) (135 - 413 kPa) 4500 rpm
Gas Turbine Alarm 110 psig ± 10 psig 10 - 100 psig Scavenge
Scavenge Dis- (759 kPa ± 69 kPa) (69 - 690 kPa) Discharge Pres-
charge Pressure sure shall not
exceed 180 psig
(1242 kPa)
Gas Turbine Alarm 180° - 220°F 140° - 160°F Normal
Lube Supply (82° - 104°C) (60° - 71°C) Operating Range
ture expected dur-
ing operation
above idle speed

Q-15
GEK 97310
VOLUME I
ADDENDUM Q
Alarm/ Normal
Gas Turbine Trip 330° - 350°F 160° - 275°F Normal

Lube Scavenge (166° - 177°C) (71° - 135°C) Operating Range
Five Alarm 290° - 310°F ture expected dur-
(143° - 154°C) ing operating
above idle speed
Fuel Fuel/Steam 355 psig Normal Supply
System Supply Pressure (2448 kPa) Pressure as
(Natural reflected at the
Gas) fuel manifold inlet
Fuel/Steam Sup- Alarm 400°F (See paragraph
ply Temperature (204°C) 9-1.2, page
Q-9)
Trip 450°F
(232°C)
System Pressure (276 kPa Requirement
based on gas gen-
erator starter
torque
requirements
Ignition and
Fuel
Ignition and for start after
Fuel (if purge purge cycle
cycle is used)
1200 rpm ond time delay
simultaneously
with start
initiation

Q-16
GEK 97310
VOLUME I
ADDENDUM Q
Alarm/ Normal

Light-Off (193° - 216°C) ond time delay
simultaneously
with application
of ignition and
fuel
Starting time Trip 4500 ± 200 rpm Activate 90 sec-
to 4500 rpm ond time delay
simultaneously
with start initia-
tion. De-energize
ignition, fuel sys-
tem and starter air
supply
to 4500 rpm (if ond time delay
gize fuel and igni-
tion systems and
starter air supply
Power Failure to Trip 380° - 420°F 0 - 1600°F Trip if tempera-
Turbine Light-Off (193° - 216°C) (-18° - 871°C) ture does not
Inlet (T5.4 reach 400°F
Tempera- (205°C) within
ture (Gas 20 seconds after
Generator ignition and fuel
Overtemperature:
Power Turbine Speed

3000 rpm 3600 rpm
Natural Gas Trip 1575°F (857°C) 1575°F (857°C)
Alarm 1505°F (818°C) 1515°F (823°C)

Q-17
GEK 97310
VOLUME I
ADDENDUM Q
Alarm/ Normal
operation above
4 mils
Power Turbine Trip 10 mils ± 1 mil DA 0 - 6 mils DA Avoid continuous
operation above
7 mils
Speed
(For 60 HZ) Gas Generator Trip 10,200 rpm 0 - 10,100 rpm
(For 60 HZ) Power Turbine Trip 3,960 ± 40 rpm 0 - 3,600 rpm
(For 50 HZ) Gas Generator Trip 10,200 rpm 0 - 10,100 rpm
(For 50 HZ) Power Turbine Trip 3,300 rpm 0 - 3,000 rpm
NOTE
considered.

Q-18
GEK 97310
VOLUME I
ADDENDUM Q
Compressor discharge. . . 0-300 psig
9-2.1 General. Initial operational period is pressure (0-2070 kPa)
that period of operation immediately following Fuel supply pressure . . . . 0-400 psig
on the system. Steam supply pressure. . . 0-500 psig
(0-3447 kPa)
Fuel supply temperature . 0-400°F
Operation.
(-18 to 204°C)
Steam supply. . . . . . . . . . 0-700°F
Gas generator speed sensor.. 0-11,000 rpm
temperature (0-371°C)
Lube oil scavenge tempera- . 0-400°F Gas turbine inlet air . . . . 0-150°F
ture sensors (A-, B-, (-18 to 204°C) temperature‘ (-18 to 66°C)
C-, D-sumps and
accessory gearbox) Lube oil scavenge . . . . . . 0-200 psig
Lube oil supply temper- ....... 0-400°F
ature sensor (-18 to 204°C Remote reading . . . . . . . -5° to + 45°
variable vane indicator
Vibration indicators..............
0-3 in/sec or
gas generator ....................
0-10 mil DA Starter air supply . . . . . . 0-50 psig
power turbine ...................
0-3 in/sec or pressure (optional) (0-345 kPa)
0-15 mil DA
Power turbine speed ............ 0-5000 rpm
sensor
Power turbine inlet gas ........ 0-2000°F normal operation can commence.
Lube oil supply pressure ...... 0-100 psig
(0-690 kPa)

Fuel/Steam manifold . . . . 0-400 psi

Fuel/Steam manifold . . . . 0-500°F
temperature sensor (-18-260°C)
Compressor inlet total . . . 10-16 psia
Power turbine inlet gas . . 0-75 psia

Q-19
GEK 97310
VOLUME I
ADDENDUM Q
check list. and 10, are open (not capped) _______
a. Gas Turbine Assembly S/N _______ m. Starter is serviced per

foundation _______ n. Lube oil storage tank serviced
ducts in place and secured _______ o. Lube oil supply valves open _______

secure _______ Packager’s manual _______
e. Gas turbine and exhaust duct q. Fire alarm/extinguish system
support mounts and links in ON and operative _______
place and secure _______ r. Fuel system free of
f. All service connections made condensation _______
and secure _______ s. T5.4 thermocouple system
g. All lines have been flushed per functioning properly _______
Packager’s manual _______ t. Ignition system operative _______
h. All instrumentation connec- u. Compressor inlet total pres-
tions made and secure _______ sure probe aligned properly
i. All accessories are secure per and free of damage _______
Packager’s manual _______ v. Variable stator system secure _______
j. Gas turbine assembly free of w. Required checks and inspec-
loose objects and all lines/ tions specified in Packager’s
electrical leads connected _______ manual for gas turbine control
k. Gas turbine inlet air area free have been performed _______
secure _______ 9-2.6 Governor and Manual Control Check.

Q-20
GEK 97310
VOLUME I
ADDENDUM Q
9-2.7 Start-Up and Checkout. TACT WITH HOT PARTS, AND
MET: OPERATING.
REQUIRED DURING ENGINE a. When entering enclosure wear proper
OPERATION, CONTACT GE ear protection.
SENTATIVE WHO IS TRAINED b. Perform prestart checks per Table 4.
UNDER SUCH CONDITIONS. c. Perform ignition checkout per
paragraph 9-2.8.
paragraph 9-2.9.
DURES.
ING OR CLOSING THE
paragraph 9-2.12.
paragraph 9-2.15.

Q-21
GEK 97310
VOLUME I
ADDENDUM Q
Item Requirement
Fuel valves Closed
Ignition Off
Oil tank level Full
Lube oil temperature 140°F to 160°F (60° to 71°C)
Fuel supply
temperature (See paragraph 7-1.1, page Q-7)
flow See paragraph 9-1.1. step b.
Steam supply
pressure 400 psig (2758 kPa) Nominal
temperature 600°F (315°C) Nominal
flow See paragraph 9-1.2, step a.

Q-22
GEK 97310
VOLUME I
ADDENDUM Q
WARNING
• ASSURE POWER TO IGNITION a. Make ignition, natural-gas, and steam
SYSTEMS ARE OFF WHEN DIS- supply systems inoperative as follows:
VERTENT ACTIVATION (2) Close natural-gas and steam man-
ual shutoff valves to fuel control unit.
• ASSURE FUEL AND STEAM
VALVES ARE CLOSED b. Depress MOTORING pushbutton. Gas
THROUGHOUT THIS generator will start to rotate. If it does not,
PROCEDURE. refer to packager’s manual for supply pressure
to starter.
fuel, motor gas turbine for one minute; allow c. Hold MOTORING pushbutton closed
gas turbine to coast down. until gas generator speed stabilizes, and check
b. Disconnect number one ignition exciter pressure, release MOTORING pushbutton;
input lead at exciter. Temporarily secure input while gas generator is coasting down, loosen
lead away from the exciter. oil fittings at lube pump to bleed air from sys-
c. Turn on electrical power to the ignition minimum of 2200 RPM.
igniter fires.
d. Turn off electrical power to the ignition follows:
safety-wire connector. a. With ignition leads disconnected and
manual gas and steam valves closed, make
e. Repeat steps b, c and d, disconnecting automatic start of gas turbine per packager’s
the No. 2 exciter. manual.


Q-23
GEK 97310
VOLUME I
ADDENDUM Q
9-2.12 Wet Prestart. Perform wet prestart as • Thermal seizure of the power turbine
follows: rotor can occur when a hot gas turbine is
shut down and is most likely to occur
a. With ignition lead disconnected, but within 30 to 40 minutes following gas
with manual gas valve open and governing turbine operation. Thermal seizure is the
system operating, make automatic start of gas condition where the power turbine rotor
generator per packager’s manual. is prevented from rotating by hard con-
b. Gas generator should accelerate to interstage seals and other internal inter-
light-off speed (1100 to 1300 rpm). Fuel valve ference. This condition is the result of
should open and fuel manifold pressure should unequal cooling rates of the various
be approximately 3 psig (21 kPa). Adjust fuel power turbine components. The possi-
supply if required. Start will then abort bility of thermal seizures can be reduced
because of lack of flame. by operating the gas turbine at idle
power for at least five minutes prior to
c. Allow gas generator to coast to stop; shutdown to achieve proper cooling of
then motor it to purge any remaining natural the power turbine.
60 seconds to purge fuel from the gas turbine. (1) Shutdown gas turbine.
Refer to Table 5.
CAUTION additional start-up and shutdown cycles.
DO NOT EXCEED 6000 RPM NGG (4) If the power turbine does not
AND 30 SECONDS OF GAS TUR- rotate after accomplishing substeps (1) through
BINE OPERATION WITHOUT (3), shut down the gas turbine.
a. The power turbine must rotate by the rotation stops, re-start and accelerate to
time the gas generator speed reaches 6000 rpm 6000 rpm NGG maximum and stabilize for
NGG. If power turbine speed indication is not 30 seconds. If the power turbine still does not
obtained and it is determined that a “thermal rotate, shut down and investigate/correct the
seizure” of the power turbine has occurred pro- cause. During the investigation for the cause of
ceed as follows: a thermally seized rotor, inspect the LPT
NOTE unlatching. If blades have become unlatched,
• Power Turbine except in a new they may be relatched. LPT blades that have
installation, will be rotating when encountered shingling may be bent thereby
gas generator idle speed is attained. necessitating power turbine replacement.

Q-24
GEK 97310
VOLUME I
ADDENDUM Q

1. Assure that prestart checks are Investigate cause of condi-

completed per Table 4 tion. If T5.4 start limit is
exceeded perform overtem-
perature inspection
CAUTION
IF T5.4 RAPIDLY APPROACHES OR EXCEEDS 1300°F (704°C) ABORT START.
NOTE
NOTE
3. At 1100 to 1300 RPM NGG
a. Ignition on
(21 kPa). See
paragraph 9-1.1.
c. Note time to lightoff 10 seconds max. Abort start-automatic shut-
204°C) 1200 RPM cause.
4. Note time to 4500 ± 200 RPM 90 seconds maximum Troubleshoot system and take
corrective action if RPM
stops increasing or it takes
4300 RPM

Q-25
GEK 97310
VOLUME I
ADDENDUM Q

5. At 4300 to 4700 RPM NGG

should close supply
automatically
a. Oil Pressure See applicable figures in Alarm at 8 ± 1 psig
Trip at 6 ± 1 psig
(41 ± 6.9 kPa)
Table 7
d. NPT 1200 - 1900 RPM Troubleshoot and correct as
required
above 10 mils. Trouble shoot
g. Compressor inlet temper- Approximately equal to Troubleshoot sensing and
ature (T2) outside air temperature indicating system. Correct as
required
h. Check for fuel or oil leaks No leaks allowed Correct as required

Q-26
GEK 97310
VOLUME I
ADDENDUM Q

i. Maximum NGG with 6000 RPM NGG maxi- Shut down and investigate/
power turbine seizure mum for 30 seconds correct cause per paragraph
(thermal seizure) 9-2.13
8. Set desired power setting. Less than alarm limit Correct as required
Observe T5.4 during transient
operation
power setting, read and record
the following:
b. NGG *
NOTE
c. NPT 0-3960 RPM *
figure in Chapter 5 shutdown if ± 5 psig
(± 34 kPa) beyond
normal operating limits
e. Scavenge oil temperature 160°F to 275°F Alarm at 290-310°F
(71°C to 135°C) (143-154°C); automatic shut-
down if above 340°F (171°C)
shutdown
7 mils max (Alarm) *
shutdown
h. Fuel manifold pressure 355 psig (2448 kPa) max **
i. Fuel inlet temperature (See paragraph 7-1.1, **
page Q-7)

Q-27
GEK 97310
VOLUME I
ADDENDUM Q


manual
manual
WP 118 00 WP 118 00
n. Steam supply pressure 400 psig (2758 kPa) Adjust supply
nominal
o. Steam supply temperature 600°F (316°C) nominal Adjust supply
its, shutdown.

Q-28
GEK 97310
VOLUME I
ADDENDUM Q

1. Reduce steam flow schedule Steam/Fuel ratio returns to Troubleshoot and take cor-
before decelerating normal rective action
2. Set gas turbine at idle Gas Generator decelerates Emergency shutdown
(unloaded)
following:
Chapter 5 (55 ± 6.9 kPa): Trip at
6 ± 1 psig (41 ± 6.9 kPa)
c. T5.4 Approximately 1000°F Troubleshoot and take cor-
e. Gas generator vibration 3 mils max Alarm set at 4 mils.
Automatic normal shut-down
if above 7 mils. Troubleshoot
and take corrective action.
f. Power turbine 6 mils max Alarm set at 7 mils.
vibration Automatic normal shut-down
if above 10 mils. Trouble-
action.
g. Fuel inlet temperature (See paragraph 7-1.1,
page Q-7)
i. Lube oil supply filter Refer to packager’s manual
∆P
4. After stabilizing at idle for T5.4 drops below 400°F Manually shut off fuel supply
5 minutes, close fuel valves (204°C). NGG and NPT

Q-29
GEK 97310
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ADDENDUM Q

5. Observe T5.4 for 3 minutes 700°F (371°C) Motor gas turbine. Continue
after shutdown motoring until temperature
decreases
9-2.14 Operation to Maximum Power. e. Check fail-safe section of control sys-

CAUTION
f. After gas turbine has stabilized at idle
MANUAL OPERATION MAY for five minutes, make normal shut-down.
ITS SHALL NOT BE EXCEEDED. 9-2.15 Automatic Operation. Check auto-
matic operation per Packager’s manual.
(refer to Packager’s manual) to increase gas a. Accelerate to idle.
generator speed (see paragraph 9-1.2). After
each 500 RPM increase, log all instrument b. Accelerate to rated power.
readings, paying particular attention to vari-
able stator vane position and vibration. If vari- c. Log all instrument readings.
able stator system is not within limits, adjust it
per VOLUME II Work Packages 118 00. If d. Decelerate to idle.
local General Electric Company representa- e. Check for fuel or lube oil leaks.
tive.
b. Operate gas turbine up to rated power, shut down gas turbine.
perature (T5.4) limit. Hold at this power set- g. Check lube oil and fuel filters and
ting until all temperatures stabilize. If strainers; clean or replace as necessary.
governing system is unstable, adjust per Pack-
ager’s manual. h. Correct any leaks observed.
c. Log all instrument readings once they i. Remove all temporary instrumentation.
d. Reduce gas turbine speed to idle. After tem for 1oose components; tighten as
stabilizing at idle for three minutes, record all necessary.

Q-30
GEK 97310
VOLUME I
ADDENDUM Q
operation for normal operation, refer to Pack- DOOR AND CONFINED SPACE
BE FOLLOWED.
9-3.2 Interlocks. Refer to Packager’s manual
9-3.3 Operation. WEAR THERMALLY INSU-
WARNING SARY.
MET:
BINE.
ENTRY SHOULD BE a. When entering enclosure during gas
REQUIRED DURING ENGINE turbine operation, wear proper ear protection.
FIELD SERVICE FOR A REPRE- b. Start and operate the gas turbine per
SYSTEM SHALL BE MADE d. If required emergency shut down the
INACTIVE ACCORDING TO gas turbine per paragraph 9-4.1 and Table 7.
and V-21B, and figures 5-32A, 5-32B, 5-32N,
and 5-32Q.)
ING OR CLOSING THE
ENCLOSURE DOOR.
Q-31
GEK 97310
VOLUME I
ADDENDUM Q
f. The corrected operating pressure of the 9-5 SPECIAL GAS TURBINE
lube oil shall be per applicable table in Chapter CONSTRAINTS.
5 at standard conditions of 9000 rpm gas gen-
erator speed and 150°F (66°C) lube pump dis- 9-5.1 General. Under normal operating con-
charge temperature. Oil pressure measured at ditions, the gas turbines are constrained by the
conditions other than standard shall be cor- operating limits published in the limits table.
rected to standard conditions using applicable Continuous operating between the alarm and
table in Chapter 5. shutdown or “trip” level should not be
practiced.
9-4 EMERGENCY OPERATION. In the event that any of the following situations
or events occur, the associated special action
9-4.1 Emergency Shutdown. or limitation must be followed in order to
ation. These events are either not detected or
be shut down from any power setting by clos- not prevented by the customary protective
ing the fuel and steam valves. However, this devices of control systems.
should only be done in an emergency, since
rapid shutdown will decrease life of gas tur- • Overtemperature During Starting
bine.
• Lube Oil Pressure
• High Speed Stalls
per Table 7.
9-4.2 Post Shutdown Fire.
• Re-Start Following High Power Trip
gas temperature should decrease. If during • No Power Turbine Rotation
time gas turbine is coasting to stop, tempera- • Gas Generator Windmilling
that combustion is still taking place because of 9-5.2 Overtemperature. During starting and
a leaking fuel valve. (A slight temperature acceleration to idle, cooling flows to compo-
increase after rotation stops is normal.) Make nents of the gas turbine hot section are not suf-
certain fuel is shut off, and motor the gas tur- ficient to protect the metals at T5.4 alarm and
bine. This will blow out the fire. As soon as trip levels specified in the limits table. A lower
temperature decreases to normal, discontinue T5.4 limit is therefore established, with higher
motoring. levels acceptable provided they exist for lim-
ited times as depicted on the curve entitled
“Transient Temperature Limits for Starts” (see
figure 8). This must be monitored by the oper-
ator. The overtemperature inspection called for
by entry into area B requires hot section disas-
sembly and inspection in a qualified facility.

Q-32
GEK 97310
VOLUME I
ADDENDUM Q
9-5.3 Lube Oil Supply Pressure. The lube c. There is no duty cycle limit on the
oil supply pressure limits given in the limit hydraulic starter.
cannot reliably monitor supply pressure 9-5.6 Re-Start Following High Power Trip.
because the proper pressure is dependent on In the event that re-start of the gas turbine is
gas generator speed, oil type, oil temperature, required within two (2) hours following a trip
and number of oil jets. An operator must there- or rapid shutdown from high power, a five (5)
fore derive a corrected oil pressure as directed minute motoring at 2050 ± 50 rpm should pre-
on the appropriate pressure correction table in cede the restart. The objective is to cool the
Chapter 5 to determine if the lube system is high pressure turbine rotor, so that blade tips
performing within the high-low limits stated maintain clearance with the more rapidly cool-
on each table. ing case.
mally bound power turbine rotor could occur
can result in high pressure compressor blade
shutdown from high power. Power turbine
fracture. The gas turbine can be operated after
rotation should initiate during gas turbine
an inspection of the compressor stages 3
the following procedure should be used:
ther inspection and stress relief of the blades is a. Remain at idle for 30 seconds and shut
required, which necessitates blade removal down.
from the spool.
b. Restart and repeat step a.
9-5.5 Starter Duty Cycle - Air or
Natural Gas. c. Restart and repeat step a.
a. With starter inlet air pressure set at d. Restart and accel to 6000 rpm. Do not
40 psig (276 kPa). exceed 6000. Power turbine rotor should break
• 45 seconds on. 2 minutes off for any unlatched or shingled blades, or other cause.
number of cycles,
9-5.8 Windmilling.
or,
a. Unlimited windmilling or motoring of
• 2 minutes on, 5 minutes off with two the gas turbine is allowed at gas generator
such cycles in any 30 minute period. speeds above 1000 rpm provided the lube oil
temperature limits are not exceeded. At these
b. With starter inlet air pressure set at speeds, the lube supply and scavenge systems
15 psig (103 kPa). are in normal operation.
• 5 minutes on 2 minutes off with two
such cycles in any 30 minute period, b. Below 1000 rpm gas generator speeds,
or, with successive periods allowed if preceded by
number of cycles.
Q-33
GEK 97310
VOLUME I
ADDENDUM Q

CAUTION
SHUTDOWN FROM HIGH POWER SETTINGS. SEIZURE OF GAS GENERATOR
bine to idle and close fuel and steam 400°F (204°C) and fuel supply
valves NGG and NPT
decelerate
2. Observe T5.4 for 3 minutes after shut- 700°F (371°C) max Dry motor gas tur-
down bine. Continue
motoring until tem-
perature decreases
CAUTION
IF THE STEAM AND FUEL VALVES HAVE BEEN SHUT OFF SIMULTA-
NEOUSLY DUE TO AN EMERGENCY CONDITION, SEQUENCING THE NOR-
MALLY CLOSED DRAIN VALVE TO OPEN DURING SPEED ROLLBACK
(PREFERABLY IN THE SUB-IDLE REGION) MUST BE DONE SUCH THAT A
NATURAL PURGING OF THE MANIFOLD IS ACCOMPLISHED.
made using the normal starting pro-
cedure.

Q-34
GEK 97310
VOLUME I
ADDENDUM Q

of the 5 minute motoring/purge
accelerate to idle. Acceleration to the
desired power setting can then be
accomplished.
Tables 8 and 9. Deleted

Q-35/(Q-36 Blank)
GEK 97310
VOLUME I
ADDENDUM R
ADDENDUM
7LM2500-PE-MGX

GEK 97310
VOLUME I
ADDENDUM R
TABLE OF CONTENTS
1-0 INTRODUCTION....................................................................................... R-3

2-0 REFERENCE DATA .................................................................................. R-3
3-0 INSTALLATION DRAWINGS.................................................................. R-4
4-0 EQUIPMENT DESCRIPTION ................................................................. R-4
5-0 INSTRUMENTATION AND SUPPLY REQUIREMENTS ................... R-4
6-0 SERVICE REQUIREMENTS ................................................................... R-4
6-1.1 Natural Gas ................................................................................................... R-4
7-0 OPTIONAL HARDWARE KITS - 7LM2500-PE-MGX......................... R-10
8-0 GAS TURBINE OPERATION .................................................................. R-10
8-1.1 Performance Ratings and Operating Limits.................................................. R-10
8-1.2 Performance Ratings ..................................................................................... R-11
8-1.3 Operating Limits ........................................................................................... R-12
8-2 INITIAL OPERATION .............................................................................. R-12
8-2.1 General .......................................................................................................... R-12
8-2.2 Special Instrumentation Required for Operation .......................................... R-12
8-2.3 Special Instrumentation Required for Monitoring and Troubleshooting ...... R-17
8-2.4 Preparation .................................................................................................... R-17
8-2.5 Gas Turbine and Associated Equipment Check List..................................... R-17
8-2.6 Governor and Manual Control Check........................................................... R-18
8-2.7 Start-up and Checkout................................................................................... R-18
8-2.8 Ignition Check............................................................................................... R-19
8-2.9 Motoring........................................................................................................ R-20
8-2.10 False Start...................................................................................................... R-21
8-2.11 Governor Check ............................................................................................ R-21
8-2.12 Wet Prestart ................................................................................................... R-21
8-2.13 Manual Start and Operation .......................................................................... R-21
8-2.14 Operation to Maximum Power...................................................................... R-26
8-2.15 Automatic Operation..................................................................................... R-26
8-3 NORMAL OPERATION............................................................................ R-28
8-3.1 General .......................................................................................................... R-28
8-3.2 Interlocks....................................................................................................... R-28
8-3.3 Operation....................................................................................................... R-28
8-4 EMERGENCY OPERATION ................................................................... R-29
8-4.1 Emergency Shutdown ................................................................................... R-29
8-4.2 Post Shutdown Fire ....................................................................................... R-29
8-5 SPECIAL GAS TURBINE CONSTRAINTS ........................................... R-31
8-5.1 General .......................................................................................................... R-31
8-5.2 Overtemperature............................................................................................ R-31
8-5.3 Lube Oil Supply Pressure ............................................................................. R-31
8-5.4 High Speed Stall............................................................................................ R-31
8-5.5 Starter Duty Cycle - Air or Natural Gas........................................................ R-31

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8-5.6 Re-Start Following High Power Trip ............................................................ R-32

8-5.7 No Power Turbine Rotation .......................................................................... R-32
8-5.8 Windmilling .................................................................................................. R-32
9-0 NOX SUPPRESSION - GAS FUEL WATER INJECTION ................... R-33
9-1.1 Water Scheduling Requirements ................................................................... R-33
9-1.2 Water System Purge and Drain Requirements .............................................. R-33
9-1.3 System Flow and Pressure Requirements ..................................................... R-33
Figure Title Page
1 Transient Temperature Limits ....................................................................... R-5

2 Deleted
3 Deleted
4 Deleted
5 Deleted
6 NO X Suppression Piping Schematic - Natural Gas Fuel Supply
with Water Injection . .. .. .. ... .. .. .. ... .. .. .. ... .. .. .. .. ... .. .. .. ... .. .. .. ... R-7
7 Water to Fuel Weight Ratio and Fuel Flow - PPH x 10-3 ............................. R-12
8 Water Inlet Pressure - PSIA vs Water Flow - PPH ....................................... R-34
LIST OF TABLES
Table Title Page

1 INSTRUMENTATION CONNECTIONS - 7LM2500-PE-MGX ................ R-8
2 SUPPLY CONNECTIONS 7LM2500-PE-MGX ......................................... R-9
3 GAS TURBINE OPERATING LIMITS....................................................... R-13
4 PRESTART CHECKS .................................................................................. R-19
5 START-UP AND OPERATION.................................................................... R-22
6 GAS TURBINE SHUTDOWN .................................................................... R-27
7 EMERGENCY SHUTDOWN...................................................................... R-30
8 DELETED
9 DELETED
10 DELETED
11 DELETED
12 DELETED
13 DELETED

R-2
GEK 97310
VOLUME I
ADDENDUM R
The information contained herein describes the Compressor Rotor 552 (250)
7LM2500-PE-MGX model gas turbine basic Compressor Stator, Front 307 (139)
configuration and control system differences. Compressor Stator, Rear 93 (42)
instrumentation and supply connections, spe- Compressor Rear Frame 421 (191)
instructions for the 7LM2500-PE-MGX model
are included.
Stg 1 68 (31)
2-0 REFERENCE DATA. High Pressure Turbine Nozzle,
Stg 2 127 (58)
(General Electric Co., Cincinnati, Ohio) Low Pressure Turbine Stator 601 (273)
Model No. 7LM2500-PE-MGX Turbine Rear Frame 1071 (486)
Drawing No. L31430G18 High Speed Coupling Shaft
Forward Adapter 91 (41)
PERFORMANCE RATING
Exhaust Duct assembly 2741 (1243)
Refer to paragraph 8-1.1 Exhaust Duct 1565 (710)
GAS TURBINE WEIGHTS Inner Deflector 255 (116)
The average weights of the major gas turbine Ring Seal 49 (22)
components are: Ring Support 74 (34)
Component Wt-Lbs/(Kg) Cover, Insulation 62 (28)
Gas turbine - including inlet Variable Stator Actuating
duct, centerbody, exhaust dif- Mech 19 (9)
fuser, and coupling adapter 7915 (3590) Outside Piping and Bracketing 278 (126)

R-3
GEK 97310
VOLUME I
ADDENDUM R
The natural gas fuel is introduced through the
DRAWING LIST normal gas circuit manifold in a manner simi-
Drawing No lar to the standard gas only system. Water is
Gas Turbine Installation L31705 supplied to the interface connection on the
Drawing water manifold, and from the manifold, is
introduced into the water circuit of the fuel
nozzles and then discharged through the two
Lubrication System Flow L24328 orifices at the tip of each nozzle. A schematic
Diagram diagram of the natural gas fuel/water system is
Electrical Diagram L24329 shown on Figure 6.
Gas Turbine Assembly L31430G18 SUPPLY REQUIREMENTS.
Drawing (See Tables 1 and 2.)

been provided. 6-1.1 Natural Gas.
4-0 EQUIPMENT DESCRIPTION. a. The required supply pressure to the

natural gas fuel manifold on the gas turbine is
The 7LM2500-PE-MGX is a natural gas
355 ± 5 psig (2448 ± 35 kPa) maximum.
fueled, marinized gas turbine with NOx sup-
pression. (Refer to Chapter 2 for Fuel Specifi-
b. The temperature of the gas must be in
cation Requirements.)
the range of 20°F (-6.7°C) above the saturated
The fuel system configuration, used with the vapor temperature as a minimum, and 350°F
natural gas fueled LM2500 gas turbine with (177°C) as a maximum. If the temperature is
water injection for NOx suppression applica- not repeatable on a day-to-day basis, it will be
tions, is similar to the standard natural gas fuel necessary to change the starting fuel adjust-
only system except for the substitution of ment to adjust the supply pressure to the gas
30 natural gas/water fuel nozzles with two sep- generator to maintain a constant BTU-per-
arate circuits for gas and water, and the addi- cubic-foot supply. The maximum fuel flow
tion of a water manifold. required is 13,500 pph (6123 kg/h) with a

R-4
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ADDENDUM R

R-5
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R-6
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Figure 6. NOX Suppression Piping Schematic - Natural Gas Fuel Supply with Water Injection

R-7
GEK 97310
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ADDENDUM R
Table 1. INSTRUMENTATION CONNECTIONS - 7LM2500-PE-MGX
E-1 Vibration pickup, Gas Generator Diagnostic System Corp. Part No. 303-03
E-2 Power turbine inlet temperature MS3106-14S-9S
E-3 A-sump scavenge oil temperature MS3106R12S-3S
E-4 B-sump scavenge oil temperature MS3106R12S-3S
E-5 C-sump scavenge oil temperature MS3106R12S-3S
E-6 Accessory gearbox scavenge oil MS3106R12S-3S
temperature
E-11 Oil supply temperature MS3106R12S-3S
E-18 D-sump scavenge oil temperature MS3106R12S-3S
E-7 Gas generator speed pickup No. 1 MS3106R10SL-4S
E-13 Vibration pickup, power turbine Diagnostic System Corp. Part No. 303-03
E-14 Power turbine speed pickup No. 1 MS3106-10SL-4S
(optional)
(optional)
(optional)
-- Remote reading variable stator vane pro-
tractor (optional)
E16 Gas turbine electrical bond left
NOTE
gas turbine.

R-8
GEK 97310
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ADDENDUM R
Table 2. SUPPLY CONNECTIONS 7LM2500-PE-MGX
CAUTION
Manifold
L1 Oil Supply 1-1/2 inch line to Lube Pump on Gas Turbine AN818-24C or
MS20819-24C
AN818-16C or MS20819-16C
AN818-16C or MS20819-16C
L3 Scavenge oil discharge 1-1/4 inch line from Gas Turbine Scavenge Pump to oil
Turbine Inlet Duct AN818-16C or MS20819-16C
NOTE

R-9
GEK 97310
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ADDENDUM R
7LM2500-PE-MGX.
a. Refer to Volume II WP 001 00 for a EXISTS DO NOT OPERATE THE
8-0 GAS TURBINE OPERATION. HOT STARTS, COMPRESSORS
pany for the 7LM2500-PE-MGX Gas Turbine. IN UNDUE STRESS BEING
ume I, Chapter 4, TROUBLESHOOTING. 8-1.1 Performance Ratings and Operating
Limits.
trial Engine Department; Cincinnati, Ohio turbine manual limits.
45215-6301.

R-10
GEK 97310
VOLUME I
ADDENDUM R
8-1.2 Performance Ratings. NOTE
LM2500-PE MG/NG AVERAGE Water injection is not required to meet

PERFORMANCE the EPA Industrial NOx Standard.
Natural Gas Fuel per MID-TD-0000-1 b. Starting fuel flow for the
7LM2500-PE-MGX model gas turbine is nor-
a. The rated performance of the mally set by the minimum stop on the gas fuel
7LM2500-PE-MGX gas turbine in the new metering valve. The proper fuel flow setting
and clean condition is as follows: for the minimum stop, on a heat consumption
With Water basis, is 10.45 x 106 + 0.46 x 106 BTU/hour
Injection* for ambient temperatures of -65°F (-54°C) to
to Meet +130°F (54°C), and is based commencing fuel
EPA and ignition at 1200 ± 100 rpm.
Electric
Utility c. Refer to Packager’s Manual for the
Dry Standard 7LM2500-PE-MGX gas turbine model transient
fuel flow requirements.
Shaft Horsepower 29500 29500
Inlet Air 59 59 d. Refer to Packager’s Manual for acceler-
Temperature (°F) ation fuel rate.
Altitude (Ft) 0 0
Inlet Losses (In. H2O) 0 0 e. Above the idle speed point, low acceler-
Exhaust Back Pressure 0 0 ation fuel rates will not harm the gas turbine and
(In. H2O) will only result in slower acceleration times.
Relative Humidity (%) 60 60 f. For normal accelerations from idle to
Compressor Bleed 0 0 power settings the changes should be made
(Lbs/Sec) more slowly to enhance the time between hot
Accessory HP 0 0 section repairs and the life of the gas turbine; a
Extraction time of 2 to 3 minutes is reasonable.
Power Turbine Speed 3600 3600
(rpm) g. Refer to Packager’s Manual for acceler-
Heat Rate (Btu/HP-Hr) 6885 6939 ation fuel rate.
Power Turbine Inlet 1458 1445
h. Normal decelerations from maximum
Gas Temp. (°F)
Water Injection 0 2041
(Lbs/Hr) Avg.
Fuel Flow (LBs/Hr) 10690 10774
gas turbine.
NOx Emissions 184 110**
(ppm at 15% 02)
*Per “schedule” shown on Figure 7.
**NOx limit per US EPA standards, based on
29,500 SHP, ISO conditions

R-11
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ADDENDUM R
Figure 7. Water to Fuel Weight Ratio and Fuel Flow - PPH x 10-3
8-1.3 Operating Limits. Refer to Table 3. Lube oil scavenge ............ 0-400°F
temperature sensors (-18 to 204°C)
NOTE (A, B, C, D-sumps and
If any operating limit is exceeded, ver- transfer gearbox)
ify instrumentation accuracy before Lube oil supply ............... 0-400°F
troubleshooting or inspecting gas temperature sensor (-18 to 204°C)
generator. Vibration indicators
Gas generator ............... 0-4 in/sec or
8-2 INITIAL OPERATION. 0-10 mil DA
Power turbine............... 0-2 in/sec
8-2.1 General. Initial operational period is 0-15 mil DA
that the period of operation immediately fol- Power turbine speed......... 0-5000 RPM
lowing gas turbine replacement or major main- sensor
tenance on the system. Power turbine inlet gas .... 0-2000°F
Operation. Lube oil supply ................ 0-100 psig
Gas Generator .................. 0-11,000 RPM Recoup Pressure............... 0-150 psig
speed sensor (0-1034 kPa)

R-12
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ADDENDUM R
Alarm/ Normal
NOTE
Lubrication Gas turbine Alarm 8 psig ± 1 psig 20 - 60 psig Bypass until
System - lube supply (55 kPa ± 6.9 kPa) (138 - 414 kPa) 4500 rpm
Settings and pressure below 8000 rpm;
Ranges (103 kPa ± 6.9
kPa) above 8000
rpm
(41 kPa ± 6.9 kPa) (138 - 414 kPa) 4500 rpm
Gas turbine Alarm 110 psig ± 10 psig 10 - 100 psig Scavenge discharge
scavenge (759 kPa ± 69 kPa) (69 - 690 kPa) pressure shall not
discharge exceed 180 psig
pressure (1241 kPa)
Gas turbine Alarm 180° - 220°F 140° - 160°F Normal operating
lube supply (82° - 104°C) (60° - 71°C) range reflects tem-
temperature perature expected
during operation
above idle speed
Gas turbine Alarm 290°-310°F 160°-275°F Normal operating
lube (143°-154°C) (71°-135°C) range reflects tem-
scavenge perature expected
temperatures Trip 330°-350°F during operation
- (five (166°-177°C) above idle speed
sensors)
Fuel System Fuel 20-355 psig Supply pressure as
Natural Gas manifold (138-2448 kPa) reflected at the fuel
pressure manifold inlet on
the gas turbine
Fuel supply Alarm 150-170°F -65-150°F Starting fuel flow
temperature (66-77°C) (-54-66°C) adjustments are
required to compen-
ature variation.

R-13
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ADDENDUM R
Alarm/ Normal
Starting Starter sup- 38-42 psig Starting pressure
System ply pressure (262.0-289.60 kPa) requirement based
on gas turbine
starter torque
requirements
of fuel and
ignition
of fuel and start after purge
ignition (if cycle
purge cycle
is used)
simultaneously with
start initiation
simultaneously with
start initiation. De-
energize ignition,
fuel system and
starter air supply
(if purge upon completion of
gize fuel and igni-
tion systems and
starter air supply
Activate 10 sec-
onds time delay
simultaneously with
application of fuel
and ignition.

R-14
GEK 97310
VOLUME I
ADDENDUM R
Alarm/ Normal
Power Tur- Failure to Trip 400°F ± 20°F 0°-900°F Trip if temperature
bine Inlet light-off (204° ± 6.7°C) (-17.8 - 482°C) does not reach
temperature 400°F (204°C)
(T5.4) within 10 seconds
tion are applied
(T5.4) limits (rating: 29500 SHP/3600 NPT)
Gas fuel Control
Limit 1510°F 0 - 1510°F
(821°C) (821°C)
Alarm 1515°F
(824°C)
Trip 1575°F
(857°C)
(T5.4) limits (rating: 28,500 SHP/3000 NPT)
Gas fuel Control
Limit 1500°F 0-1500°F
(816°C) (816°C)
Alarm 1505°F
(818°C)
Trip 1575°F
(857°C)
(T5.4) Limits (AE8=208.5 in2)
Gas fuel Control
Limit 1510°F 0-1510°F
(821°C) (823°C)
Alarm 1515°F
(823°C)
Trip 1575°F
(857°C)
Loss of Combustor Close and lockout
upon loss of flame

R-15
GEK 97310
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ADDENDUM R
Alarm/ Normal
Thrust Recoup See remarks Recoup See Chapter 4 for
Balance pressure pressure: acceptable enve-
Pressure 0-150 psig lope (corrected
(0-1034 kPa) recoup pressure vs
P54: corrected exhaust
0-60 psig gas total pressure,
(0-414 kPa) P54)
Vibration Gas Alarm 4 mils DA 0-3 mils DA Avoid continuous
generator operation above
4 mils
Trip 7 mils DA
Power Alarm 7 mils DA 0-6 mils DA Avoid continuous
turbine operation above
7 mils
Trip 10 mils DA
Speed
(for 60 HZ) Gas Trip 10,200 rpm 0-10,100 rpm
generator
(for 60 HZ) Power Trip 3,960 rpm 0-3,600 rpm
turbine
(for 50 HZ) Gas Trip 10,200 rpm 0-10,100 rpm
generator
(for 50 HZ) Power Trip 3,300 rpm 0-3,000 rpm
turbine

R-16
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ADDENDUM R
8-2.3 Special Instrumentation Required for f. All service connections
Monitoring and Troubleshooting. made and secure. _________
Fuel manifold pressure 0-400 psi g. All lines have been flushed
sensor ................................... (0-2758 kPa) per Packager’s manual. _________
Compressor inlet total pres- 10-16 psia h. All instrumentation connec-
sure sensor ........................... (69-110 kPa) tions made and secure. _________
Power turbine inlet gas 0-75 psia i. All accessories are secure
pressure................................ (0-517 kPa) per Packager’s manual. _________
Compressor discharge 0-300 psig j. Gas turbine assembly free
pressure ............................... (0-2068 kPa) of loose objects and all
Fuel supply pressure ............ 0-400 psig
connected. _________
(0-2758 kPa)
Fuel supply temperature ..... 0-250°F free of foreign objects. Inlet
(-18 to 121°C) screen secure. _________
Gas turbine inlet air -65 to 150°F l. Gas turbine compressor rear
temperature ......................... (-54 to 66°C) frame leakage ports, struts
Lube oil scavenge pressure.. 0-200 psig 7 and 10, are open (not
(0-1379 kPa) capped). _________
Remote reading variable vane m. Starter is serviced per Pack-
indicator (optional) .............. -5° to +45° ager’s manual. _________
Starter air supply pressure 0-50 psig n. Lube oil storage tank ser-
(optional) ............................. (0-345 kPa) viced to full level. _________
8-2.4 Preparation. The gas turbine and asso- open. _________
ciated systems must be inspected and checked p. All filters are serviced per
out for proper installation and operation before Packager’s manual. _________
normal operation can commence. q. Fire alarm/extinguish sys-
8-2.5 Gas Turbine and Associated Equip- tem “ON” and operative. _________
ment Check List. Complete the following r. T5.4 thermocouple system
checklist. functioning properly. _________
a. Gas Turbine Assembly S/N. _________ s. Ignition system operative. _________
b. Mounting base secured to t. Compressor inlet total pres-
foundation. _________ sure probe aligned properly
c. Intake air and exhaust gas and free of damage. _________
ducts in place and secured. _________ u. Variable stator vane system
d. Bonding straps in place and secure. _________
secure. _________ v. Required checks and
e. Gas turbine and exhaust inspections specified in
duct support mounts and Packager’s manual for gas
links in place and secure. _________ turbine control have been
performed. _________

R-17
GEK 97310
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ADDENDUM R
Refer to Packager’s manual. SHALL BE KEPT OPEN. IF THE
8-2.7 Start-up and Checkout. AN OBSERVER SHALL BE STA-
WARNING
WHEN ENTERING THE GAS TUR- BE FOLLOWED.
ING REQUIREMENTS SHALL BE • ALLOW THE GAS TURBINE TO
MET: COOL DOWN. AVOID CON-
• THE GAS TURBINE SHALL BE WEAR THERMALLY INSU-
SHUT DOWN. LATED GLOVES AS
NECESSARY.
ENGINE OPERATION IS PRO- • EAR PROTECTION SHALL BE
HIBITED IN GENERAL. IF WORN IF GAS TURBINE IS
ENTRY SHOULD BE OPERATING.
OPERATION, CONTACT GE • DO NOT REMAIN IN THE
FIELD SERVICE FOR A REPRE- ENCLOSURE OR IN THE
SENTATIVE WHO IS TRAINED PLANE OF ROTATION OF THE
TO ENTER THE ENCLOSURE STARTER WHEN STARTING OR
UNDER SUCH CONDITIONS. MOTORING THE GAS
TURBINE.
SYSTEM SHALL BE MADE a. When entering enclosure during gas
INACTIVE ACCORDING TO turbine operation, wear proper ear protection.
DURES. b. Perform prestart checks per Table 4.
• SECONDARY AIR TO THE c. Perform ignition checkout per

FLOW MAY PREVENT OPEN- d. Perform motoring procedure per
ENCLOSURE DOOR.

R-18
GEK 97310
VOLUME I
ADDENDUM R
Item Requirements
Fuel valves Closed
Ignition Off
Oil tank level Full
Lube oil temperature Above +20°F (-6.7°C) for MIL-L-23699
Fuel supply - natural gas: 50 psig maximum (345 kPa) -65° to 150°F
pressure at manifold inlet (-54° to 66°C) see paragraph 8-1.2, step b.
temperature
flow (starting)
e. Perform false start per 8-2.8 Ignition Check.

paragraph 8-2.10.
WARNING
f. Perform governor check per
g. Perform a wet prestart per CONNECTING AND CONNECT-
h. Perform a manual start and operate per SERVICE” TO PRECLUDE
paragraph 8-2.13. INADVERTENT ACTIVATION.
i. Operate to maximum power per • ASSURE FUEL VALVES ARE

paragraph 8-2.14. CLOSED THROUGHOUT THIS
PROCEDURE.
paragraph 8-2.15. a. To clear combustor of any residual

R-19
GEK 97310
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ADDENDUM R
b. Disconnect number one ignition exciter 8-2.9 Motoring. After all preliminary checks
input lead at exciter. Temporarily secure input have been completed and lines flushed, the gas
lead away from the exciter. generator can be motored as follows:
c. Turn on electrical power to the ignition a. Make ignition and natural-gas supply
system (No. 2 ignition exciter energized). An systems inoperative as follows:
second) should be heard when the No. 2 spark (1) Disconnect power supply to igni-
igniter fires. tion unit.
d. Turn off electrical power to the ignition (2) Close natural gas manual shutoff
system. Reconnect input lead to No. 1 ignition valve to fuel control unit.
exciter and safety-wire connector.
b. Depress MOTORING pushbutton. Gas
e. Repeat steps b, c and d, disconnecting turbine will start to rotate. If it does not, refer
the No. 2 exciter. to Packager’s manual for supply pressure to
starter.
No. 1 and/or No. 2 igniters, check out the sys- c. Hold MOTORING pushbutton closed
tem to isolate the problem, and take appropri- until gas generator speed stabilizes, and check
ate corrective action. for oil pressure. If there is no indication of oil
fittings at lube pump to bleed air from system.
of 2200 rpm.


R-20
GEK 97310
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ADDENDUM R
follows:
of gas turbine per Packager’s manual. POWER TURBINE ROTATION.
b. Gas turbine should go through normal a. The power turbine must rotate by the
start cycle and then abort because of lack of time the gas generator speed reaches 6000 rpm
flame. NGG. If power turbine speed indication is not
obtained and it is determined that a “thermal
8-2.11 Governor Check. Check governor sys- seizure” of the power turbine has occurred,
tem per Packager’s manual. proceed as follows:
8-2.12 Wet Prestart. Perform wet prestart as NOTE

follows: • Power Turbine, except in a new
installation, will be rotating when
a. With ignition lead disconnected, but gas generator idle speed is attained.
with manual gas valve open and governing
system operating, make automatic start of gas • Thermal seizure of the power turbine
turbine per Packager’s manual. rotor can occur when a hot gas turbine is
shutdown and is most likely to occur
b. Gas generator should accelerate to within 30 to 40 minutes following gas
light-off speed (1100 to 1300 rpm). Fuel valve turbine operation. Thermal seizure is the
should open and fuel manifold pressure should condition where the power turbine rotor
be approximately 3 psig (21 kPa). Adjust fuel is prevented from rotating by hard con-
supply if required. Start will then abort tact between LPT blades and shrouds,
because of lack of flame. interstage seals and other internal inter-
c. Allow gas turbine to coast to stop; then unequal cooling rates of the various
motor it to purge any remaining natural gas power turbine components. The possi-
from turbine. Continue to motor for 60 sec- bility of thermal seizures can be reduced
onds to purge fuel from the gas turbine. by operating the gas turbine at idle
8-2.13 Manual Start and Operation. Perform shutdown to achieve proper cooling of
manual start per Packager’s manual with fuel the power turbine.
valve open and with ignition lead connected.
Refer to Table 5. (1) Shutdown gas turbine.


R-21
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ADDENDUM R


CAUTION
IF T5.4 RAPIDLY APPROACHES OR EXCEEDS VALUES SHOWN IN
FIGURE 1 ABORT START. INVESTIGATE CAUSE OF CONDITION. IF T5.4 START
LIMIT IS EXCEEDED PERFORM OVERTEMPERATURE INSPECTION.
NOTE
NOTE
If purge cycle is required, NGG in step 3 may be revised. See Table 3.
3. At 1100 to 1300 RPM NGG
a. Ignition on
(21 kPa). See
paragraph 8-2.12, step b.
c. Note time to lightoff 10 seconds maximum Abort start-automatic shut-
204°C) 1200 rpm cause.

to reach 4300 RPM

R-22
GEK 97310
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ADDENDUM R

5. At 4300 to 4700 RPM NGG

should close supply
automatically

Chapter 5 (55 ± 6.9 kPa). Trip at
6 ± 1 psig (41 ± 6.9 kPa)

Table 7
d. NPT (unloaded) 1600 - 1900 RPM Troubleshoot and take cor-
rective action
g. Compressor inlet tem- Approximately equal to out- Troubleshoot sensing and
as required
h. Check for fuel and oil No leaks allowed Correct as required
leaks

R-23
GEK 97310
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ADDENDUM R

i. Maximum NGG with 6000 RPM NGG maximum Shutdown and investigate/
7A. Operating with NOX Sup-

pression Refer to Packager’s
Manual
sient operation
a. T5.4 Less than alarm limit
b. NGG (corrected) 0-10,100 rpm *
NOTE
c. NGG 0 - 3960 rpm *

out of limits.
e. Scavenge oil temperature 160°F to 275°F Alarm set at 300°F.
(71°C to 135°C) Automatic shutdown if
above 340°F.
f. Gas generator vibration 0-3 mils normal Alarm set at 4 mils.
4 mils (alarm) Automatic shutdown
7 mils (trip) if above 7 mils.
Troubleshoot.
g. Power turbine vibration 0-6 mils normal Alarm set at 7 mils.
7 mils (alarm) Automatic shutdown
10 mils (trip) if above 10 mils.
Troubleshoot.

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ADDENDUM R


(-54° to +66°C)
m. Variable stator vane See applicable figures in Correct as required per
angle WP 118 00 WP 118 00
its, shutdown.

R-25
GEK 97310
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ADDENDUM R
(3) Repeat steps (1) and (2) for two system is unstable, adjust per Packager’s
additional start-up and shutdown cycles. manual.
(4) If the power turbine does not c. Log all instrument readings once they
rotate after accomplishing substeps (1) through stabilize. Refer to Table 5, step 9.
(5) Immediately after gas turbine stabilizing for three minutes, record all instru-
rotation stops, re-start and accelerate to ment readings. Refer to Table 6, Step 2.
30 seconds. If the power turbine still does not e. Check fail-safe section of control sys-
rotate, shut down and investigate/correct the tem per Packager’s manual.
they may be relatched. LPT blades that have 8-2.15 Automatic Operation. Check automatic
encountered shingling may be bent thereby operation per Packager’s manual.
CAUTION
(refer to Packager’s manual) to increase gas shut down gas turbine.
within limits, adjust it per work package h. Correct any leaks observed.
sult the local General Electric Company i. Remove all temporary instrumentation.
representative.
b. Operate gas turbine up to rated power, tem for loose parts; tighten as necessary.

R-26
GEK 97310
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ADDENDUM R

1. Set gas turbine at idle power Gas generator decelerates to Emergency shut down
(unloaded) idle
following:
Trip at 6 ± 1 psig
(41 ± 6.9 kPa)
b. NGG 5000 rpm ± 250 Adjust
c. T5.4 1000°F Max (538°C) Troubleshoot and take cor-

rective action
d. NPT (unloaded) 1200 - 1900 rpm
e. Gas generator vibration 0-3 mils DA Alarm set at 4 mils. Auto-

above 7 mils.Troubleshoot
f. Power turbine vibration 0-6 mils DA Alarm set at 7 mils. Auto-
g. Fuel inlet temperature -65° to +150°F
(-54° to +66°C)
5 minutes, close fuel valves (204°C) NGG decelerates supply
and stops
4. Observe T5.4 for 3 minutes 700°F (371°C) Motor gas turbine. Con-
ature decreases

R-27
GEK 97310
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ADDENDUM R
operation for normal operation, refer to ENCLOSURE DOOR.
Packager’s manual.
8-3.2 Interlocks. Refer to Packager’s manual SHALL BE KEPT OPEN. IF THE
BE FOLLOWED.
WARNING
LATED GLOVES AS
SHUT DOWN.
• THE FIRE EXTINGUISHING turbine operation, wear proper ear protection.
THE CUSTOMER’S PROCE- Table 5. Do not exceed operating limits of
DURES. Table 3.

R-28
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ADDENDUM R
c. Shut down the gas turbine per Table 6. 8-4 EMERGENCY OPERATION.
d. Emergency shut down the gas turbine 8-4.1 Emergency Shutdown.

per Table 7.
e. Refer to paragraph 5-3.30 and 5-3.31, be shut down from any power setting by clos-
for lube correction factors and lube supply ing the fuel valve. However, this should only
pressure characteristics. (See tables V-21A, be done in an emergency, since rapid shutdown
V-21B, V-21E, and V-21F, and figures 5-32A, will decrease life of gas turbine.
5-32B, 5-32E, 5-32F, 5-32J, 5-32L, 5-32N,
and 5-32Q.) b. Emergency shutdown shall be made
per Table 7.
NOTE
Addendum R affects P/N L34379P01 8-4.2 Post Shutdown Fire.
only.
f. Idle lube oil pressure is 29 psig gas temperature should decrease. If, during
(200 kPa) maximum after five minutes time gas turbine is coasting to stop, tempera-
stabilization. ture increases instead of decreases, it indicates
g. The corrected operating pressure of the a leaking fuel valve. (A slight temperature
lube oil shall be per applicable table in increase after rotation stops is normal.) Make
Chapter 5 at standard conditions of 9000 rpm certain fuel is shut off, and motor the gas tur-
gas generator speed and 150°F (66°C) lube bine. This will blow out the fire. As soon as
pump discharge temperature for either temperature decreases to normal, discontinue
MIL-L-7808 or MIL-L-23699 lube oil. Oil motoring.
pressure measured at conditions other than
standard shall be corrected to standard condi-
tions using applicable tables in Chapter 5.

R-29
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ADDENDUM R

CAUTION
bine to idle and close fuel valves 400°F (204°C); fuel supply
NGG and NpT
decelerate
2. Observe T5.4 for 3 minutes after shutdowns 700°F (371°C) max Motor gas turbine.
Continue motoring
until temperature
decreases
(621°C) has occurred, and a “hot restart” is
a. If the fault detection and sequencing sys-
tem can be cleared and the gas turbine
can be restarted within 1 minute follow-
ing coastdown of the HPC rotor, accept-
able restarts can be made using the
turbine at 2000 - 2500 rpm NGG for 5
tion to the desired power setting can then
be accomplished.

R-30
GEK 97310
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ADDENDUM R
CONSTRAINTS. supply pressure limits given in the limit table
8-5.1 General. Under normal operating con- reliably monitor supply pressure because the
ditions, the gas turbines are constrained by the proper pressure is dependent on gas turbine
operating limits published in the limits table. speed, oil type, oil temperature. and number of
Continuous operation between the alarm and oil jets. An operator must therefore derive a
shutdown or “trip” level should not be corrected oil pressure as directed in the appro-
practiced. priate pressure correction tables in Chapter 5
to determine if the lube system is performing
In the event that any of the following situations within the high-low limits stated on each table.
or limitation must be followed in order to 8-5.4 High Speed Stall. Stalls incurred at gas
assure the gas turbines continued normal oper- generator rotational speeds above 7500 rpm
ation. These events are either not detected or can result in high pressure compressor blade
not prevented by the customary protective fracture. The gas turbine can be operated after
devices of control systems. an inspection of the compressor stages 3
• Overtemperature During Starting not occurred. If tip clanging has occurred, fur-
• Lube Oil Pressure required, which necessitates blade removal
from the spool.
• Starter Duty Cycle Gas.
• No Power Turbine Rotation 40 psig (276 kPa):
• Gas Generator Windmilling • 45 seconds on, 2 minutes off for any

numbers of cycles,
8-5.2 Overtemperature. During starting and
acceleration to idle, cooling flows to compo- or
ficient to protect the metals at T5.4 alarm and • 2 minutes on, 5 minutes off with two
trip levels specified in the limits table. A lower such cycles in any 30 minute period.
ited times as depicted on the curve titled
“Transient Temperature Limits for Starts”
(figure 1). This must be monitored by the oper-
by entry into area B requires hot section disas-
sembly and inspection in a qualified facility.

R-31
GEK 97310
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ADDENDUM R
b. With starter inlet air pressure set at 15 a. Remain at idle for 30 seconds and shut
psig (103 kPa) for motoring: down.
• 5 minutes on, 2 minutes off with two b. Refire and repeat Item a.
or
d. Refire and accel to 6000 rpm. Do not
• 10 minutes on, 20 minutes off for any exceed 6000. Power turbine should break
number of cycles. away. If not, shut down and investigate for
hydraulic starter, provided that the oil tempera- 8-5.8 Windmilling.
ture to the starter is maintained under 140°F
(60°C). a. Unlimited windmilling or cranking of
8-5.6 Re-Start Following High Power Trip. speeds above 1000 rpm provided the lube oil
In the event that re-start of the gas turbine is temperature limits are not exceeded. At these
required within two (2) hours following a trip speeds, the lube supply and scavenge systems
or rapid shutdown from high power, a five (5) are in normal operation.
minute cranking at 2050 ± 50 rpm should pre-
cede the fire up. Refer to Table 7. The objec- b. Below 1000 rpm gas generator speeds,
tive is to cool the high pressure turbine rotor, windmilling is allowed up to five (5) minutes,
so that blade tips maintain clearance with the with successive periods allowed if preceded by
more rapidly cooling case. normal gas turbine operation.
8-5.7 No Power Turbine Rotation. A ther-

mally bound power turbine rotor could occur
shutdown from high power. Power turbine

R-32
GEK 97310
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ADDENDUM R
9-0 NOX SUPPRESSION - GAS FUEL c. During deceleration of the gas turbine
WATER INJECTION. including load shedding operation, the metered
water flow should follow the metered fuel flow
9-1.1 Water Scheduling Requirements. during the transient. (As a limit the water/fuel
ratio must not exceed 0.6 during the transient.)
a. Water flow must be scheduled as a
function of fuel flow, but must be shut off dur- d. Figure 8 shows the water flow versus
ing any operation below idle speed, including water supply pressure required at the water
starting and acceleration to idle. In order to supply interface connection for the EPA elec-
meet the EPA standard for electric utility appli- tric utility standard at the 29,500 SHP site rat-
cations with a site rating of 29,500 SHP ing condition shown as an example in
(Figure 7) water flow should be initiated at a Figure 7. Note that the water supply system
fuel flow of 5700 pph ± 450 pph on accelera- and maximum water supply pressure require-
tion and should be shut off at this point on ments for a specific application must be estab-
deceleration. (For the 29,500 SHP site rating lished by the Buyer on the basis of the
condition illustrated, NOX suppression is not contractual site rating and actual applicable
required below a power level corresponding to emissions standard.
approximately 5700 pph fuel flow). During
initiation of water flow it is recommended that 9-1.2 Water System Purge and Drain
the gas turbine be operating at a stabilized Requirements: (Refer to Packager’s Manual)
9-1.3 System Flow and Pressure Require-
b. During gas turbine accelerations after ments: (Refer to Packager’s Manual)
initiation of water flow and from lower power
settings to higher power settings, two methods
of operation, or water flow regulation, are
acceptable; (1) increases water flow as fuel
flow is increased, or (2) accelerate the gas tur-
ing the water flow rate constant, then gradually
increase the water flow to the desired level
after the gas turbine is on point.

R-33
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ADDENDUM R
Figure 8. Water Inlet Pressure - PSIA vs Water Flow - PPH

R-34
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ADDENDUM S
ADDENDUM
7LM2500PC104D

GEK 97310
VOLUME I
ADDENDUM S
TABLE OF CONTENTS
1-0 INTRODUCTION....................................................................................... S-3

2-0 REFERENCE DATA .................................................................................. S-3
3-0 INSTALLATION DRAWINGS.................................................................. S-4
4-0 EQUIPMENT DESCRIPTION ................................................................. S-4
5-0 NOX SUPPRESSION (WATER INJECTION SYSTEM)....................... S-4
6-0 INSTRUMENTATION AND SUPPLY REQUIREMENTS ................... S-6
7-0 SERVICE REQUIREMENTS ................................................................... S-9
7-1.1 Natural Gas ................................................................................................... S-9
7-1.2 Water Servicing and Pump Requirements (NOX Suppression).................... S-9
7-1.3 Water Purity Requirements. .......................................................................... S-9
7-1.4 Water System Purge and Drain Requirements .............................................. S-9
8-0 OPTIONAL HARDWARE KITS .............................................................. S-10
9-0 GAS TURBINE OPERATION .................................................................. S-10
9-1 PERFORMANCE RATINGS AND OPERATING LIMITS .................. S-11
9-1.1 Performance Ratings ..................................................................................... S-11
9-1.2 Water Scheduling Requirements During Operation (NOX Suppression)..... S-12
9-1.3 System Flow and Pressure Requirements ..................................................... S-16
9-1.4 Operating Limits ........................................................................................... S-17
9-2 INITIAL OPERATION .............................................................................. S-17
9-2.1 General .......................................................................................................... S-17
9-2.2 Special Instrumentation Required for Operation .......................................... S-17
9-2.3 Special Instrumentation Required for Monitoring and Troubleshooting ...... S-17
9-2.4 Preparation .................................................................................................... S-21
9-2.5 Gas Turbine and Associated Equipment Check List.................................... S-21
9-2.6 Governor and Manual Control Check........................................................... S-22
9-2.7 Start-Up and Checkout.................................................................................. S-22
9-2.8 Ignition Check............................................................................................... S-23
9-2.9 Motoring........................................................................................................ S-24
9-2.10 False Start...................................................................................................... S-24
9-2.11 Governor Check ............................................................................................ S-24
9-2.12 Wet Prestart ................................................................................................... S-24
9-2.13 Manual Start and Operation .......................................................................... S-25
9-2.14 Operation to Maximum Power...................................................................... S-30
9-2.15 Automatic Operation..................................................................................... S-30
9-3 NORMAL OPERATION............................................................................ S-30
9-3.1 Interlocks....................................................................................................... S-30
9-3.2 Operation....................................................................................................... S-32
9-4 EMERGENCY OPERATION ................................................................... S-34
9-4.1 Emergency Shutdown ................................................................................... S-34
9-4.2 Post Shutdown Fire ....................................................................................... S-34

S-1
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ADDENDUM S
Figure Title Page
1 Deleted
2 Deleted
3 Deleted
4 Deleted
5 Deleted
6 Typical Acceleration Fuel Flow Schedule .................................................... S-13
7 Water Supply Pressure vs Flow for NOX Suppression................................. S-14
8 Water/Fuel Ratio Requirement When Operating on Natural Gas Fuel......... S-15
9 Transient Temperature Limits ....................................................................... S-35
LIST OF TABLES
Table Title Page
1 INSTRUMENTATION CONNECTIONS - 7LM2500PC104D................... S-6

2 SUPPLY CONNECTIONS - 7LM2500PC104D.......................................... S-7
3 GAS TURBINE OPERATING LIMITS....................................................... S-18
4 PRESTART CHECKS .................................................................................. S-23
5 START-UP AND OPERATION.................................................................... S-26
6 GAS TURBINE SHUTDOWN .................................................................... S-31
7 EMERGENCY SHUTDOWN...................................................................... S-33
8 Deleted

S-2
GEK 97310
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ADDENDUM S
The information contained herein describes the Compressor Stator, Rear 93 (42)
7LM2500PC104D gas turbine basic configura- Compressor Rear Frame 421 (191)
tion and control system differences. In addi- Combustor 120 (54)
instrumentation and supply connections, spe- High Pressure Turbine Rotor 419 (190)
cial servicing requirements, optional hardware High Pressure Turbine Nozzle,
kits and the complete gas turbine operating Stg 1 68 (31)
instructions for the 7LM2500PC104D model High Pressure Turbine Nozzle,
are included. Stg 2 127 (58)
Turbine Mid Frame 530 (240)
2-0 REFERENCE DATA.
EQUIPMENT Low Pressure Turbine Rotor 1095 (497)

Model No. 7LM2500PC104D High Speed Coupling Shaft
Drawing No. L31430G08 Forward Adapter 91 (41)
Exhaust Duct
PERFORMANCE RATING Ring Seal 49 (62)
Ring Support 74 (34)
Refer to paragraph 9-1
GAS TURBINE WEIGHTS Mech 19 (9)
components are: DRAWING LIST
Component Wt-Lbs/(Kg) Drawing No.

Gas turbine - including inlet 7396 (3355) Gas Turbine Installation
duct, centerbody, exhaust Drawing L31705
diffuser, and coupling nut
Fuel System Kit 682L310G07
Power Turbine 2777(1260) Drawing L24328
Inlet Gearbox 38 (17) Electrical Diagram L24329
Transfer Gearbox 245 (111) Ignition Units L21454P02
Compressor Front Frame 517 (235) Gas Turbine Assembly
Compressor Rotor 552 (250) Drawing L31430G08

S-3
GEK 97310
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ADDENDUM S
3-0 INSTALLATION DRAWINGS. b. The EPA New Source Performance
Standard (NSPS) for stationary gas turbines is
A complete set of installation drawings have contained in Title 40 Code of Federal Regula-
been provided. tions, Part 60, Subpart GG. The current rule
was published in 1982 and contains different
4-0 EQUIPMENT DESCRIPTION. NOX standards depending upon whether the
gas turbine is to be used for an electric utility
The LM2500PC104D is a natural gas fueled or an industrial application. The EPA defines
marinized gas turbine that incorporates a natu- an electric utility gas turbine application as one
ral gas manifold, a water manifold, and 30 fuel which sells more than one-third of its potential
nozzles. The gas turbine is provided with an capacity to a utility power distribution sys-
exhaust duct as standard equipment. The gas tem. Industrial gas turbines are defined as
turbine is configured with NOX Suppression those which include all stationary applications
equipment, and prior to initiation of water flow other than electric utilities. These standards, as
for NOX Suppression, it is recommended that applied to the LM2500 gas turbine, are as
the gas generator be operating at a stabilized follows:
• Electric utility application gas turbines:
5-0 NOX SUPPRESSION (WATER STD=75 (10180/y) + F,
INJECTION SYSTEM). ppm by volume referenced to 15% 02
a. The LM2500PC104D gas turbine is • Industrial application gas turbines:

equipped for suppression of oxides of nitrogen STD=150 (10180/y) + F,
(NOX) in the gas generator exhaust gases. ppm, by volume referenced to 15% 02
This is accomplished by introduction of water
into the fuel nozzles. The LM2500 NOX sup- Where:
pression system has been designed to meet the
requirements of the U.S. E.P.A. standard for y = heat rate in BTU/HP-Hr at peak
NOX emissions for stationary gas turbines and power
includes a conservative margin for meeting the F = allowance for fuel bound nitrogen
tive, local codes where applicable. c. Since the NOX standard is a function
of the gas turbine heat rate at peak power, it
will vary somewhat from one application to
another. Unless otherwise specified, the NOX
performance data contained in this addendum
is based upon an assumed LM2500 gas turbine
application subject to the 75 ppm standard
with an ISO site rating condition of
27,500 shp.

S-4
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S-5
GEK 97310
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ADDENDUM S
See Tables 1 and 2.
Table 1. INSTRUMENTATION CONNECTIONS - 7LM2500PC104D
Bell & Howell Electronics Part No.

E-1 Vibration pickup, Gas Generator
173960 or 364450

E-3A “A” sump T/C (optional equipment) MS3106R-12S-3SW except pin A iron
and pin B constantan
E-4A “B” sump T/C (optional equipment) MS3106R-12S-3SW except pin A iron
E-5A “C” sump T/C (optional equipment) MS3106R-12S-3SW except pin A iron
E-6 Accessory gearbox scavenge oil temperature MS3106R12S-3S
E-6A Accessory gearbox T/C MS3106R-12S-3SW except pin A iron
(optional equipment) and pin B constantan
E-11A Inlet T/C (optional equipment) MS3106R-12S-3SW except pin A iron
E-18 D-sump scavenge oil temperature MS3106R12D-3S
E-18A “D” sump T/C (optional equipment) MS3106R-12S-3SW except pin A iron
E-7 Gas generator speed pickup No. 1 MS3106R-10SL-4S
E-12 Gas generator speed pickup No. 2 MS3106R-10SL-4S
E-13 Vibration pickup, power turbine Bell & Howell Electronics Part No.
173960 or 364450

S-6
GEK 97310
VOLUME I
ADDENDUM S
Table 1. INSTRUMENTATION CONNECTIONS - 7LM2500PC104D - Continued

F3 Fuel manifold gas pressure tap AN818-4C or MS20819-4C
(optional)
W2 Water Inlet Liquid Pressure Tap #1 AN818-6C or MS20819-6C
W3 Water Inlet Liquid Pressure Tap #2 AN818-6C or MS 20819-6C
NOTE
For all other instrumentation connections, see the Installation Drawings, provided with
gas turbine.
Table 2. SUPPLY CONNECTIONS - 7LM2500PC104D

CAUTION
OR ON GAS GENERATOR. IF EXCESSIVE FORCE IS REQUIRED TO COM-
PLETE A CONNECTION, LOOSEN ALL CONNECTIONS AND CHECK/ADJUST
Manifold
W1 Water manifold inlet Water Manifold Inlet, mates with AN818-12C or
(NOX) MS20819-12C or equivalent.

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GEK 97310
VOLUME I
ADDENDUM S
Table 2. SUPPLY CONNECTIONS - 7LM2500PC104D - Continued

L1 Oil supply 1-1/4 inch line to Lube Pump on Gas Generator AN818-24C
or MS20819-24C
AN819-16C or MS20819-16C
L4 Lube supply inlet port 1 inch line from Oil Supply Filters to Gas Generator,
AN818-16C or MS20819-16C
L3 Scavenge oil discharge 1-1/4 inch line from Gas Generator Pump to oil Scavenge Fil-
ter and Cooler, AN818-20C or MS20819-20C
Al Bleed air port 8th stage Shipped with cover that must remain in place if port is not
used
A6 Starter air or gas inlet See Installation Drawings provided with gas turbine
port
A7 Starter air or gas outlet See Installation Drawings provided with gas turbine
port (optional equipment)
A12 Air/Oil separator 3-inch line from air/oil separator to atmospheric vent or to
A20 Sump overboard vent left If used - 2-inch line attaching hardware
bottom
A21 Sump overboard vent If used - 2-inch line attaching hardware
right
bottom
A22 C sump overboard vent If used - 2 inch line attaching hardware
right top
Sl or Waterwash manifold 1-inch line - hot water line to waterwash manifold on Gas
SlA Generator Inlet Duct AN818-16C or MS20819-16C

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GEK 97310
VOLUME I
ADDENDUM S
7-0 SERVICE REQUIREMENTS. 7-1.3 Water Purity Requirements. Water
supplied to the gas turbine must meet the fol-
7-1.1 Natural Gas. lowing minimum requirements:
a. The required supply pressure to the • Sodium + Potassium + Lead + Vana-

fuel manifold on the gas turbine is 350 ± 5 psig dium + Lithium = 0.1 ppm max
(2415 ± 35 kPa).
• Total ionizable solids, both dissolved
b. The temperature of the gas must be in and undissolved = 5 ppm max
the range of -65° to +150°F (-54 to +60°C). If
the temperature is not repeatable on a day-to- • Ph = 6.5 to 7.5
starting fuel adjustment to adjust the supply • The water shall not contain more than
pressure to the engine to maintain a constant 10 mg of solid contaminants per gal-
BTU-per-cubic-foot supply. Once started, the lon and the maximum contaminant
engine will accept variations in supply temper- sized shall not exceed 20 microns
ature of ±20°F (±12°C). The maximum fuel absolute.
flow required is 13,400 pph (6078 kg/h) with a
lower heating value of 19,000 Btu/1b. 7-1.4 Water System Purge and Drain
Requirements.
7-1.2 Water Servicing and Pump Require-
ments (NOX Suppression). a. A continuous purge system shall be
incorporated into the water system circuit in
a. The maximum allowable water deliv- order to ensure a continuous positive pressure
ery pressure at the water connection is in that system during periods of operation in
800 psig (5516 kPa). The temperature of the which water is not being injected. This purg-
water supplied to the manifold shall not exceed ing action will prevent the possibility of com-
180°F (82°C) and shall be free of pressure pul- bustion gases back-flowing through the water
sations in the 0 to 300 Hz range. system.
b. The required water/fuel ratio vs fuel
flow schedule in terms of water supply deliv- b. Either natural gas or compressed air
ery pressure may be developed from the cus- may be used as the purge medium. The purge
tomers performance data package as described gas or air must be filtered to 20 microns abso-
in paragraph 9-1.2. The design of the water lute and the temperature must not exceed
system should provide margin for varying the 350°F (177°C).
water flow rate by ±15 percent to permit
adjustment at the time of initial installation c. The water drain valves should be open
testing as required to satisfy EPA or other code only after closing the gas fuel shutoff valves
requirements. and should be closed before the gas fuel valves
are reopened.

S-9
GEK 97310
VOLUME I
ADDENDUM S
d. Refer to current Installation Design WARNING
Manual for recommendations/requirements
necessary for the buyer to establish a suitable IF A QUESTIONABLE CONDITION
purging system. EXISTS, DO NOT OPERATE THE
8-0 OPTIONAL HARDWARE KITS - OUGH INVESTIGATION HAS
LM2500PC104D. BEEN MADE. DO NOT REPEAT
a. Refer to Volume II, WP 001 00 for a STALLS, OR OTHER RECOGNIZED
detailed list of optional kits available for this INVESTIGATION. FAILURE TO
particular gas turbine model. DO SO CAN RESULT IN UNDUE
STRESS BEING IMPOSED ON GAS
9-0 GAS TURBINE OPERATION. TURBINE COMPONENTS, WITH
IMMEDIATE OR SUBSEQUENT
a. These instructions contain the detailed DESTRUCTIVE FAILURE OF THE
gas turbine operating procedures and limits GAS TURBINE AND INJURY TO
recommended by the General Electric PERSONNEL.
Company for the 7LM2500PC104D Gas
Turbine. NOTE
b. The instructions are intended to pro- direct mathematical conversions and
vide operating personnel with the information may be rounded off in most instances
required to operate the gas turbine. They per- at the users discretion. Examples of
tain to routine and emergency conditions and units that may be rounded off are those
procedures. When a fault exists, refer to utilized for temperatures, torque val-
Chapter 4 entitled, TROUBLESHOOTING. ues, pressures, etc. Examples where
c. It is possible that these instructions those utilized for drop checks, rigging
may not provide for every possible variation in adjustments, runouts, etc.
Refer requests for additional information to the

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GEK 97310
VOLUME I
ADDENDUM S
9-1 PERFORMANCE RATINGS AND With NOX
OPERATING LIMITS. Suppression to
Meet
NOTE Normal EPA Electrical
Ratings published in this manual apply (Dry) Standard
to the gas turbine. The driven unit rat- Relative 60% 60%
ings/limits may be lower in some cases Humidity
turbine manual limits. Compressor 0 lbs/secs 0 lbs/sec
Bleed
9-1.1 Performance Ratings. Accessory 0 0
Horsepower
a. The rated performance of the Extraction
LM2500PC104D gas turbine in the new and Power Turbine 3600 rpm 3600 rpm
clean condition, as compared to gas turbine Speed
Heat Rate, Avg.
6907 6959 BTU/hp-hr
follows:
BTU/hp-
hr
NOTE
Power Turbine 1406°F 1404°F
The use of water injection to control Inlet Gas (763.3°C) (762.2°C)
NOX emissions results in a change in Temperature
cifically agreed to in the applicable Water Injection 0 lbs/hr 1828 lbs/hr (829
contract documents, all performance (Average) kg/hr)
guarantees are based upon “dry” opera- Fuel Flow 9,996 lbs/ 10,072 lbs/hr
tion with no water injection. hr (4569 kg/hr)
(4534 kg/
With NOX hr)
Suppression to NOX 170 109
Meet Emissions*
Normal EPA Electrical
* No water injection is required to meet the
(Dry) Standard
EPA industrial NOX standard.
Brake 27,500 27,500
Horsepower
Inlet Air 59°F 59°F (15°C)
Temperature (15°C)
Altitude 0 ft. 0 ft.
Inlet Losses 0”H2O 0”H2O
Exhaust Back 0”H2O 0”H2O
Pressure

S-11
GEK 97310
VOLUME I
ADDENDUM S
As noted above, the use of water injection to f. For normal accelerations from idle to
control NOX emissions results in a change in power settings the changes should be made
gas turbine performance. Unless specifically more slowly to enhance the time between hot
agreed to in the applicable contract documents, section repairs and the life of the gas turbine; a
all performance guarantees are based upon time of 2 to 3 minutes is reasonable.
“dry” operation of gas turbines with no water
injection. The tabulation in step a depicts a g. The fuel rates shown on the curves will
comparison of the gas turbine performance at give starting times to 5000 rpm idle of 60 to 90
27,500 SHP and ISO conditions in both the seconds and accelerations from idle to maxi-
“dry” operational mode and with water injec- mum power of 15 seconds.
tion to meet EPA standards for electric utility
applications. Water injection for NOX sup- h. The maximum deceleration fuel flow
pression is not required in order to meet the rate should consist of a step fuel decrease of
EPA standard for industrial applications when 1500 (680 kg/h) + 10% pph followed by a rate
operating the LM2500-PC104D gas turbine on change of 1330 pph (603 kg/h) ± 10% per sec-
natural gas fuel. ond to idle fuel flow. Rates greater than this
can cause the gas turbine to lose fire. Normal
b. Approximate starting fuel flow require- decelerations from maximum power to idle
ments are: should be made in approximately 2 to 3 min-
utes - this will enhance the time between hot
465 pph (211 kg/h) ± 25 pph (11 kg) @ section repairs and the life of the gas turbine.
-65°F (-54°C) Inlet Air Temperature.
9-1.2 Water Scheduling Requirements Dur-
550 pph (249 kg/h ± 25 pph (11 kg) @
ing Operation (NOX Suppression).
+60°F (15°C) Inlet Air Temperature.
595 pph (270 kg/h) ± 25 pph (11 kg) @ a. Water schedules required to meet EPA
+130°F (54°C) Inlet Air Temperature. NOX Standards for electric utility applications
with natural gas fuel are shown in figure 8.
c. Figure 6 defines the maximum fuel The lower water schedule is that calculated for
acceleration schedule for the gas generator. an average new gas turbine with a 27,500 SHP
peak rating. The higher water schedule is the
d. Acceleration fuel rates greater than maximum value, which considers the effects of
those shown will result in over-temperature gas turbine to gas turbine deviation and mea-
and possible stall of the gas turbine. Accelera- surement variability. Water to fuel ratios in
tion fuel rates lower than those shown can excess of the values shown in figure 8 may be
result in “hung” starts in the below idle speed used to meet higher ratings under the EPA reg-
range. ulations, or to meet the requirements of other,
more stringent, local suppression codes.
times.

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VOLUME I
ADDENDUM S

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VOLUME I
ADDENDUM S
Figure 7. Water Supply Pressure vs Flow for NOX Suppression

S-14
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VOLUME I
ADDENDUM S
Figure 8. Water/Fuel Ratio Requirement When Operating on Natural Gas Fuel

S-15
GEK 97310
VOLUME I
ADDENDUM S
b. The nominal water schedule for a site d. During deceleration, including load
rating of 27,500 HP at ISO conditions is shedding operation, the water flow scheduling
shown on figure 8. The actual maximum on- should follow the fuel flow decel schedule.
site adjusted water flow required will fall
within the range shown. Water flow must be e. During emergency trip from power, the
scheduled as a function of fuel flow but must water shall be shut off coincident with the fuel.
be shut off during starting and acceleration to
idle. Water flow should be initiated at a fuel f. Water flow vs water supply pressure
flow of 5300 pph ± 450 pph on access and requirements to the gas turbine water supply
should be shut off at this point on decel. For interface connector are shown in figure 7 for
the 27,500 HP site rating condition illustrated, the EPA electric utility standard of 27,500 SHP
NOX suppression is not required below a site rating condition shown as an example in
power level corresponding to approximately figure 8. The water supply system and maxi-
5300 pph fuel flow. During initiation of water mum water supply pressure requirements for a
flow it is recommended that the engine be specific application must be established by the
operating at a stabilized steady state condition. buyer on the basis of the contractual site rating
Figure 7 shows the water pressure vs flow and actual applicable emissions standard using
characteristics at the manifold connections the method presented in paragraph 9-1.4.
based on the water to fuel schedule shown in
figure 8. Water to fuel ratios of up to 1.0 to 1 9-1.3 System Flow and Pressure
may be used to meet higher ratings under the Requirements.
EPA regulations or to meet the requirements of
other codes. When water is injected at flow a. A tabular gas turbine performance data
rates necessary to meet the U.S. EPA require- sheet will be provided for each specific NOX
ments, the maximum gas generator corrected suppression application upon customer request
speed limit must be reduced to 9650 rpm. No following receipt of a definition of the contrac-
change to the 9800 rpm maximum physical tual site rating and applicable NOX suppres-
speed limits is required. sion standard or code. This performance data
will list the following:
c. During gas turbine accelerations, after
initiation of water flow and from a lower (1) The calculated average gas tur-
power setting to a higher power setting, two bine water flow (WW) required to meet the
methods of operation or water flow regulation requirement of the applicable EPA standard or
are acceptable; (1) increase water flow as fuel other applicable code described in the contract
flow is increased, or (2) accelerate the gas tur- documents.
ing the water flow constant, then gradually (2) The corresponding fuel flow (wf).
increasing the water flow to the desired level
after the gas turbine is on point. (3) The internal gas turbine cycle
pressure level (PE16D).

S-16
GEK 97310
VOLUME I
ADDENDUM S
b. The above data may then be used to Lube oil scavenge tem-
establish the fuel and water supply delivery perature sensors
pressure requirements at the gas turbine inter- (A-, B-, C-, D-sumps and 0-400°F
face points utilizing the following equations: transfer gearbox) ............ (-17.8 to 205°C)
Lube oil supply 0-400°F
(1) Water pressure requirements
temperature ................... (-17.8 to 205°C)
WIP = (WW)² X 2.07 X 10-7
+ PE16D gas generator ............ 0-3 in/sec or
0-10 mil DA
Where: WIP + water inlet pres-
sure at the water manifold inter- power turbine ........... 0-3 in/sec or
face connection in psia 0-10 mil DA
Power turbine speed
WW = water flow - pph sensor ............................ 0-5000 rpm
PE16D = PS3 = fuel nozzle dis- Power turbine inlet gas 0-2000°F
charge pressure in psia temperature (T5.4) ......... (-17.8 to 1093°C)
(2) Fuel pressure requirement. The
pressure .......................... (0-690 kPa)
fuel supply pressure requirements for natural
gas fuel with water injection are the same as Compressor discharge 0-300 psig
those for the natural gas fuel system only. pressure .......................... (0-2070 kPa)
9-1.4 Operating Limits. Refer to Table 3. 9-2.3 Special Instrumentation Required for
NOTE
sensor ............................. (0-2760 kPa)
troubleshooting or inspecting gas Compressor inlet total 10-16 psia
generator. pressure sensor............... (69-110.4 kPa)
9-2 INITIAL OPERATION. pressure .......................... (0-517.5 kPa)
Fuel supply 0-400 psig
9-2.1 General. Initial operational period is pressure .......................... (0-2760 kPa)
gas turbine replacement or major maintenance Fuel supply 0-250°F
on the system. temperature .................... (-17.8-121.1°C)
Gas turbine inlet air tem- 0-150°F
9-2.2 Special Instrumentation Required for perature .......................... (-17.8-121.1°C)
Operation. Remote reading variable
vane indicator................. -5° to +45°
Gas generator speed
sensor ............................. 0-10,000 rpm
(optional)........................ (0-345 kPa)

S-17
GEK 97310
VOLUME I
ADDENDUM S
Normal
Alarm/ Operating
NOTE
Lubrication Gas Turbine Alarm 8 psig ± 1 psig 20-60 psig Bypass until
above 8000 rpm
Gas Turbine Trip 6 psig ± 1 psig 20-60 psig Bypass until
Lube Supply (41 kPa ± 6.9 kPa) (135-413 kPa) 4500 rpm
Pressure
Gas Turbine Alarm 110 psig ± 10 psig 10-100 psig Scavenge Discharge
Scavenge Dis- (759 kPa ± 69 kPa) (69-690 kPa) Pressure shall not
charge Pressure exceed 180 psig
(1242 kPa)
Gas Turbine Alarm 180°-220°F 140°F-160°F Normal Operating
Lube Supply (82°-104°C) (60° - 71°C) Range reflects tem-
during operation
above idle speed
Gas Turbine Trip 330°-350°F 215°-275°F Normal operating
Lube Scavenge (166°-177°C) (102°-135°C) Range reflects tem-
Temperatures - perature expected
Five Alarm 290°-310°F during operation
(143°-154°C) above idle speed
System Manifold (138-2448 reflected at the fuel
(Natural Gas) Pressure kPa) manifold inlet on the
gas turbine

S-18
GEK 97310
VOLUME I
ADDENDUM S
Normal
Alarm/ Operating
Fuel Supply Alarm 150°-170°F -65° to 150°F Starting Fuel Flow

Temperature (66°-77°C) (-54° to 66°C) adjustments may be
required to compen-
ture variation
on engine starter
torque requirements
Fuel and
Ignition
Fuel and igni- start after purge cycle
tion (if purge
cycle is used)
neously with start
initiation
Failure to Trip 380°- 420°F Activate 20 seconds
Light-Off (193°-216°C) time delay simulta-
tion of fuel and
ignition
neously with start ini-
tiation. De-energize
and starter air supply

S-19
GEK 97310
VOLUME I
ADDENDUM S
Normal
Alarm/ Operating

to 4500 rpm (if time delay upon com-
purge cycle is pletion of purge. De-
used) energize fuel and
starter air supply
Power Failure to Trip 380°-420°F 0-1600°F Trip if temperature
Turbine Inlet Light-Off (193°-216°C) (0-871°C) does not reach 400°F
Temperature (204°C) within 10
seconds after fuel and
ignition are applied
Over- Trip 1450°F (788°C) 1378°-1438°F Values given are for
temperature (748°-781°C) installations using
Alarm 1438°F (781°C) constant T5.4 control
as the power limit.
Installations using
constant power con-
trol mode should con-
sult the contract
mining alarm and trip
settings, which are
unique to each appli-
cation, but never to
exceed 1616°F
(880°C) (alarm) and
1625°F (885°C) (trip)
Generator operation over
Power Trip 10 mils ± 1 mil DA Avoid continuous
Turbine operation over

S-20
GEK 97310
VOLUME I
ADDENDUM S
Normal
Alarm/ Operating
Speed Gas Trip 9950 ± rpm 0-9850 rpm

Generator
Power Trip 3960 ± 40 rpm 0-3600 rpm
Turbine
Flame Flame fuel shut off valve
upon loss of flame
9-2.4 Preparation. The gas turbine and asso- h. All accessories are secure
ciated systems must be inspected and checked per packager’s manual _________
normal operation can commence. i. Gas turbine assembly free
9-2.5 Gas Turbine and Associated Equip- lines/electrical leads
ment Check List. Complete the following connected _________
check list. j. Gas turbine inlet air area
free of foreign object.
a. Gas Turbine Assembly Inlet screen secure _________
S/N _________
k. Gas turbine compressor
b. Mounting base secured to rear frame leakage ports,
foundation _________ struts 7 and 10, are open
c. Intake air and exhaust gas (not capped) _________
ducts in place and secured _________ 1. Starter is serviced per
d. Gas turbine and exhaust packager’s manual _________
duct support mounts and m. Lube oil storage tank ser-
links in place and secure _________ viced to full level _________
e. All service connections n. Lube oil supply valves
made and secure _________ open _________
f. All lines have been o. All filters are serviced per
flushed per packager’s packager’s manual _________
manual _________
p. T5.4 thermocouple system
g. All instrumentation con- functioning properly _________
nections made and secure _________
q. Ignition system operative _________

S-21
GEK 97310
VOLUME I
ADDENDUM S
r. Compressor inlet total • THE FIRE EXTINGUISHING
pressure probe aligned SYSTEM SHALL BE MADE
properly and free of INACTIVE ACCORDING TO
damage _________ THE CUSTOMER’S
PROCEDURES.
s. Variable stator system
secure _________ • SECONDARY AIR TO THE
t. Required checks and ENCLOSURE SHALL BE SHUT
inspections specified in OFF. HIGH SECONDARY AIR-
packager’s manual for gas FLOW MAY PREVENT OPEN-
turbine control have been ING OR CLOSING THE
performed _________ ENCLOSURE DOOR.

Refer to packager’s manual. SHALL BE KEPT OPEN. IF THE
9-2.7 Start-Up and Checkout. AN OBSERVER SHALL BE STA-
WARNING DOOR AND CONFINED SPACE
BE FOLLOWED.
MET:
SHUT DOWN.
LATED GLOVES AS
NECESSARY.
ENTRY SHOULD BE
OPERATING.
ENCLOSURE OR IN THE
MOTORING THE GAS
TURBINE.

S-22
GEK 97310
VOLUME I
ADDENDUM S
Item Requirement
Fuel valves Closed
Ignition Off
Ventilation inlet air (secondary cooling air) Off-air temp below 70°F (21°C)
Oil tank level Full
Lube oil temperature 140°F to 160°F (60° to 71.1°C)
Fuel supply
temperature -65 to 150°F (-54 to 65.5°C)
flow 13,400 pph (6078 kg/h) max @ 19000 BTU/lb.
c. Perform ignition checkout per 9-2.8 Ignition Check.

paragraph 9-2.8.
WARNING
e. Perform false start per CONNECTING AND CONNECT-
f. Perform governor check per LEAD. TAG SWITCH OUT OF
paragraph 9-2.11. SERVICE TO PRECLUDE INAD-
VERTENT ACTIVATION.
paragraph 9-2.12. • ASSURE FUEL VALVES ARE
PROCEDURE.
paragraph 9-2.13.
paragraph 9-2.14.
paragraph 9-2.15.

S-23
GEK 97310
VOLUME I
ADDENDUM S
b. Disconnect number one ignition exciter c. Hold MOTORING pushbutton closed
input lead at exciter. Temporarily secure input until gas generator speed stabilizes, and check
lead away from the exciter. for oil pressure. If there is no indication of oil
c. Turn on electrical power to the ignition while gas generator is coasting down, loosen
system (No. 2 ignition exciter energized). An oil fittings at lube pump to bleed air from sys-
audible report (approximately two sparks per tem. Starter should motor gas generator to
second) should be heard when the No. 2 spark minimum of 2200 RPM.
igniter fires.
d. Turn off electrical power to the ignition dure until an indication of oil pressure appears.
safety wire connector. 9-2.10 False Start. Perform false start as
follows:
e. Repeat steps b, c and d disconnecting
the No. 2 exciter. a. With ignition leads disconnected and
f. If an audible report is not heard on of gas turbine per packager’s manual.
tem to isolate the problem, and take appropri- b. Gas generator should go through nor-
ate corrective action. mal start cycle and then abort because of lack
of flame.
9-2.9 Motoring. After all preliminary checks
have been completed and lines flushed, gas 9-2.11 Governor Check. Check governor sys-
generator can be motored as follows: tem per packager’s manual.
a. Make ignition and natural-gas supply 9-2.12 Wet Prestart. Perform wet prestart as
systems inoperative as follows: follows:
(1) Disconnect power supply to igni- a. With ignition lead disconnected but
tion units. with manual gas valve open and governing
(2) Close natural-gas manual shutoff generator per packager’s manual.
b. Depress MOTORING pushbutton. Gas light-off speed (1700 rpm). Fuel valve should
generator will start to rotate. If it does not, open and fuel manifold pressure should be
refer to packager’s manual for supply pressure approximately 3 psig (20.7 kPa). Adjust fuel
to starter. supply if required. Start will then abort

gas from gas generator.

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GEK 97310
VOLUME I
ADDENDUM S
9-2.13 Manual Start and Operation. Perform (1) Shutdown gas turbine.
system normal and with ignition lead con- (2) Immediately after the gas turbine
nected. Refer to Table 5. stops rotating, re-start and stabilize at idle
CAUTION
DO NOT EXCEED 7000 RPM NGG additional start-up and shutdown cycles.
BINE OPERATION WITHOUT (4) If the power turbine does not
POWER TURBINE ROTATION. rotate after accomplishing substeps (1) through
NOTE
rotation stops, re-start and accelerate to 7000
rpm NGG maximum and stabilize for 30 sec-
onds. If the power turbine still does not rotate,
a. The power turbine must rotate by the shut down and investigate/correct the cause.
time the gas generator speed reaches 7000 rpm During the investigation for the cause of a
NGG. If power turbine speed indication is not thermally seized rotor, inspect the LPT blades
obtained and it is determined that a “thermal in stages 4, 5 and 6 for shingling and unlatch-
seizure” of the power turbine has occurred, ing. If blades have become unlatched, they
proceed as follows: may be relatched. LPT blades that have
encountered shingling may be bent and must
NOTE be replaced accordingly.

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GEK 97310
VOLUME I
ADDENDUM S


are completed per Table 4 1450°F (788°C). Refer to
figure 9
CAUTION
IF T5.4 RAPIDLY APPROACHES OR EXCEEDS 1438°F (781.1°C),
ABORT START.
NOTE
A start may be aborted at any time by closing fuel valve, allowing gas gen-
erator to motor for 60 seconds, then closing starter shutoff valve
NOTE
3. At 1100 rpm NGG
a. Ignition on
(21 kPa)
c. Note time to light- 10 seconds max. Abort start-automatic
off (T5.4 above shutdown
400°F-[204°C])
4. Note time to 4500 ± 200 90 seconds max. Troubleshoot system and
take corrective action if
rpm stops accelerating or it
reach 4300 rpm
5. At 4300 to 4700 rpm NGG
a. Starter shutoff Valve closed Close fuel valve and allow

valve close gas generator to motor for
automatically 60 seconds, then shut off
starter

S-26
GEK 97310
VOLUME I
ADDENDUM S

6. Note time to 5000 rpm
NGG
7. At idle check the

following:
Chapter 5 (41 kPa)
b. Fuel manifold pres- Approx 25 psig (173 kPa) Troubleshoot system and
sure take corrective action.
d. Maximum NGG 7000 rpm NGG Shut down and investigate/

with power turbine maximum for 30 seconds correct cause per
seizure (thermal (for early model gas turbines paragraph 9-2.13
seizure) that have tighter LPT blade
tip clearances, do not exceed
onds of gas turbine operation
without power turbine
rotation)
e. T5.4 1000°F (530°C) maximum Emergency shutdown
Table 7

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GEK 97310
VOLUME I
ADDENDUM S


action
action
as required
j. Check for fuel or No leaks allowed Correct as required
oil leaks
8. Set desired power setting. 1438°F (781.1°C) max. Correct as required. Refer
Observe T5.4 during tran- to transient temperature
sient operation limits contained in figure 9
a. T5.4 1378° - 1438°F *
(748° - 781°C)

e. Scavenge oil 215°F to 275°F Automatic shutdown if
temperature (102° to 135°C) above 340°F (171°C)

S-28
GEK 97310
VOLUME I
ADDENDUM S

f. Gas generator 3 mils maximum *
shutdown
g. Power turbine 6 mils maximum *
shutdown
h. Fuel manifold inlet 25-320 psig **
i. Fuel inlet -65° to 150°F **
temperature (-54° to 66°C)
∆P
filter ∆P
WP 118 00 WP 118 00
*Reduce power to stay within limits. If reducing power does not bring parameters
within limits, shutdown.

S-29
GEK 97310
VOLUME I
ADDENDUM S
CAUTION
TIVE CIRCUITS. OPERATING
LIMITS SHALL NOT BE c. Log all instrument readings.
EXCEEDED.
(refer to packager’s manual) to increase gas e. Check for fuel or lube oil leaks.
generator speed. After each 5000 rpm
increase, log all instrument readings, paying f. After a total of five minutes at idle,
particular attention to variable stator vane shut down gas turbine.
position and vibration. If variable stator sys-
tem is not within limits, adjust it per g. Check lube oil and fuel filters and
WP 118 00. If vibrations are not within limits, strainers; clean or replace as necessary.
consult the local General Electric Company
representative. h. Correct any leaks observed.
b. Operate gas turbine up to rated power, i. Remove all temporary instrumentation.
perature (T5.4) limit. Hold at this power set- j. Check gas turbine and mounting sys-
ting until all temperatures stabilize. If tem for loose parts; tighten as necessary.
governing system is unstable, adjust per pack-
ager’s manual. 9-3 NORMAL OPERATION.
c. Log all instrument readings once they 9-3.1 Interlocks. Refer to packager’s manual
stabilize. Refer to Table 5, step 9. for description of interlocks which affect gas
turbine operation.



S-30
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ADDENDUM S
1. Set gas turbine at idle Gas generator Emergency shutdown
power (unloaded) decelerates
2. After stabilizing for 3
minutes, read and record
the following:
b. Fuel manifold Approximately 25 psig
pressure: (173 kPa). Refer to
paragraph 9-1.3.
d. T5.4 1000°F (538°C) Troubleshoot and take corrective
maximum action
f. Gas generator 3 mils maximum Alarm above 4 mils. Automatic
vibration normal shutdown if above 7
mils. Troubleshoot and take cor-
rective action
g. Power turbine 6 mils maximum Alarm above 7 mils. Automatic
rective action
h. Fuel inlet
temperature:
(-54° to +66°C)
i. Scavenge oil fil- Refer to packager’s
ter ∆P manual
j. Lube oil supply Refer to packager’s
filter ∆P manual
3. After stabilizing at idle T5.4 drops below 400°F Shut off fuel supply
for 5 minutes, close fuel (204°C) NGG and NPT
valves decelerate and stop
4. Observe T5.4 for 3 min- 700°F (371°C) Motor gas turbine and fuel sup-
utes after shutdown ply. Continue motoring until
temperature decreases.

S-31
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ADDENDUM S
LATED GLOVES AS
NECESSARY.
OPERATING.
SHUT DOWN.
ENCLOSURE OR IN THE
ENTRY SHOULD BE
MOTORING THE GAS
TURBINE.
THE CUSTOMER’S
PROCEDURES. NOTE
• SECONDARY AIR TO THE During normal shut down with NOX

ENCLOSURE SHALL BE SHUT suppression being used, closure of the
OFF. HIGH SECONDARY AIR- fuel valve should be delayed after
FLOW MAY PREVENT OPEN- water is shut off to allow purging of
ING OR CLOSING THE water from the fuel manifold.
ENCLOSURE DOOR.
• THE ENCLOSURE DOOR per Table 7.
GAS TURBINE IS OPERATING, e. Refer to applicable table in Chapter 5
AN OBSERVER SHALL BE STA- for oil pressure correction factors.
BE FOLLOWED.

S-32
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ADDENDUM S

CAUTION
ASSURE FREEDOM OF ROTATION OF GAS GENERATOR AFTER AN EMER-
GENCY SHUTDOWN FROM HIGH POWER SETTINGS. SEIZURE OF GAS GENER-
ATOR ROTOR MAY OCCUR DUE TO TIGHT CLEARANCES. NORMALLY THE
1. Conditions permitting, decelerate gas T5.4 drops below Manually shut off fuel
turbine to idle and close fuel valves 400°F (204.4°C) supply
and NGG and NPT
decelerate
2. Observe T5.4 for 3 minutes after shutdown 700°F Motor gas turbine
(371.1°C) max. until temperature
decreases
3. If an emergency shutdown from a high power
setting (T5.4 greater than 1150°F (621°C) has
occurred, and a “hot restart” is required, pro-
ceed as follows:
. a. If the fault detection and sequencing
bine can restarted within 1 minute fol-
lowing coastdown of the HPC rotor,
. b. If a “hot restart” is to be performed
for 5 minutes. At the end of the 5
minute motoring/purge cycle, perform
normal restart and accelerate to idle.
Acceleration to the desired power set-
ting can then be accomplished.

S-33
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ADDENDUM S


NOTE 9-4 EMERGENCY OPERATION.

Refer to figures 6 through 10 for fuel
system requirements. Refer to 9-4.1 Emergency Shutdown.
figures 7 and 8 when operating with
NOX suppression. a. In an emergency, the gas generator may
(200.1 kPa) maximum after five (5) minutes be done in an emergency, since rapid shutdown
stabilization. decrease life of gas generator.

5 at standard conditions of 9000 rpm gas gen-
erator speed and 150°F (65.6°C) at lube pump c. If an emergency shutdown must be ini-
at conditions other than standard shall be cor- on-line, the water and fuel valve shall be shut
h. Prior to initiation of water flow for startup.
ture increases instead of decreasing, it indi-
cates that combustion is still taking place
because of a leaking fuel valve. (A slight tem-
perature increase after rotation stops is nor-
mal.) Make certain fuel is shut off, and motor

S-34
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ADDENDUM S

S-35
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ADDENDUM S
Table 8. Deleted

S-36
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ADDENDUM T
ADDENDUM
INDUSTRIAL GAS GENERATOR MODEL
7LM2500GA101

GEK 97310
VOLUME I
ADDENDUM T
TABLE OF CONTENTS
1-0 INTRODUCTION....................................................................................... T-3

2-0 REFERENCE DATA .................................................................................. T-3
3-0 EQUIPMENT .............................................................................................. T-3
4-0 PERFORMANCE RATING ...................................................................... T-3
5-0 GAS GENERATOR WEIGHT .................................................................. T-3
6-0 DRAWING LIST......................................................................................... T-3
7-0 INSTALLATION DRAWINGS.................................................................. T-3
8-0 EQUIPMENT DESCRIPTION ................................................................. T-3
9-0 ACCESSORY DRIVE SYSTEM............................................................... T-3
9-1.1 General .......................................................................................................... T-3
9-1.2 Components .................................................................................................. T-3
9-1.3 Description .................................................................................................... T-3
10-0 IGNITION SYSTEM .................................................................................. T-4
10-1.1 Ignition Exciter ............................................................................................. T-4
10-1.2 Ignition Leads ............................................................................................... T-12
10-1.3 Igniters .......................................................................................................... T-12
11-0 THERMOCOUPLE SYSTEM (T5.4) ........................................................ T-12
12-0 LUBRICATION SYSTEM......................................................................... T-14
12-1.1 General .......................................................................................................... T-14
12-1.2 Components .................................................................................................. T-14
12-1.3 Description .................................................................................................... T-14
12-1.4 Components Description............................................................................... T-18
13-0 SERVICE REQUIREMENTS ................................................................... T-22
13-1.1 Natural Gas ................................................................................................... T-22
14-0 OPTIONAL HARDWARE KITS - LM2500GA101 ................................ T-22
15-0 GAS GENERATOR OPERATION ........................................................... T-22
15-1 PERFORMANCE RATINGS AND OPERATING LIMITS .................. T-23
15-2 INITIAL OPERATION .............................................................................. T-23
15-2.1 General .......................................................................................................... T-23
15-2.2 Special Instrumentation................................................................................. T-23
15-2.3 Preparation .................................................................................................... T-32
15-2.4 Startup and Checkout .................................................................................... T-33
15-3 NORMAL OPERATION............................................................................ T-37
15-3.1 General .......................................................................................................... T-37
15-3.2 Interlocks....................................................................................................... T-37
15-3.3 Operation....................................................................................................... T-37
15-4 EMERGENCY OPERATION ................................................................... T-41
15-4.1 Emergency Shutdown ................................................................................... T-41
15-4.2 Post-Shutdown Fire....................................................................................... T-43

T-1
GEK 97310
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ADDENDUM T
Figure Title Page
1 Gas Generator Variable Stator Schedule - PN L21035P02 Speed Sensor ............. T-6
2 Speed Sensor Output Scale Reading...................................................................... T-7
3 Variable Stator Vane Schedule - L21808P06 Speed Sensor .................................. T-8
4 Speed Sensor Output Scale Reading - L21808P06................................................ T-9
5 Inlet and Transfer Gearboxes................................................................................. T-10
6 Accessory Drive System ........................................................................................ T-11
7 Ignition Exciter ...................................................................................................... T-11
8 Igniter Schematic ................................................................................................... T-13
9 Thermocouple Schematic ...................................................................................... T-13
10 Lubrication System Flow Diagram........................................................................ T-15
11 Lube and Scavenge Pump...................................................................................... T-19
12 Forward Scavenge Pump ....................................................................................... T-20
13 Air-Oil Separator ................................................................................................... T-21
14 Gas Generator Performance - Isentropic Gas Horsepower Vs. Inlet Air
Temperature, Exhaust Gas Pressure, and Exhaust Gas Temperature................. T-24
Temperature, Fuel Flow, and Exhaust Gas Flow ............................................... T-25
Temperature and Gas Generator Speed.............................................................. T-26
17 Performance Correction Factors ............................................................................ T-27
18 Transient Temperature Limits for Starts ................................................................ T-29
19 Transient Temperature Limits (Except Starts) ....................................................... T-29
20 Vibration Limits ..................................................................................................... T-30
21 Gas Generator Air Flow, Temperature, and Pressure Profiles (8900 RPM) .......... T-31
LIST OF TABLES
Table Title Page
1 INSTRUMENTATION CONNECTIONS - 7LM2500GA101.............................. T-4

2 MECHANICAL SERVICE CONNECTIONS - LM2500GA101 ......................... T-5
3 OPERATING LIMITS - LM2500GA101.............................................................. T-28
4 MIL-L-23699 OIL PRESSURE CORRECTIONS FOR TEMPERATURE AT
8000 RPM .......................................................................................................... T-39
5 MIL-L-7808 OIL PRESSURE CORRECTIONS FOR TEMPERATURE AT
8000 RPM ...................................................................................................... T-40
6 EMERGENCY SHUTDOWN............................................................................... T-42

T-2
GEK 97310
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ADDENDUM T
1-0 INTRODUCTION. 8-0 EQUIPMENT DESCRIPTION.
This addendum provides information which
1 Gas generator
applies specifically to the LM2500GA101 gas
1 Inlet duct with water wash manifold
generator model, and may or may not be appli-
1 Centerbody
cable to other gas generator models covered by
30 Natural gas fuel nozzles and 1 fuel
this manual. Reference data, instrumentation
manifold
and service connection information, special
1 Lubrication system (less oil tank,
servicing requirements, optional equipment
cooler and filter)
information, and complete operating instruc-
1 Ignition unit
tions are included.
1 Set of instrumentation sensors.
2-0 REFERENCE DATA.
9-0 ACCESSORY DRIVE SYSTEM.
Refer to table 1.
See figures 5 and 6.
3-0 EQUIPMENT.
9-1.1 General.
Gas Generator Assembly
General Electric Co., Cincinnati, Ohio 45215
The accessory drive system provides suitable
Model No. 7LM2500GA101
mounting provisions and mechanical power
Dwg. No. L16760G01
extraction for pumps, etc.
4-0 PERFORMANCE RATING.
9-1.2 Components.
Refer to paragraph 15-1.
a. Inlet gearbox.
5-0 GAS GENERATOR WEIGHT.
b. Forward and aft transfer gearbox.
The average weight of the LM2500GA101 gas
9-1.3 Description.
generator is 3800 pounds (1724 kilograms).
6-0 DRAWING LIST. The accessory drive system consists of a right-
angled bevel gearbox, located in front frame;
Drawing No.
the forward transfer gearbox, mounted on the
Gas Generator Installation L16795 front frame at the bottom of the gas generator;
an aft transfer gearbox mounted on the com-
Fuel Flow and Governor
pressor casing aft of the forward transfer gear-
Schematic L21126
box; and radial and horizontal drive shafts.
Power to drive the transfer gearboxes is
Diagram L21226
extracted from the compressor stub-shaft and
Electrical Diagram L21128 transmitted through a large-diameter, hollow
shaft, which encircles the stub-shaft, to a bevel
Ignition Unit L14460
gear set in the inlet gearbox. The radial shaft
Gas Generator Assembly L16760G01 carries the power from the inlet gearbox to the
forward transfer gearbox located at the bottom
of the front frame. Power from the forward
A complete set of installation drawings have transfer gearbox is transmitted to the aft trans-
been provided. fer gearbox by a horizontal drive shaft.

T-3
GEK 97310
VOLUME I
ADDENDUM T
10-0 IGNITION SYSTEM. to energize 2 igniters at a rate of 2 sparks per
second (nominal), and operates from a power
The ignition system produces the high-energy supply of 115V, 60 Hz. The circuit is described
sparks which ignite the fuel-air mixture in the as a "series dual" in that one storage capacitor
gas generator combustor. It consists of an igni- is discharged thru 2 igniters, electrically con-
tion exciter, 2 ignition leads, and 2 igniters. nected in series. It includes a filter to prevent
feedback transient energy from being con-
10-1.1 Ignition Exciter. See figure 7. The ducted out of the ignition unit housing by way
ignition exciter converts the input power sup- of the input power connections. The duty cycle
plied by the Purchaser's electrical system to a of the exciter is 2 minutes on, 3 minutes off, 2
high-voltage, high-current, pulsed output. It is minutes on, 23 minutes off.
a capacitor-discharge type having a stored
energy of nominally 14 joules and is designed .
Table 1. INSTRUMENTATION CONNECTIONS - 7LM2500GA101

P1 Compressor Inlet Pressure MS33656-6
P4 Lube Supply Pressure AND10050-4
P5 Exhaust Gas Pressure AN824-4C
P6 Fuel Manifold Pressure MS33656-4
P7 Lube Scavenge Discharge Pressure AN818-4C or MS20819-4C
T2 Exhaust Gas Temperature MS3100-12S-3P
T3 A-sump Lube Scavenge Temperature (RTD) MS33678-12S-3P
T4 B-sump Lube Scavenge Temperature (RTD) MS33678-12S-3P
T5 C-sump Lube Scavenge Temperature (RTD) MS33678-12S-3P
T6 Lube Oil Inlet Temperature (RTD) MS33678-12S-3P
T9 Gas Generator Speed MS3101A-10SL-4P
T11 Gas Generator Vibration MS33656-6
NOTE
gas generator.

T-4
GEK 97310
VOLUME I
ADDENDUM T
.
Table 2. MECHANICAL SERVICE CONNECTIONS - LM2500GA101

E3 Compressor Inlet Temperature Signal Port AND10050-4
E9 Compressor Inlet Temperature Sensor Drain MS33656-4
E10 Compressor Inlet Temperature Sensor Supply AND10050-4
L1 Lube Pump Supply AN818-20C or MS20819-20C
L2 Lube Supply AN818-16C or MS20819-16C
L6 Lube Pump Discharge AN818-16C or MS20819-16C
L9 Lube Oil Drain AN818-6C or MS20819-6C
L14 Lube Scavenge Discharge AN818-20C or MS20819-20C
L19 Starter Fill Port AN818-4C or MS20819-4C
T7 Starter Electrical Connection MS3102A-10SL-4P
T8 Ignition Electrical Connection MS33678-12S-3P
T10 Governor Input Speed Signal MS3101A-10SL-4P
W1 Compressor Cleaning Connection AN818-12C or MS20819-12C
NOTE
For all other mechanical service connections, see the Installation Drawings, provided with
gas generator.

T-5
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ADDENDUM T
Figure 1. Gas Generator Variable Stator Schedule - PN L21035P02 Speed Sensor

T-6
GEK 97310
VOLUME I
ADDENDUM T
Figure 2. Speed Sensor Output Scale Reading

T-7
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ADDENDUM T
Figure 3. Variable Stator Vane Schedule - L21808P06 Speed Sensor

T-8
GEK 97310
VOLUME I
ADDENDUM T
Figure 4. Speed Sensor Output Scale Reading - L21808P06

T-9
GEK 97310
VOLUME I
ADDENDUM T
Figure 5. Inlet and Transfer Gearboxes

T-10
GEK 97310
VOLUME I
ADDENDUM T
Figure 6. Accessory Drive System
Figure 7. Ignition Exciter

T-11
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VOLUME I
ADDENDUM T
10-1.2 Ignition Leads. The ignition leads are in swaged, stainless steel sheathing, which is
high-tension, flexible cable assemblies of co- filled with magnesium oxide for insulation.
axial construction incorporating a copper con- Each dual-immersion probe assembly consists
ductor enclosed in a stainless steel shield. Each of 2 single loop-junction thermocouples which
lead is housed in a gas-tight conduit, which are enclosed in swaged, stainless steel tubes
also provides a shield to prevent radiation of with magnesium oxide insulation.
RF energy. Connection to the ignition exciter
b. A thermocouple junction is formed
and to the igniters is provided by button-type
when 2 dissimilar metals are joined. KP and
terminal contacts.
KN are used as the dissimilar metals. A com-
plete circuit is formed when both ends of the
10-1.3 Igniters. The igniters produce the
KP and KN wires are joined. The junctions are
sparks which ignite the fuel-air mixture in the
termed "hot" and "cold". When the cold junc-
combustion section of the gas generator. See
tion is maintained at a known reference tem-
figure 8. They are of high-voltage design with
perature and the hot junction is exposed to a
semi-conductor material used on the tip insula-
high temperature, an electromotive force
tor. The igniters are mounted in threaded pads
(EMF) will be generated which is proportional
at about the 4 and 5 o'clock positions on the
to the temperature of the hot junction. The
compressor rear frame. The tips of the igniters
EMF is extremely small in magnitude. [At a
are inserted into ferrules of the swirl cups in
hot junction temperature of 1560°F (850°C)
the combustion liner. During gas generator
and cold junction temperature of 32°F (0°C),
starting the ignition exciter provides energy to
about 0.035 volts will be generated.] When
both igniters. Each igniter consists of a center
considering a circuit with several thermocou-
electrode, a ground electrode, and a semicon-
ples connected in parallel, a problem of bal-
ductor material that provides a constant resis-
ancing the system presents itself. The line
tance between the 2 electrodes. Normally a
voltage drops of all the thermocouple leads
potential of 1000-1500 volts will force enough
must be equal, to prevent current from flowing
current through the semi-conductor to ionize
between 2 parallel thermocouples. System bal-
the air gap between the electrodes and provide
ancing can be accomplished in a number of
a bridge for the ignition spark.
ways. For the 7LM2500GA101 gas generator,
a common junction and geometrically bal-
11-0 THERMOCOUPLE SYSTEM
anced system is used. (This accounts for the
(T5.4).
long thermocouple leads which are routed
back and forth on the turbine frame.) The elec-
The thermocouples generate an electrical sig- trical output of each of the 22 junctions is aver-
nal which is proportional to the temperature of aged (electrically) by successively paralleling
the turbine discharge gas. This temperature is conductors of equal resistance. The resultant
sometimes referred to as T5.4. output signal of both harness halves represents
the average temperature of the turbine dis-
a. See figure 9. The thermocouple har- charge gas.
ness consists of 2 half-sections. One half-sec-
tion has 6 probe assemblies; the other has 5.
The separate probe assemblies are connected
in a parallel configuration by using equal-
length leads. The electrical leads are contained

T-12
GEK 97310
VOLUME I
ADDENDUM T
Figure 8. Igniter Schematic
Figure 9. Thermocouple Schematic

T-13
GEK 97310
VOLUME I
ADDENDUM T
12-0 LUBRICATION SYSTEM. (2) Scavenge portions of the lube and
scavenge pump.
12-1.1 General.
(3) Anti-static leakage check valve.
Oil is distributed to components requiring
lubrication and cooling by the supply element (4) Scavenge piping.
of the lube and scavenge pump. Distribution is
controlled by nozzles, which direct oil at each c. Oil seal pressurization subsystem.
component. Five separate scavenge elements
(1) Seal air-to-oil cooler.
(3 in one pump; 2 in another) remove the oil
from the gas generator cavities and return it to (2) Ejector.
the purchaser's tank. The gas generator lubri-
(3) Frame strut inlets.
cation system is connected with and depends
on the Purchaser-provided lubrication system, (4) Low pressure cavities.
which includes such components as the oil
(5) Labyrinth oil and air seals.
tank, filters, coolers, etc. Refer to the pur-
chaser's instruction manuals for information on d. Sump vent subsystem.
the purchaser's system and its components.
(1) Air/oil separator.
Four subsystems, each of which accomplishes
a specific function to assure adequate lubrica- (2) Vent piping.
tion for the bearings and gears of the gas gen-
12-1.3 Description. See figure 10.
erator, make up the gas generator lubrication
system. They are as follows:
a. Lube Supply Subsystem. Oil flows
from the purchaser's oil tank to the lube supply
a. Lube supply subsystem.
element of the lube and scavenge pump. It
b. Lube scavenge subsystem. enters the pump through a lube inlet screen,
which removes particles larger than 0.037 inch
c. Oil seal pressurization subsystem.
(0.94 mm). A pressure relief valve, which is
d. Sump vent subsystem. part of the pump, protects the system. From the
pump, oil flows through a purchaser-supplied
12-1.2 Components.
filter, through an anti-static leakage check
valve, through the seal air-to-oil cooler, to the
a. Lube supply subsystem.
3 bearing areas, and to the gearboxes. The lube
(1) Lube portions of the lube and supply subsystem also supplies oil to the vari-
scavenge pump, including a pressure relief able stator system and to the starter.
valve.
(2) Anti-static leakage check valve.
(3) Lube discharge nozzles.
(4) Lube supply piping.
b. Scavenge subsystem.
(1) Forward scavenge pump.

T-14
GEK 97310
VOLUME I
ADDENDUM T
Figure 10. Lubrication System Flow Diagram (Sheet 1 of 2)

T-15
GEK 97310
VOLUME I
ADDENDUM T
Figure 10. Lubrication System Flow Diagram (Sheet 2 of 2)

T-16
GEK 97310
VOLUME I
ADDENDUM T
b. Lube Scavenge Subsystem. The scav- (4) The scavenge subsystem and the
enge subsystem consists of 5 elements, 5 inlet sump vent subsystem use flexible, line cou-
screens with magnetic chip detectors, an anti- plings to compensate for gas generator growth.
static leakage check valve, and associated pip-
ing. The scavenge elements and associated c. Oil Seal Pressurization Subsystem.
areas are as follows: See figure 10.
(1) Main bearing oil seals require

No. of pressurization air in order to cause air to flow
Area Elements Pump across the oil seals into the sumps during all
Transfer gearbox 1 Fwd. operating conditions. If air is allowed to flow
- Fwd. Scavenge out of the sump, across the oil seals, some oil
Transfer gearbox 1 Fwd. will be carried with the air and result in exces-
- Aft Scavenge sive oil consumption. Pressurization air is
extracted from stage-8 of the compressor and
A Sump 1 Fwd. routed through an ejector where the pressure is
Scavenge dropped and the temperature is lowered by
B Sump 1 Lube and mixing-in ambient air. The air is then distrib-
Scavenge uted internally, through the gas generator, to
C Sump 1 Lube and each oil seal area.
Scavenge
(2) The bearing sumps contained in
(1) The forward scavenge pump scav- the compressor rear frame and in the turbine
enges the rear portion of the A sump. The cen- frame are isolated from the high-pressure,
ter portion of the A sump drains into the high-temperature air of the gas generator by
transfer gearbox-forward and is scavenged by use of a low-pressure cavity placed between
the transfer gearbox-forward scavenge ele- the oil-seal pressurization-air cavity and the
ment. The forward scavenge pump also scav- high-pressure air of the gas generator.
enges the transfer gearbox-aft. Scavenge oil
from all elements of the forward scavenge (3) There are essentially 2 low-pres-
pump is discharged into a common port and is sure cavities surrounding the B sump. Com-
then routed to a scavenge discharge manifold pressor discharge leakage air enters the outer
in the lube and scavenge pump. cavity through the B sump bearing air seals.
The compressor discharge leakage air in the
(2) The lube and scavenge pump outer cavity is then piped to the turbine frame
scavenges oil from the B and C sumps. for cooling purposes. The inner cavity sur-
Because of the large quantity of oil supplied to rounding the B sump contains a mixture of
the B sump bearings, a dual, side-by-side ele- stage-8 air and leakage from the outer cavity.
ment is used to scavenge the B sump.
(3) Scavenge discharge from both

pumps is routed through an anti-static leakage
check valve and back to the purchaser's
system.

T-17
GEK 97310
VOLUME I
ADDENDUM T
d. Sump Vent Subsystem. See figure 10. (4) The valve will crack at 300 psi
(2070 kPa) and will be in the full bypass con-
(1) Each area of the gas generator dition at a differential pressure of 400 psid
which requires pressurization of the oil seals is (2750 kPa). It re-seats at 275 psid (1900 kPa).
vented, to remove the air which enters the The pump removes scavenge oil from the B
sumps through the oil seals and to keep the and C sumps, using separator gerotor ele-
sump internal pressure low enough to prevent ments. To provide adequate scavenge capacity
airflow out through the oil seals during a rapid at all inlet pressure conditions, 2 elements are
reduction in power setting. used for the B sump. One geroter element is
used for the C sump. Each sump inlet to the
(2) Each sump area is connected to a pump is provided with a removable screen
sump vent manifold through vent lines. All of capable of removing particles larger than
the air in the manifold is then vented to ambi- 0.037 inch (0.94 mm). Each screen contains a
ent through an air/oil separator. The air/oil sep- magnetic-chip particle collector.
arator is sized to handle 50 percent more than
the expected maximum vent airflow through b. Forward Scavenge Pump. See
worn oil seals. figure 12. The forward scavenge pump scav-
enges oil from the A sump, transfer gearbox-
12-1.4 Components Description. forward, and transfer gearbox-aft. The pump is
off the positive-displacement type, with 3
a. Lube and Scavenge Pump. See gerotor elements and contains an inlet screen
figure 10. in each of the scavenge inlet ports. Scavenge
oil from the A sump enters the pump through
(1) The lube and scavenge pump pro- the A sump inlet port. Two ports on the face of
vides oil under pressure for lubrication and the gearbox pad permit the pump to scavenge
cooling of the bearings and accessory drives. oil from the gearboxes. An inlet screen in each
In addition, it scavenges oil from the B and C port removes particles larger than 0.037 inch
sumps. (0.94 mm). Each screen has a magnetic-chip
particle collector. The scavenge oil from all
(2) The pump is a positive-displace- elements is discharged into a common cham-
ment-type containing gerotor elements. The ber, and then routed to the outlet port of the
B sump scavenge portion of the pump uses a pump.
dual, side-by-side element. Integral within the
pump are inlet screens and a pressure relief c. Air/Oil Separator. See figure 13. The
valve. air/oil separator removes the oil from the sump
vent air before the air is vented at atmosphere.
(3) Oil enters the lube supply element It consists of a fabricated, sheet metal impeller
through a removable, non-by-passing, pump- with a cast aluminum housing mounted on the
mounted inlet screen. The inlet screen removes front of the transfer gearbox-forward.
particles larger than 0.037 inch (0.94 mm). A
pressure relief valve is provided to limit dis-
charge pressure to 400 psi (2750 kPa). The
relief valve is located between the inlet and
outlet of the supply element.

T-18
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ADDENDUM T
Figure 11. Lube and Scavenge Pump

T-19
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ADDENDUM T
Figure 12. Forward Scavenge Pump

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Figure 13. Air-Oil Separator

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(1) To prevent excessive oil loss by 14-0 OPTIONAL HARDWARE KITS -
venting oil vapor to atmosphere, all sumps are LM2500GA101.
vented to the air/oil separator. Oil is collected
on the inside of the impeller as the oil-laden Item Kit PN Nomenclature Qty
sump air passes through the separator. Small
holes in the segments of the impeller allow the 1 L21126 Fuel and Gover- 1
collected oil to be discharged to the separator nor System
outer housing. Since the oil droplets leaving
the impeller have a high rotational component, 2 536L211G01 Off Engine Con- 1
vanes on the housing wall are used to collect trol
and direct the oil to the separator outlet, where 3 536L262G01 Variable Stator 1
it is returned to the gearbox. The separator Actuator Hard-
uses a labyrinth seal, which is pressurized with ware
stage-8 air.
4 536L298G02 Spad Drawing 1
13-0 SERVICE REQUIREMENTS. List
5 537L300G01 Brackets, Servo 1
13-1.1 Natural Gas. Valve
a. The required supply pressure to the 6 681L449G01 Starter Kit 1
7 681L459G01 Kit-Retrofit 1
(2448 ± 34 kPa).
b. The temperature of the gas must be in 15-0 GAS GENERATOR OPERATION.

the range of -65° to +150°F (-54 +66°C).
c. During starting, the gas temperature gas generator operating procedures and limits
must be constant ±10°F (±5.6°C), and must be recommended by the General Electric Com-
repeatable on a day-to-day basis to ensure reli- pany for the 7LM2500GA101 Gas Generator.
able starting. If the temperature is not repeat-
able on a day-to-day basis, it will be necessary b. The instructions are intended to pro-
to change the starting fuel adjustment to adjust vide operating personnel with the information
the supply pressure to the engine to maintain a required to operate the gas generator. They
constant Btu-per-cubic-foot supply. Once pertain to routine and emergency conditions
started, the engine will accept variations in and procedures. When a fault exists, refer to
supply temperature of -65 to +150°F Chapter 4, TROUBLESHOOTING.
(-54 to +66°C).
d. The maximum fuel flow required is

11,000 pph (4990 kg/h) with a lower heating
value of 19,000 Btu/lb.

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c. It is possible that these instructions 15-1 PERFORMANCE RATINGS AND
may not provide for every possible variation in OPERATING LIMITS.
tion with the operation of the gas generator. Refer to figures 14 through 17 for information
Refer requests for additional information to the on gas generator performance ratings. Refer to
General Electric Company, Marine and Indus- table 3 for gas generator operating limits.
trial Projects Department, Cincinnati, Ohio
45215. 15-2 INITIAL OPERATION.
15-2.1 General.
WARNING
IF A QUESTIONABLE CONDITION In this section, an initial operational period is
EXISTS, DO NOT OPERATE THE considered to be that period of operation
GAS GENERATOR UNTIL A THOR- immediately following gas generator installa-
OUGH INVESTIGATION HAS tion or major maintenance on the system.
HOT STARTS, COMPRESSOR 15-2.2 Special Instrumentation.
PROBLEMS WITHOUT PRIOR Install the following special instrumentation
THOROUGH INVESTIGATION. for initial operation:
IN UNDUE STRESS BEING a. Natural-gas supply pressure to fuel
IMPOSED ON GAS GENERATOR control unit - 0-500 psig (0-3500 kPa) gage.
COMPONENTS, WITH IMMEDI-
ATE OR SUBSEQUENT DESTRUC- b. Natural-gas fuel manifold pressure -
TIVE FAILURE OF THE GAS 0-300 psig (0-2070 kPa) gage, and 0-30 psig
GENERATOR AND INJURY TO (0-210 kPa) gage with automatic gage shutoff.
PERSONNEL. (0-30 gage used only for gas generator speed
range of 0-5000 rpm).
NOTE
The S.I. units shown in this chapter are c. Starter gas supply pressure -
direct mathematical conversions and 0-60 psig (0-420 kPa) gage.
at the users discretion. Examples of d. Servo-limiter servo oil pressure -
units that may be rounded off are those 0-500 psig (0-3500 kPa) gage with shutoff
utilized for temperatures, torque val- valve in gage line.
e. Oil supply temperature indicator -
0 to 300°F (-18 to 149°C).
adjustments, runouts, etc. f. Variable stator vane position indicator.

T-23
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Figure 14. Gas Generator Performance - Isentropic Gas Horsepower Vs. Inlet Air
Temperature, Exhaust Gas Pressure, and Exhaust Gas Temperature
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Temperature, Fuel Flow, and Exhaust Gas Flow
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Temperature and Gas Generator Speed
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Figure 17. Performance Correction Factors

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Table 3. OPERATING LIMITS - LM2500GA101
ITEM LIMIT
Gas Generator
Idle RPM 5000 ± 250 RPM
Maximum RPM 9700 RPM
Exhaust Gas Temperature 1380°F (749°C), Maximum (See figures 18 and 19).
Vibration 2.5 inches (63.5 mm)/sec. peak velocity, maximum
(See figure 20)
Lube Consumption 2.0 lbs (0.9 kg)/hour, maximum
Lube Supply Pressure 6 psig (41 kPa) min. @ Idle RPM (See table 4 or 5)
20 psig (138 kPa) minimum (corrected) @
8000 RPM (See table 4 or 5)
Lube Supply Temperature 200°F (93°C), maximum
Lube Scavenge Pressure 20 psig (138 kPa), maximum
Lube Scavenge Temperature 340°F (171°C), maximum
Fuel Gas Supply Pressure to Fuel Control 355 ± 5 psig (2450 ± 34 kPa)
Unit
Starter
Normal Start - Gas/Air Supply Pressure 35 ± 3 psig (241 ± 21 kPa)
Normal Start - Duty Cycle One minute max. ON, with 15 seconds at zero speed
between start attempts.
Motoring & cleaning - Gas/air supply 21 ± 1 psig (145 ± 7 kPa)
pressure
Motoring & cleaning - Duty cycle Five minutes max. ON, two minutes at zero speed,
five minutes max. ON at any one hour period.

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Figure 18. Transient Temperature Limits for Starts
Figure 19. Transient Temperature Limits (Except Starts)

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Figure 20. Vibration Limits

T-30
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Figure 21. Gas Generator Air Flow, Temperature, and Pressure Profiles (8900 RPM)

T-31
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15-2.3 Preparation. (14) Assure that gas generator’s com-
pressor rear frame leakage ports - struts #7 and
a. Gas Generator and Associated Equip- #10 are “open” (not capped).
ment Check. Prepare gas generator and associ-
ated equipment for initial operation as follows: (15) Perform required checks and
inspections specified in purchaser’s instruc-
(1) Make certain that lines have been tions for process control panel, etc.
flushed.
(16) Remove all tooling and loose
(2) Check that gas generator inlet and material from vicinity of gas generator.
exhaust are clear of obstructions, loose parts,
tools, etc. b. Governor and Manual Potentiometer
Calibration Check. Check governor and man-
(3) Inspect compressor inlet for blade
ual potentiometer as follows:
and vane damage.
(4) Inspect compressor inlet probe for (1) Set 1406 hz on oscillator.
proper alignment and damage.
(2) Governor terminals 6, 7, and 8
(5) Inspect CIT sensor for damage wired to manual potentiometer terminals 3, 2,
and security. and 1.
(6) Inspect variable stator actuating (3) Potentiometer input to governor

system for security and damage. should be 0 volts between terminals 6 and 7 on
governor and as potentiometer setting is
(7) Inspect external wiring and piping increased the voltage between 6 and 7 should
for security and damage. increase to 6 volts.
(8) Inspect all controls and accesso- (4) Trim potentiometer in manual
ries for security, damage and leaks. potentiometer, high speed trim and low speed
trim all have an effect on setting up this circuit.
(9) Inspect gas generator mounts for
security and damage. (5) Set potentiometers as follows:
(10) Check that all attaching hardware
(a) Set oscillator to 2520 hz.
is secure.
(11) Assure that all lube and fuel filters (b) Turn manual potentiometer
are properly serviced. to full increase speed position and adjust high-
trim potentiometer so that output of governor
(12) Assure that oil tanks (gas genera- is .75V with terminal 4- and terminal 5+.
tor and fuel control unit) are properly serviced.
(c) Set oscillator to 1406 hz.
(13) Assure that starter’s oil sump is (d) Turn manual potentiometer
full of oil. to minimum position.

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ADDENDUM T
(e) Adjust low-speed trim poten- • THE FIRE EXTINGUISHING
tiometer so that output of governor is .75V SYSTEM SHALL BE MADE
with terminals 4- and 5+. INACTIVE ACCORDING TO
THE CUSTOMER’S
(f) If above adjustments are not PROCEDURES.
completely effective, adjust trim potentiometer
inside of manual potentiometer. • SECONDARY AIR TO THE
(g) Repeat steps a through e until ENCLOSURE SHALL BE SHUT
conditions are met at both ends. OFF. HIGH SECONDARY AIR-
(6) Set oscillator at 2000 hz and rotate ING OR CLOSING THE
manual potentiometer from minimum to maxi- ENCLOSURE DOOR.
mum. Voltage on governor terminals 4 and 5
should go from +8 to -8 V. • THE ENCLOSURE DOOR
(7) Resistance from common to wiper GAS TURBINE IS OPERATING,
on potentiometer should be approximately AN OBSERVER SHALL BE STA-
20 ohms at idle setting and 180 ohms at maxi- TIONED AT THE ENCLOSURE
mum position. DOOR AND CONFINED SPACE
15-2.4 Startup and Checkout. ENTRY PROCEDURES SHALL
BE FOLLOWED.
WARNING • ALLOW THE GAS TURBINE TO
NECESSARY.
UNDER SUCH CONDITIONS. a. Ignition Check. Assure that gas genera-
tor’s ignitors operate satisfactorily when
115 volts power is supplied to ignition exciter.

T-33
GEK 97310
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ADDENDUM T
b. Motoring. After all preliminary checks (2) Gas generator should go through
have been completed and lines flushed, gas normal start cycle and then abort because of
generator can be motored as follows: lack of flame.
(1) Make ignition and natural-gas d. Governor Check. Check governor sys-
supply systems inoperative as follows: tem as follows:
(a) Disconnect power supply to (1) Start electro-hydraulic actuator

ignition unit. drive motor, and allow governor oil system to
operate until control pressure (Pc) stabilizes at
(b) Close natural-gas manual minimum of 300 psig (2070 kPa).
shutoff valve to fuel control unit.
CAUTION
(2) Depress MOTORING pushbutton.
Gas generator will start to rotate. Observe gas IT MAY BE NECESSARY TO ADD
supply pressure to starter. It should not exceed OIL TO FUEL CONTROL UNIT OIL
38 psig. If it does, reset pressure regulating TANK TO REPLACE OIL USED TO
valve. FILL SERVO-LIMITER AND LINES.
SYSTEM CAN BE DAMAGED IF
(3) Hold MOTORING pushbutton OIL LEVEL IS TOO LOW.
closed until gas generator speed stabilizes, and
check for oil pressure. If there is no indication (2) Check oil level in reservoir.
of oil pressure, release MOTORING pushbut-
ton; while gas generator is coasting down, (3) Governor calibration is normally
break oil fittings loose at lube pump to bleed done at the factory and should not require
air from system. Starter should motor gas gen- adjustment at this time. However, if a new
erator to minimum of 2200 RPM. governing system component is installed, it
will be necessary to adjust it. Refer to
(4) Repeat motoring and bleeding Chapter 4, TROUBLESHOOTING, for adjust-
procedure until an indication of oil pressure ment procedures.
appears.
e. Wet Prestart. Perform a wet prestart as
c. False Start. Perform false start as follows:
follows:
(1) With ignition lead disconnected,
(1) With ignition lead disconnected but with manual gas valve open and governing
and manual gas valve closed, make automatic system operating, make automatic start of gas
start of gas generator. Observe operation of gas generator. Pay particular attention to fuel man-
shutoff valve and gas vent valve. Shutoff valve ifold pressure on gas generator. Fuel supply
should open, and vent valve should close at pressure to fuel control unit should be
1200 - 1300 RPM. 355 ± 5 psig (2450 ± 34 kPa). If not, reset the
supply pressure regulator.

T-34
GEK 97310
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(2) At 1200 to 1300 rpm, fuel shutoff (c) Oil supply temperature---
valve on fuel control unit should open, and 140 to 180°F (60 to 82°C)
fuel manifold pressure should be 2 - 4 psig
(14-28 kPa). Check system for gas leaks. Start (d) Scavenge oil temperature---
will then abort because of lack of flame. If fuel 40 to 60°F (22 to 33°C) above oil supply temp.
manifold pressure is not within limits, adjust (e) Fuel supply pressure to fuel
servo-limiter. Refer to Chapter 4, TROUBLE- control unit---355 psig (2450 kPa)
SHOOTING, for adjustment procedure.
(NOTE: At 1200-1300 rpm, there will be a few (f) Fuel manifold pressure---
pounds of compressor discharge pressure evi- 14 - 25 psig (97-172 kPa)
dent on fuel manifold gage).
(g) Exhaust gas temperature---
650 to 725°F (343 to 385°C)
(3) Allow gas generator to coast to
stop; then motor it to purge any remaining nat- (h) Vibration---0.1 - 1.0 inch
ural gas from gas generator. (2.5 - 25 mm)/sec. (peak velocity)
f. Manual Start. Perform a manual start as (3) If exhaust gas temperature at

follows: light-off exceeded 1200°F (649°C), adjust fuel
flow downward. Refer to Chapter 4, TROU-
(1) With governor selector switch in BLESHOOTING, for adjustment procedure.
MANUAL position, with ignition lead con-
(4) Check gas generator for gas and
nected, and with manual speed potentiometer
oil leaks; repair as necessary.
at its mid-point position, attempt a start. Gas
generator should not start because speed g. Operation to Maximum Power. Check
potentiometer is not in a minimum speed posi- operation of gas generator as follows:
tion. If light-off is experienced, abort start and
establish/correct cause for condition. CAUTION
MANUAL OPERATION ELIMI-
(2) Set the speed potentiometer at its NATES CERTAIN PROTECTIVE
minimum speed position, and start the gas gen- CIRCUITS. OPERATING LIMITS OF
erator. Gas generator should light-off and ALL PORTIONS OF UNIT ARE NOT
accelerate to idle speed (5000 rpm). Starter and TO BE EXCEEDED.
ignition systems should de-energize at
4500 rpm. Log the speed at light-off, fuel man- (1) Slowly increase setting of manual
ifold pressure at light-off, inlet air temperature, speed potentiometer to increase gas generator
and maximum exhaust gas temperature during speed. After each 500 rpm increase, log all
start; then log all instrument readings at idle. instrument readings, paying particular atten-
The following are typical idle readings. tion to variable stator vane position and vibra-
tion. If variable stator system is not within
(a) Gas generator speed--- limits, adjust it per WP 118 01. If vibrations
5000 rpm are not within limits, consult the local General
(b) Oil supply pressure--- Electric Company representative.
10-16 psig (69-110 kPa)

T-35
GEK 97310
VOLUME I
ADDENDUM T
(2) Operate gas generator up to rated h. Automatic Operation. Check automatic
power [1360°F (738°C) exhaust gas tempera- operation of gas generator as follows:
ture], if possible. Hold at this power setting
until all temperatures stabilize. If governing (1) With governor selector switch in
system is unstable, adjust per Chapter 4, AUTOMATIC position, motor-operated poten-
TROUBLESHOOTING. tiometer driven to low-speed position, and
speed input signal reconnected, start gas gen-
(3) Log all instrument readings once erator. It should accelerate to idle (5000 rpm)
they stabilize. The following are some typical and remain at this speed until potentiometer
readings at rated power: position is changed.
(2) Apply power to RAISE portion of
(a) Gas generator speed--- motor-operated potentiometer, and operate gas
8940 rpm generator to rated power.
(b) Oil supply pressure--- (3) Log all instrument readings at
25-40 psig (172-276 kPa) rated power, and then apply power to LOWER
PORTION OF motor-operated potentiometer
(c) Oil supply temp.---160 to until gas generator reaches idle.
180°F (72 to 82°C)
(4) Check gas generator for gas and
(d) Scavenge oil temp.---225 to oil leaks.
265°F (107 to 129°C)
(5) After 2-minute cooling period,
(e) Fuel supply pressure to fuel shut down gas generator by opening circuit to
control unit---355 psig (2450 kPa) fuel shutoff valve. Observe fuel inlet-pressure
gage; it should drop to zero at once.
(f) Fuel manifold pressure---
225 - 250 psig (1550-1725 kPa) (6) Check lube and fuel filters and
strainers for cleanliness; clean and replace as
(g) Exhaust gas temp.---1360°F necessary.
(738°C)
(7) Repair any leaks observed in
(h) Vibration 0.1 - 1.0 inches step (4).
(2.5-25 mm)/sec. (peak velocity)
(8) Drain oil from governor control
(4) Reduce gas generator speed to oil tank, and replace with clean oil.
idle, let temperature stabilize and cool for 2
minutes, and disconnect speed input signal to (9) Remove all temporary instrumen-
governor. Gas generator should decelerate to tation.
below idle speed. If gas generator does not
decelerate, troubleshoot the fail-safe section of (10) Check gas generator and its
the electronic governor. If speed drops below mounting system for loose parts; tighten as
idle, de-energize the fuel shut-off valve to necessary.
shutdown gas generator. Reconnect lead to
governor. (11) Unit should now be ready for nor-
mal operation.

T-36
GEK 97310
VOLUME I
ADDENDUM T
15-3 NORMAL OPERATION. ING OR CLOSING THE
ENCLOSURE DOOR.
15-3.1 General.
Normal operation is “the day-to-day, routine” • THE ENCLOSURE DOOR
operation of the gas generator. For directions SHALL BE KEPT OPEN. IF THE
in the use of manual or automatic operation for GAS TURBINE IS OPERATING,
normal procedure, refer to the unit manufac- AN OBSERVER SHALL BE STA-
turer’s instructions. TIONED AT THE ENCLOSURE
15-3.2 Interlocks. ENTRY PROCEDURES SHALL
Refer to paragraph 2-8.9 for a description of BE FOLLOWED.
the interlocks which affect gas generator oper- • ALLOW THE GAS TURBINE TO
ation. COOL DOWN. AVOID CON-
WARNING LATED GLOVES AS
NECESSARY.
MET: OPERATING.
ENGINE OPERATION IS PRO- MOTORING THE GAS
HIBITED IN GENERAL. IF TURBINE.
ENTRY SHOULD BE
REQUIRED DURING ENGINE a. Manual Starting.
FIELD SERVICE FOR A REPRE- (1) Check lubricating and control oil
SENTATIVE WHO IS TRAINED tanks to see that each is filled to proper level.
TO ENTER THE ENCLOSURE (2) Check inlet to gas generator to see
UNDER SUCH CONDITIONS. that it is free of debris, etc.
• THE FIRE EXTINGUISHING (3) Open manual fuel shutoff valve.
INACTIVE ACCORDING TO (4) Start governing system actuator
THE CUSTOMER’S drive motor.
PROCEDURES.
(5) Set governor AUTO-MANUAL
• SECONDARY AIR TO THE selector switch in MANUAL position, and
ENCLOSURE SHALL BE SHUT manual and motor-operated potentiometers in
OFF. HIGH SECONDARY AIR- their minimum-speed positions. Close FAIL-
FLOW MAY PREVENT OPEN- SAFE BYPASS switch to electronic governor.

T-37
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ADDENDUM T
(6) Open the unit electrically operated (e) Scavenge oil temperature---
fuel shutoff valve. (This is not the shutoff 40 to 60°F (22-33°C) above oil supply temper-
valve on the fuel control unit.) ature
(7) Energize starter. b. Manual Operating.

CAUTION
(8) When gas generator reaches
1200 to 1300 rpm, energize ignition system SWITCHING FROM MANUAL
and gas generator fuel shutoff and vent valves. MODE OF OPERATION TO AUTO-
Gas generator will light-off and accelerate. MATIC WHILE GAS GENERATOR
IS OPERATING ABOVE IDLE
(9) When gas generator reaches SHOULD NEVER BE DONE. IF GAS
4500 rpm, de-energize starter and ignition sys- GENERATOR IS AT IDLE AND
tem, and open governor FAIL-SAFE BYPASS BOTH POTENTIOMETERS ARE AT
switch. Gas generator will then continue to THEIR MINIMUM-SPEED POSI-
acclerate to idle speed (5000 rpm). TIONS, SWITCHING IS PERMISSI-
BLE. MANUAL OPERATION
(10) During starting, gas generator ELIMINATES CERTAIN PROTEC-
exhaust gas temperature should not exceed TIVE CIRCUITS. ALL OPERATING
1380°F (749°C). If it does, de-energize fuel LIMITS MUST BE OBSERVED.
shutoff valves and determine cause of high
(1) Allow gas generator to operate at
temperature.
idle for minimum of 5 minutes, and then
increase speed of gas generator by slowly
(11) Normal time for a start, from
rotating manual speed potentiometer knob
energizing starter to idle speed, is approxi-
clockwise until desired power setting is
mately 45 seconds. Typical instrument read-
reached. Since gas generator is operating in
ings at idle are as follows:
MANUAL mode, it may be necessary to adjust
NOTE speed setting potentiometer as load changes. It
is also the responsibility of the operator to
Exact oil supply pressure and scavenge
make sure that the operating limits called out
oil temperature will be a function of
in table 3 are not exceeded. See table 4 and 5
type of oil and oil supply temperature.
for oil pressure correction factors.
tables 4 and 5 give correction factors.
(2) To shut down gas generator,
(a) Gas generator speed---
slowly rotate manual potentiometer to mini-
5000 rpm
mum-speed position until gas generator
(b) Oil supply pressure--- reaches idle speed of 5000 rpm. Allow gas
10 - 16 psig (69-110 kPa) generator to operate at this speed for minimum
of 2 minutes, and then close electrically oper-
(c) Exhaust gas temperature--- ated fuel shutoff valves. Gas generator will
650 to 725°F (343 to 385°C) shut down.
(d) Vibration---0.1 - 1.0 inch
(2.5 - 25 mm)/sec. (peak velocity)

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GEK 97310
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Table 4. MIL-L-23699 OIL PRESSURE CORRECTIONS FOR
TEMPERATURE AT 8000 RPM
Oil Oil Oil Oil Oil
Temp. Pressure Temp. Pressure Temp. Pressure Temp. Pressure Temp. Pressure
°F Additive °F Additive °F Additive °F Additive °F Additive
100 -12.6 130 -1.5 160 +5.7 190 +9.8 220 +12.6
101 -12.3 131 -1.2 161 +5.9 191 +9.9 221 +12.7
102 -11.8 132 -1.0 162 +6.0 192 +10.0 222 +12.8
103 -11.4 133 -0.7 163 +6.2 193 +10.1 223 +12.8
104 -11.0 134 -0.4 164 +6.4 194 +10.3 224 +12.7
105 -10.6 135 -0.0 165 +6.6 195 +10.4 225 +13.0
106 -10.2 136 +0.3 166 +6.8 196 +10.5 226 +13.1
107 -9.8 137 +0.5 167 +6.9 197 +10.6 227 +13.2
108 -9.4 138 +0.8 168 +7.0 198 +10.7 228 +13.2
109 -9.0 139 +1.1 169 +7.2 199 +10.8 229 +13.3
110 -8.6 140 +1.3 170 +7.3 200 +10.8 230 +13.4
111 -8.2 141 +1.5 171 +7.4 201 +10.9
112 -7.8 142 +1.8 172 +7.6 202 +11.0
113 -7.4 143 +2.0 173 +7.7 203 +11.1
114 -7.1 144 +2.3 174 +7.9 204 +11.2
115 -6.7 145 +2.5 175 +8.0 205 +11.3
116 -6.4 146 +2.8 176 +8.1 206 +11.4
117 -6.0 147 +3.0 177 +8.3 207 +11.5
118 -5.6 148 +3.2 178 +8.4 208 +11.6
119 -5.3 149 +3.5 179 +8.5 209 +11.7
120 -5.0 150 +3.7 180 +8.7 210 +11.8

121 -4.6 151 +3.9 181 +8.8 211 +11.9
122 -4.2 152 +4.1 182 +8.9 212 +12.0
123 -3.9 153 +4.3 183 +9.0 213 +12.0
124 -3.5 154 +4.5 184 +9.1 214 +12.1
125 -3.2 155 +4.8 185 +9.2 215 +12.2
126 -2.8 156 +5.0 186 +9.3 216 +12.3
127 -2.5 157 +5.2 187 +9.4 217 +12.4
128 -2.2 158 +5.4 188 +9.6 218 +12.4
129 -1.9 159 +5.6 189 +9.7 219 +12.5
Read Oil Pressure and Temperature. Algebraically add the pressure additive (as indicated by observed
temperature) to observed pressure.
Example: Observed oil pressure 55 psig

Oil temperature 120°F
Pressure additive -5.0 psig
Corrected pressure 55-5 = 50 psig

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ADDENDUM T
Table 5. MIL-L-7808 OIL PRESSURE CORRECTIONS FOR
TEMPERATURE AT 8000 RPM
Oil Oil Oil
Temp. Pressure Temp. Pressure Temp. Pressure
°F Additive °F Additive °F Additive
100 -5.5 144 +1.1 188 +7.6

102 -5.2 146 +1.4 190 +7.9
104 -4.8 148 +1.7 192 +8.2
106 -4.5 150 +2.0 194 +8.5
108 -4.2 152 +2.2 196 +8.8
110 -3.8 154 +2.5 198 +9.1
112 -3.5 156 +2.8 200 +9.4
114 -3.2 158 +3.1 202 +9.7
116 -2.9 160 +3.4 204 +10.0
118 -2.6 162 +3.7 206 +10.3
120 -2.3 164 +4.0 208 +10.6
122 -2.0 166 +4.3 210 +10.9
124 -1.7 168 +4.5 212 +11.2
126 -1.4 170 +4.9 214 +11.5
128 -1.1 172 +5.2 216 +11.8
130 - .8 174 +5.5 218 +12.1
132 - .5 176 +5.8 220 +12.4
134 - .2 178 +6.1 222 +12.7
136 - .0 180 +6.4 224 +13.0
138 + .3 182 +6.7 226 +13.3
140 + .6 184 +7.0 228 +13.6
142 + .8 186 +7.3 230 +13.9
Read Lube Pump Discharge Pressure and Lube Pump Inlet Temperature. Algebraically add the pressure
additive, as indicated by observed temperature, to observed pressure.
Examples: Observed Lube Pump Discharge Pressure 40 psig

Lube Pump Inlet Temperature 164°F
Pressure Additive +4
Corrected Pressure 40 + 4 = 44 psig
(3) Turn off governing system actua- operated fuel shutoff valve. However, this
tor drive motor and close the manual fuel shut- should only be done in an emergency, since
off valve. rapid shutdowns will decrease life of gas
generator.
(4) Gas generator may be shut down
from any power setting by closing electrically

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GEK 97310
VOLUME I
ADDENDUM T
c. Automatic Operation. reaches 1200 rpm, the ignition is initiated, the
normally-closed fuel shutoff valve is opened,
CAUTION and the normally-open-fuel vent valve is
closed. The gas generator will then light-off
SWITCHING FROM AUTOMATIC and accelerate, assisted by the starter.
MODE OF OPERATION TO MAN-
UAL WHILE GAS GENERATOR IS (2) At 4500 rpm, the ignition and
OPERATING ABOVE IDLE, starter are de-energized, the governor fail-safe
SHOULD NEVER BE DONE. IF GAS bypass opens, and the gas generator continues
GENERATOR IS AT IDLE AND to accelerate to the idle speed setting of
BOTH POTENTIOMETERS ARE AT 5000 rpm.
THEIR MINIMUM-SPEED POSI-
TIONS, SWITCHING IS (3) Below 5000 rpm, gas generator
PERMISSIBLE. speed is controlled by the servo-limiter. At
5000 rpm and above, gas generator speed is
(1) Place governor AUTO-MANUAL controlled by the electronic governor. Gas gen-
selector switch in AUTOMATIC position, and erator speed can then be increased by changing
manual and motor-operated potentiometers in the speed-demand electrical input signal to the
their minimum-speed positions. electronic governor by varying the setting of
the manual or motor operated potentiometer.
(2) Start gas generator, and allow it to
accelerate to idle. (4) A normal shutdown is made by
slowly reducing the electrical input signal to
(3) Purchaser’s process controller the electronic governor to the minimum-speed
will now change motor-driven potentiometer value by changing the setting of the manual or
setting to match process demand. Gas genera- motor operated potentiometer, allowing the
tor speed will continue to change as necessary gas generator to operate at the idle condition
to match requirements of process controller. for 2 minutes, and then closing the fuel shut-
(4) To shut down the gas generator, off valve to shut down the gas generator.
drive the motor-operated potentiometer to its 15-4 EMERGENCY OPERATION.
minimum-speed position (5000 rpm). Allow
gas generator to operate at this speed for mini- 15-4.1 Emergency Shutdown.
mum of 2 minutes, and then close electrically
operated fuel shutoff valves. Gas generator a. In an emergency, the gas generator may
will shut down. be shutdown from any power setting by clos-
ing the electrically operated fuel shutoff valve.
(5) Turn off governing system actua- However, this should only be done in an emer-
tor drive motor and manual fuel shutoff valve. gency since rapid shutdown will decrease the
life of the gas generator.
d. Typical Operation Sequence. A typical
operation sequence is as follows: b. If an emergency shutdown from a high
power setting (T54 greater than 1150°F/621°C)
(1) The manual- and motor-operated
has occurred, and a “hot restart” is required,
potentiometers are set at their minimum speed
proceed with table 6.
positions. The gas generator is started by ener-
gizing the starter. When the rotor speed

T-41
GEK 97310
VOLUME I
ADDENDUM T

CAUTION
ASSURE FREEDOM OF ROTATION OF GAS GENERATOR AFTER AN
EMERGENCY SHUTDOWN FROM HIGH POWER SETTINGS. SEIZURE
OF GAS GENERATOR ROTOR MAY OCCUR DUE TO TIGHT CLEAR-
ANCES. NORMALLY THE ROTOR WILL FREE ITSELF AFTER A
COOLING PERIOD OF 3 TO 4 HOURS. CHECK FOR FREEDOM OF
ROTATION BY TURNING ROTOR BY HAND.
1. Conditions permitting, T5.4 drops below 400°F Manually shut off fuel
decelerate gas generator to (204°C) and NGG and NPT supply
idle and close fuel valves decelerate
2. Observe T5.4 for 3 minutes 700°F (371°C) max Motor gas generator. Con-
ature decreases
ceed as follows:
generator can be
restarted within 1 minute
following coastdown of
the HPC rotor, accept-
able restarts can be made
procedure.

T-42
GEK 97310
VOLUME I
ADDENDUM T
Table 6. EMERGENCY SHUTDOWN - Cont.

b. If a “hot restart” is
performed between
1 minute and 2 hours fol-
shutdown, motor the gas
generator at
5 minutes. At the end of
the 5 minute motoring/
purge cycle, perform
normal restart and accel-
erate to idle. Accelera-
tion to the desired power
setting can then be
accomplished.
procedure.
15-4.2 Post-Shutdown Fire. leaking fuel shutoff valve. (A slight tempera-

ture increase after rotation stops is normal.)
During a normal shutdown, exhaust gas tem- Make certain fuel is shut off, and motor gas
perature should decrease. If, during time gas generator by depressing MOTORING push-
generator is coasting to stop, temperature button. This will blow out the fire. As soon as
increases instead of decreases, it indicates that temperature decreases to normal, release
combustion is still taking place because of a MOTORING pushbutton.

T-43/(T-44 Blank)
GEK 97310
VOLUME I
ADDENDUM U
ADDENDUM
7LM2500-PE-ML

GEK 97310
VOLUME I
ADDENDUM U
TABLE OF CONTENTS
1-0 INTRODUCTION....................................................................................... U-3

2-0 REFERENCE DATA .................................................................................. U-3
3-0 INSTALLATION DRAWINGS.................................................................. U-4
4-0 EQUIPMENT DESCRIPTION ................................................................. U-4
5-0 INSTRUMENTATION AND SUPPLY REQUIREMENTS ................... U-4
6-0 SERVICE REQUIREMENTS ................................................................... U-4
6-1.1 Liquid Fuel.................................................................................................... U-4
7-0 OPTIONAL HARDWARE KITS - 7LM2500-PE-ML ............................ U-4
8-0 INSTRUMENTATION AND SUPPLY REQUIREMENTS. .................. U-4
9-0 GAS TURBINE OPERATION .................................................................. U-8
9-1 PERFORMANCE RATINGS AND OPERATING LIMITS .................. U-8
9-1.1 Performance Ratings ..................................................................................... U-9
9-1.2 Operating Limits ........................................................................................... U-13
9-2 INITIAL OPERATION .............................................................................. U-13
9-2.1 General .......................................................................................................... U-13
9-2.2 Special Instrumentation Required for Operation .......................................... U-13
9-2.3 Special Instrumentation Required for Monitoring and Troubleshooting ...... U-18
9-2.4 Preparation .................................................................................................... U-18
9-2.5 Gas Turbine and Associated Equipment Checklist ....................................... U-18
9-2.6 Governor and Manual Control Check........................................................... U-19
9-2.7 Start-up and Checkout................................................................................... U-19
9-2.8 Ignition Check............................................................................................... U-21
9-2.9 Motoring........................................................................................................ U-21
9-2.10 False Start...................................................................................................... U-21
9-2.11 Wet Prestart ................................................................................................... U-22
9-2.12 Manual Start .................................................................................................. U-22
9-2.13 Operation to Maximum Power...................................................................... U-28
9-2.14 Automatic Operation..................................................................................... U-28
9-3 NORMAL OPERATION............................................................................ U-30
9-3.1 General .......................................................................................................... U-30
9-3.2 Interlocks....................................................................................................... U-30
9-3.3 Operation....................................................................................................... U-30
9-4 EMERGENCY OPERATION ................................................................... U-31
9-4.1 Emergency Shutdown ................................................................................... U-31
9-4.2 Post Shutdown Fire ....................................................................................... U-31
9-5 SPECIAL GAS TURBINE CONSTRAINTS ........................................... U-33
9-5.1 General .......................................................................................................... U-33
9-5.2 Overtemperature............................................................................................ U-33
9-5.3 Lube Oil Supply Pressure ............................................................................. U-33
9-5.4 High Speed Stall............................................................................................ U-33
9-5.5 Starter Duty Cycle - Air or Natural Gas........................................................ U-33

U-1
GEK 97310
VOLUME I
ADDENDUM U
TABLE OF CONTENTS-Continued
9-5.6 Re-Start Following High Power Trip ............................................................ U-34

9-5.7 No Power Turbine Rotation .......................................................................... U-34
9-5.8 Windmilling .................................................................................................. U-34
Figure Title Page
1 Transient Temperature Limits ....................................................................... U-10

2 Deleted
3 Deleted
4 Deleted
5 Deleted
6 Acceleration Fuel Flow Schedule ................................................................. U-12
7 Fuel Manifold Pressure ................................................................................. U-27
LIST OF TABLES
Table Title Page
1 INSTRUMENTATION CONNECTIONS - 7LM2500-PE-ML ................... U-5

2 SUPPLY CONNECTIONS - 7LM2500-PE-ML .......................................... U-6
3 GAS TURBINE OPERATING LIMITS....................................................... U-14
4 PRESTART CHECKS .................................................................................. U-20
5 START-UP OPERATION ............................................................................. U-23
6 GAS TURBINE SHUTDOWN .................................................................... U-29
7 EMERGENCY SHUTDOWN...................................................................... U-32
8 DELETED
9 DELETED
10 DELETED
11 DELETED
12 DELETED
13 DELETED

U-2
GEK 97310
VOLUME I
ADDENDUM U
The information contained herein describes Compressor Rear Frame 421(191)
the 7LM2500-PE-ML model gas turbine basic Combustor 120(54)
configuration and control system differences. High Pressure Turbine Rotor 419(190)
cial servicing requirements, optional hardware Stg 1 68(31)
instructions for the 7LM2500-PE-ML model Stg 2 127(58)
are included. Turbine Mid Frame 530(240)
2-0 REFERENCE DATA.
EQUIPMENT Turbine Rear Frame 1071(486)
Gas Turbine Assembly High Speed Coupling Shaft 91(41)
(General Electric Co., Cincinnati, Ohio) Forward Adapter
Model No. 7LM2500-PE-ML Outer Cone 410(186)
Drawing No. L31430G25 or G26 Inner Diffuser 255(116)
PERFORMANCE RATING Ring Seal 49(22)
Ring Support 74(34)
Refer to paragraph 9-1.1 Insulation 269(122)
GAS TURBINE WEIGHTS Cover, Insulation 69(31)
The average weights of the major gas turbine Mech 19(8.6)
components are: Outside Piping and Bracketing 278(126)
Component Wt-Lbs/(Kg) DRAWING LIST

duct, centerbody, exhaust Drawing No
diffuser, and coupling nut 7396(3355) Gas Turbine Installation Draw- L31705
Exhaust duct without exhaust ing (7LM2500-PE-ML)
diffuser 2313(1049) Fuel System 682L310
Gas Generator 4212(1911) Lubrication System Flow L24328
Power Turbine 2777(1260) Diagram
Inlet Gearbox 38(17) Electrical Diagram L24329
Transfer Gearbox 245(111) Ignition Units L21454
Compressor Front Frame 517(235) Gas Turbine Assembly L31430G25
Compressor Rotor 552(250) Drawing or G26
Compressor Stator, Rear 93(42)

U-3
GEK 97310
VOLUME I
ADDENDUM U
A complete set of installation drawings have 6-1.1 Liquid Fuel.

been provided.
a. The required pressure to the fuel mani-
4-0 EQUIPMENT DESCRIPTION. fold on the gas turbine is 150-900 psig
(1035-6210 kPa).
a. The 7LM2500-PE-ML is a liquid fuel
marinized gas turbine. It is equipped with 30 b. The fuel temperature supplied to the
fuel nozzles and is designed to operated only gas turbine shall be a minimum of 20°F (-7°C)
on liquid fuel. above the wax point of the fuel and a maxi-
mum of 150°F (66°C). The fuel shall be fil-
5-0 INSTRUMENTATION AND SUP- tered to 20 microns absolute.
PLY REQUIREMENTS. See tables 1 and 2.
7-0 OPTIONAL HARDWARE KITS
- 7LM2500-PE-ML.



U-4
GEK 97310
VOLUME I
ADDENDUM U
Table 1. INSTRUMENTATION CONNECTIONS - 7LM2500-PE-ML
pin B constantan
pin B constantan
pin B constantan
temperature
E6A Accessory gearbox T/C (optional MS3106R-12S-3SW except pin A iron and
equipment) pin B constantan
pin B constantan
pin B constantan
A13 Power turbine inlet pressure AN818-6C or MS20819-6C
probe (optional)
A23 CDP pressure port 0.500-20UNJF-3B

U-5
GEK 97310
VOLUME I
ADDENDUM U
Table 1. INSTRUMENTATION CONNECTIONS - 7LM2500-PE-ML - Continued
A18 CIT sensor (pad)
NOTE
For all other instrumentation connections, see the Installation Drawing provided with gas
turbine.
Table 2. SUPPLY CONNECTIONS - 7LM2500-PE-ML

CAUTION
OR ON GAS GENERATOR. IF EXCESSIVE FORCE IS REQUIRED TO COMPLETE
A CONNECTION, LOOSEN ALL CONNECTIONS AND CHECK/ADJUST ROUT-
ING AS REQUIRED.
F2 Fuel manifold inlet No. 1 Fuel manifold inlet liquid, mates with AN818-10C or
MS20819-10C or equivalent
L1 Oil Supply 1-1/2 inch line to lube pump on gas generator AN818-24C
or MS20819-24C
L2 Lube pump discharge 1 inch line from lube pump to oil supply filters
AN819-16C or MS20819-16C
L4 Lube supply inlet port 1 inch line from oil supply filters to gas generator
AN818-16C or MS20819-16C

U-6
GEK 97310
VOLUME I
ADDENDUM U
Table 2. SUPPLY CONNECTIONS - 7LM2500-PE-ML - Continued
L3 Scavenge oil discharge 1-1/4 inch line from gas generator scavenge pump to oil
scavenge filter and cooler AN818-20C or MS20819-20C
A1 Bleed air port 8th stage Shipped with cover that must remain in place if port is not
used
(optional)
(optional)
A4 Inlet duct seal flange If used - attaching hardware
A20 C-sump overboard vent left If used - 2-inch line attaching hardware
bottom
A21 C-sump overboard vent If used - 2-inch line attaching hardware
right bottom
A22 C-sump overboard vent If used - 2-inch line attaching hardware
right top
A12 Air/oil separator discharge 3 inch line from air/oil separator to atmospheric vent or to
S1 or Waterwash manifold 1 inch line - hot water line to waterwash manifold on Gas
S1A Turbine Inlet Duct AN818-16C or MS20819-16C
NOTE
For all other supply connections needed, see the Installation Drawings, provided with
gas turbine.

U-7
GEK 97310
VOLUME I
ADDENDUM U
9-0 GAS TURBINE OPERATION. WARNING
a. These instructions contain the detailed IF A QUESTIONABLE CONDITION
gas turbine operating procedures and limits EXISTS, DO NOT OPERATE THE
recommended by the General Electric Com- GAS TURBINE UNTIL A THOR-
pany for the 7LM2500-PE-ML Gas turbine. OUGH INVESTIGATION HAS
BEEN MADE. DO NO REPEAT HOT
b. The instructions are intended to pro- STARTS, COMPRESSOR STALLS,
vide operating personnel with the information OR OTHER RECOGNIZED PROB-
required to operate the gas turbine. They per- LEMS WITHOUT PRIOR THOR-
tain to routine and emergency conditions and OUGH INVESTIGATION. FAILURE
procedures. When a fault exists, refer to TO INVESTIGATE THOROUGHLY,
Chapter IV, TROUBLESHOOTING. AND CORRECT AS NECESSARY,
CAN RESULT IN UNDUE STRESS
c. It is possible that these instructions BEING IMPOSED ON GAS TUR-
may not provide for every possible variation in BINE COMPONENTS, WITH IMME-
equipment or contingency to be met in connec- DIATE OR SUBSEQUENT
tion with operation of the gas turbine. Refer DESTRUCTIVE FAILURE OF THE
requests for additional information to The GAS TURBINE AND INJURY TO
General Electrical Company, Marine and PERSONNEL A RESULT.
Industrial Projects Department, Cincinnati,
Ohio 42515. 9-1 PERFORMANCE RATINGS AND
OPERATING LIMITS.
NOTE
NOTE
direct mathematical conversions and Ratings published in this manual apply
may be rounded off in most instances to the gas turbine. The driven unit rat-
at the users discretion. Examples of ings/limits may be lower in some
units that may be rounded off are those cases, and shall take precedence over
utilized for temperatures, torque val- the gas turbine manual limits.

U-8
GEK 97310
VOLUME I
ADDENDUM U
9-1.1 Performance Ratings. Fuel, Liquid per
a. The rating of the 7LM2500-PE-ML gas GE Specification
turbines in the new and clean condition and MID-TD-0000-2
operating on 100% liquid fuel, in accordance
with MID-TD-0000-2 fuel specification, is as b. The gas turbine must be started on
follows: 100 percent liquid fuel. The starting fuel flows
for liquid fuel are:
Power Turbine Speed
3600 rpm 3000rpm 530 pph (240 kg/h) ± 25 pph (11 kg) at
-65°F (-54°C) Inlet Air Temperature
Brake 29,500 28,500
Horsepower 625 pph (284 kg/h) ± 25 pph (11 kg) at
(Continuous) +60°F (16°C) Inlet Air Temperature
Heat Rate, Liquid
680 pph (308 kg/h) ± 25 pph (11 kg) at
- Average (Base 6920 BTU 7125 BTU +130°F (54°C) Inlet Air Temperature
/hp-hr /hp-hr
- Average 6955 BTU 7211 BTU c. Figure 6 defines the maximum liquid
(Maximum /hp-hr /hp-hr fuel acceleration fuel schedule for the gas
generator.
Based on the following conditions:
Inlet Air 59°F 59°F d. The tolerance on the fuel schedule is
Temperature +4 percent of point. The schedule is plotted
against compressor discharge pressure.
Inlet Losses 0”H2O 0”H2O e. Acceleration fuel rates greater than
those shown will result in overtemperature and
Exhaust Losses 0”H2O 0”H2O possible stall of the gas turbine. Acceleration
Relative Humidity 0% 0% fuel rates lower than those shown can result in
“hung” starts in the below idle speed range.
Accessory Power 0 0 f. Above the idle speed point, low accel-
Extraction eration fuel rates will not harm the gas turbine
Power Turbine times.
Inlet Gas Tempera-
ture, T5.4 Avg.
Liquid:
- At Base Rating 1483°F 1471°F
(750.6°C) (799.4°C)
- At Maximum 1575°F 1538°F
Rating (857.2°C) (816.7°C)

U-9
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VOLUME I
ADDENDUM U

U-10
GEK 97310
VOLUME I
ADDENDUM U

U-11
GEK 97310
VOLUME I
ADDENDUM U

U-12
GEK 97310
VOLUME I
ADDENDUM U
g. The fuel rates shown on the curve will 9-1.2 Operating Limits. Refer to Table 3.
seconds and accelerations from idle to maxi- NOTE
mum power of 15 seconds. If any operating limit is exceeded, ver-
h. For normal accelerations from idle to troubleshooting or inspecting gas
power settings, the changes should be made generator.
section repairs and the life of the gas turbine. 9-2 INITIAL OPERATION.
A time of 2 to 3 minutes is reasonable.
i. The maximum deceleration fuel flow that period of operation immediately following
rate should consist of a step fuel decrease of gas turbine replacement, or major maintenance
1500 pph (680 kg/h) ± 10 percent followed by on the system.
a rate change of 1330 pph (603 kg/h ± 10 per-
cent per second at a basepoint fuel flow of 9-2.2 Special Instrumentation Required for
10,000 pph (4536 kg/h). Fuel flow jump or rate Operation:
at any other fuel flow shall be the above jump
rate multiplied by the square root of the ratio
Gas Generator speed sensor 0-10,000 rpm
of fuel flow to the basepoint fuel flow. Normal
decelerations from maximum power to idle Lube oil scavenge temperature
should be made in approximately 2 to 3 min- sensor (A-, B-, C-, D-sumps 0-400°F
utes. This will enhance the time between hot and accessory gearbox) (-18 to 204°C)
section repairs and the life of the gas turbine. Lube oil supply temperature 0-400°F
j. The liquid fuel system must be free of Vibration indicator
periodic or random hunting which result in gas generator 0-10 mil DA
cycling of gas generator speed or temperature. power turbine 0-10 mil DA
shall not be a harmonic of the natural fre- Power turbine speed sensor 0-5000 rpm
quency of the springs in the fuel nozzles. The Power turbine inlet gas 0-2000°F
natural frequency of these springs is 200 Hz. temperature (T5.4) (-18 to 1093°C)
Cycling of these parameters will reduce time Lube oil supply pressure 0-100 psig
between hot section repairs and the life of the (0-690 kPa)
gas turbine.

U-13
GEK 97310
VOLUME I
ADDENDUM U
Alarm Normal
NOTE
Lubrication Gas turbine Alarm 8 psig ± 1 psig 20-60 psig Bypass until
System - lube pump (55 kPa ± 6.9 kPa) (138-414 kPa) 4500 rpm
above 8000 rpm
(41 kPa ± 6.9 kPa) (138-414 kPa) 4500 rpm
Gas turbine Alarm 110 psig ± 10 psig 10-100 psig Scavenge dis-
scavenge dis- (759 kPa ± 69 kPa) (69-690 kPa) charge pressure
charge shall not exceed
pressure 180 psig
(1242 kPa)
Gas turbine Alarm 180°-220°F 140°-160°F Normal operating
lube supply (82°-104°C) (60°-71°C) range reflects tem-
during operation
above idle speed
Gas turbine Trip 330°-350°F 180°-275°F Normal operating
lube scavenge (166°-177°C) (82.2°-135°C) range reflects tem-
temperatures perature expected
Alarm 290°-310°F
- Five during operation

U-14
GEK 97310
VOLUME I
ADDENDUM U
Alarm Normal
Fuel System Fuel manifold 150-900 psig Supply pressure as
(Liquid) pressure (1034-6205 kPa) reflected at the fuel
manifold inlet on
the gas turbine
Fuel supply 20° to 150°F Starting fuel flow
temperature (-7° to 66°C) adjustments may be
required to com-
pensate for fuel
temperature
variation
Starting Starter supply 40 psig Starting pressure
System pressure (276 kPa) requirement based
(Pneumatic) on gas turbine
starter torque
requirements
of fuel and
ignition
of fuel and start after purge
ignition (if cycle
purge cycle is
used)
simultaneously
Failure to Trip 380°-420°F Activate 10 sec-
light-off (193°-216°C) onds time delay
T5.4 simultaneously
with application of
fuel and ignition

U-15
GEK 97310
VOLUME I
ADDENDUM U
Alarm Normal
simultaneously
with start initia-
tion. De-energize
ignition, fuel sys-
tem and starter air
supply
(if purge upon completion of
gize fuel and igni-
tion systems and
starter air supply
Power Tur- Failure to Trip 380°F - 420°F 0° - 1600°F Trip if temperature
bine Inlet light-off (194° ± 216°C) (-18° - 871°C) does not reach
temperature 400°F (204°C)
(T5.4) Tem- within 20 seconds
perature after fuel and igni-
(Gas tion are applied
Generator
Exhaust)
Power Turbine Speed
3000 rpm 3600 rpm
Liquid Fuel Trip 1575°F 1575°F
(857°C) (857°C)
Alarm 1530°F 1540°F
(832°C) (838°C)
Vibration Gas generator Trip 7 mils DA 0-3 mils DA Avoid continuous
operation above
4 mils
Alarm 4 mils DA

U-16
GEK 97310
VOLUME I
ADDENDUM U
Alarm Normal
Power turbine Trip 10 mils DA 0-6 mils DA Avoid continuous
operation above
7 mils
Alarm 7 mils DA
Speed
(For 60 HZ) Gas generator Trip 10,200 rpm 0-10,100 rpm
(For 60 HZ) Power turbine Trip 3,960 rpm 0-3,600 rpm
(For 50 HZ) Gas generator Trip 10,200 rpm 0-10,100
(For 50 HZ) Power turbine Trip 3,300 rpm 0-3,000 rpm
NOTE
are considered.
upon loss of flame

U-17
GEK 97310
VOLUME I
ADDENDUM U
9-2.3 Special Instrumentation Required for f. All service connections made
Monitoring and Troubleshooting: and secure _______
g. All lines flushed, per Pack-
Fuel manifold pressure sensor0-1200 psi ager’s manual _______
- Liquid fuel (0-8280 kPa) h. All instrumentation connec-
Compressor inlet total 10-16 psia tions made and secure _______
pressure sensor (69-100 kPa) i. All accessories secured, per
Power turbine inlet gas 0-75 psia Packager’s manual _______
pressure (0-517 kPa) j. Gas turbine assembly free of
Compressor discharge 0-300 psig loose objects and all lines/
pressure (0-2070 kPa) electrical leads connected _______
Fuel supply pressure - Liquid0-1200 psig k. Gas turbine inlet air area free
fuel (0-8280 kPa) of foreign objects. Inlet screen
Fuel supply temperature - 0-250°F secure. _______
Liquid fuel (-18 to 121°C) l. Gas turbine compressor rear
Gas turbine inlet air 0-150°F frame leakage ports, struts 7
temperature (-18 to 66°C) and 10, open (not capped) _______
Lube oil scavenge pressure 0-100 psig m. Starter serviced per Packager’s
(0-690 kPa) manual _______
Remote reading variable vane -5° to +45° n. Lube oil storage tank serviced
indicator to full level _______
Pneumatic starter air supply 0-50 psig o. Lube oil supply valves open _______
pressure (optional) (0-0345 kPa) p. All filters serviced per
9-2.4 Preparation. The gas turbine and asso- q. Fire alarm/extinguish system
ciated systems must be inspected and checked ON and operative _______
out for proper installation and operation before r. T5.4 thermocouple system
normal operation can commence. functioning properly _______
9-2.5 Gas Turbine and Associated Equip- s. Ignition system operative _______
ment Checklist. Complete the following t. Compressor inlet total pres-
checklist. sure probe aligned properly
u. Variable stator system secure _______
foundation _______
tion specified in packager’s
c. Intake air and exhaust gas manual for gas turbine control
ducts in place and secured _______ have been performed _______
d. Bonding straps in place and
secure _______
e. Gas turbine and exhaust duct
place and secure _______

U-18
GEK 97310
VOLUME I
ADDENDUM U
Refer to packager’s manual. COOL DOWN. AVOID CON-
LATED GLOVES AS
WARNING NECESSARY.
OPERATING.
MET:
ENCLOSURE OR IN THE
SHUT DOWN.
ENTRY SHOULD BE

THE CUSTOMER’S
paragraph 9-2.10.
PROCEDURES.
f. Perform governor check per packer’s
manual.
OFF. HIGH SECONDARY AIR- g. Perform a wet prestart per
ING OR CLOSING THE
paragraph 9-2.12.
SHALL BE KEPT OPEN. IF THE i. Operat to maximum power per
TIONED AT THE ENCLOSURE j. Check automatic operation per
DOOR AND CONFINED SPACE paragraph 9-2.14
BE FOLLOWED.

U-19
GEK 97310
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ADDENDUM U
Item Requirement
Fuel valves Closed
Ignition Off
Ventilation inlet air (secondary cooling air Off-air temp. below 70°F (21°C)
Ventilation exit air 180°F (82°C) max.
Oil tank level Full
Lube oil temperature (min.) +20°F (+1°C) for MIL-L-23699
-20°F (-29°C) for MIL-L-7808
pressure 0-1000 psig (0-6895 kPa)
temperature 0-250°F (-18-121°C)

U-20
GEK 97310
VOLUME I
ADDENDUM U
WARNING
• ASSURE POWER TO IGNITION a. Make ignition and liquid fuel supply
VERTENT ACTIVATION. (2) Close liquid fuel manual shutoff
lead away from exciter. while gas generator is coasting down, loosen
system (No. 2 ignition exciter energized). An minimum of 2000 rpm.
d. Turn off electrical power to the ignition 9-2.10 False Start. Perform false start as
system. Reconnect input lead to exciter and follows:
e. Repeat steps b, c, and d, disconnecting connected and manual fuel shutoff valve
the No. 2 exciter. closed, make automatic start of gas turbine, per
operator’s manual.
No. 1 and/or No. 2 igniters, check out the sys- b. Gas generator should go through nor-
tem to isolate the problem, and take appropri- mal start cycle and then abort because of lack
ate corrective action. of flame.

U-21
GEK 97310
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ADDENDUM U
a. With supply to ignition unit discon- obtained and it is determined that a “thermal
nected, with the liquid fuel manual shutoff seizure” of the power turbine has occurred,
valve open, and the governing system operat- proceed as follows:
ing, make an automatic start of the gas turbine
per the operator’s manual. NOTE
b. Gas generator should accelerate and
stabilize at a speed dependent on starter inlet
lack of ignition.
c. Allow gas generator to coast to a stop.
Purge fuel nozzles of liquid with compressed
contact is prevented from rotating by
air at 200 psid (1380 kPa) maximum. After
hard contact between LPT blades and
wet prestart, drain liquid fuel from fuel mani-
fold. Then motor gas generator on starter for
60 seconds to purge fuel from gas turbine.
9-2.12 Manual Start. Perform manual start
with ignition lead connected and fuel system
normal, per table 5.
CAUTION
AND 30 SECONDS OF GAS TUR- (1) Shutdown gas turbine.
POWER TURBINE ROTATION. (2) Immediately after the gas turbine
FOR EARLY MODEL GAS TUR- stops rotating, re-start and stabilize at idle
BINES THAT HAVE TIGHTER LPT speed (4950 ± 50 rpm) for 30 seconds.
NOT EXCEED 6000 RPM NGG AND (3) Repeat steps (1) and (2) for two
30 SECONDS OF GAS TURBINE additional start-up and shutdown cycles.
TURBINE ROTATION. (4) If the power turbine does not
NOTE (3), shut down the gas turbine.


U-22
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ADDENDUM U
Table 5. START-UP OPERATION

CAUTION
• IF T5.4 RAPIDLY APPROACHES OR EXCEEDS 1450°F (788°C) FOR LIQUID FUEL,
ABORT START.
• THE GAS TURBINE IS DESIGNED TO OPERATE ON 100% LIQUID FUEL.

• WHEN OPERATING ON 100% LIQUID FUEL IT IS NECESSARY TO DRAIN THE
LIQUID FUEL MANIFOLD WHEN THE GAS TURBINE IS SHUT DOWN. THE
MAXIMUM TEMPERATURE OF THE FUEL WILL BE 200°F (93°C). REFER TO
OPERATOR’S MANUAL FOR PROCEDURE.
NOTE
4. At 1100 to 1300 RPM NGG
a. Ignition on

90-150 psig (621-1035 kPa)
(Liquid fuel)
c. Note time to light off 10 seconds maximum Abort start-automatic

T5.4 above 400° F shutdown
(204° C)

RPM take corrective action if rpm
stops increasing or it takes
longer than 90 seconds to
reach 4300 rpm (see
figure 6).

U-23
GEK 97310
VOLUME I
ADDENDUM U
Table 5. START-UP OPERATION - Continued

6. At 4300 to 4500 rpm NGG

should close supply valve.
automatically

Chapter 5 (41 kPa)
b. Fuel manifold pressure: Approximately 150 psig Troubleshoot system and

Liquid fuel (1035 kPa) take corrective action. See
figures 7.
c. NGG 5000 RPM ± 250 rpm Adjust
d. T5.4 1000°F (538°C) max Emergency shutdown
e. NPT (unloaded) 1200 - 1900 rpm
f. Gas generator vibration 0 to 3 mils DA Alarm if above 4 mils.

Automatic normal shutdown
action
g. Power turbine vibration 0 to 6 mils DA Alarm if above 7 mils.

if above 10 mils Trouble-
action
h. Compressor inlet tem- Approximately equal to Normal shutdown

perature (T2) outside air temperature

U-24
GEK 97310
VOLUME I
ADDENDUM U

i. Check for fuel and oil
leaks
9. Set desired power setting. Less than alarm limit Ref. Note 1
Observe T5.4 during tran-
sient operation

a. T5.4 Less than alarm limit
b. NGG The maximum allowable

speed is 10100 rpm
(corrected)
c. NPT 0-3960 rpm max
d. Oil pressure See applicable table and Emergency shutdown if

figure in Chapter 5 below 5 psig (34 kPa) out of
limits
e. Scavenge oil temperature 160°F to 275°F Ref. Note 1. Automatic

(71°C to 135°C) shutdown if above
340°F ± -10°F
(171°C ± 6°C).
f. Gas generator vibration 3 mils maximum Ref Note 1.
4 mils (Alarm) Emergency shutdown
7 mils (Trip)
g. Power turbine vibration 6 mils maximum Ref Note 1

7 mils max. (Alarm) Emergency shutdown
10 mils max. (Trip)
h. Fuel manifold inlet pres- 150-900 psig Ref. Note 2.

sure - Liquid fuel (1035 - 6205 kPa)
i. Fuel inlet temperature 20°F (11°C) above wax Ref. Note 2.

Liquid fuel point of fuel minimum to
+ 150°F (66°C) maximum

U-25
GEK 97310
VOLUME I
ADDENDUM U

l. T2 Approximately equal to out- Ref. Note 2.


WP 118 00 WP 118 00
NOTE 1: Reduce power to stay within limits. If reducing power does not bring parameters
NOTE 2: If all other parameters are normal, correct discrepancy at next opportunity.

U-26
GEK 97310
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ADDENDUM U

U-27
GEK 97310
VOLUME I
ADDENDUM U
(5) Immediately after gas turbine d. Reduce gas generator speed to idle.
rotation stops, re-start and accelerate to After stabilizing for three minutes, record all
7000 rpm NGG maximum and stabilize for instrument readings. Refer to Table 6, step 2.
rotate, shut down and investigate/correct the e. Check fail-safe section of control sys-
cause. During the investigation for the cause of tem per packager’s manual.
blades in stages 4, 5 and 6 for shingling and f. After gas turbine has been stabilized at
unlatching. If blades have become unlatched, idle for five minutes, make normal shut-down.
they may be relatched. LPT blades that have Refer to Table 6, steps 3 and 4.
necessitating replacement of the power 9-2.14 Automatic Operation. Check automatic
turbine. operation per packager’s manual.
9-2.13 Operation to Maximum Power. a. Accelerate to idle.
CAUTION b. Accelerate to rated power.

TIVE CIRCUITS. OPERATING LIM- d. Decelerate to idle
(Refer to packager’s manual.) to increase gas f. After a total of five minutes at idle,
generator speed. After each 500 rpm increase, shut down gas turbine.
attention to variable stator vane position and g. Check lube oil and fuel filters and
vibration. If variable stator system is not strainers; clean or replace as necessary.
within limits (see figure 3 or 4) adjust it per
WP 118 00. If vibrations are not within limits, h. Correct any leaks observed.
consult the local General Electric Company
representative. i. Remove all temporary instrumentation.
b. Operate gas turbine up to rated power, j. Check gas turbine and mounting sys-
if possible, but do not exceed exhaust gas tem- tem for loose parts; tighten as necessary.
perature (T5.4) limit. (See table 3.) Hold at this
power setting until all temperatures stabilize.
If governing system is unstable, adjust per
packager’s manual.


U-28
GEK 97310
VOLUME I
ADDENDUM U
1. Set gas turbine at idle power Gas generator decelerates to Emergency shutdown
(unloaded) idle
following:
Liquid fuel (1035 kPa). See figure 8.
d. T5.4 Approximately Troubleshoot and take
1000°F (538°C) corrective action.
e. NPT 1200 - 1900 rpm Ref. Note 1.
f. Gas generator vibration 3 mils max. Alarm if above 4 mils.
action.
g. Power turbine vibration 6 mils max. Alarm if above 7 mils.
action.
h. Fuel inlet temperature 20°F (11°C) above wax
Liquid fuel point of fuel minimum to
∆P
3. After stabilizing at idle for 5 T5.4 drops below 400°F Shut off fuel supply
minutes, close fuel valve (204°C) NGG and NPT
4. Observe T5.4 for 3 minutes 700°F (371° C) Motor gas turbine. Con-
ature decreases

U-29
GEK 97310
VOLUME I
ADDENDUM U
ager’s manual.
9-3.2 Interlocks. Refer to paragraph 2-11.9 SHALL BE KEPT OPEN. IF THE
BE FOLLOWED.
WARNING
LATED GLOVES AS
SHUT DOWN.
• THE FIRE EXTINGUISHING ear protection.
THE CUSTOMER’S
PROCEDURES.

U-30
GEK 97310
VOLUME I
ADDENDUM U
b. Start and operate the gas turbine per 9-4 EMERGENCY OPERATION.
Table 3. 9-4.1 Emergency Shutdown.
c. Shut down the gas turbine per Table 6. a. In an emergency, the gas generator may
d. Emergency shut down the gas turbine ing the fuel valve. However, this should only
per Table 7. be done in an emergency, since rapid shutdown
for lube correction factors and lube supply b. Emergency shut-down shall be made
pressure characteristics. (See tables V-21A, per Table 7.
5-32B, 5-32E, 5-32F, 5-32J, 5-32L, 5-32N, 9-4.2 Post Shutdown Fire. During a normal
and 5-32Q.) shutdown, exhaust gas temperature should
decrease. If during time gas generator is coast-
NOTE ing to stop, temperature increases instead of
Addendum U affects PNL34379P01 decreases, it indicates that combustion is still
only. taking place. (A slight temperature increase
after rotation stops is normal.) Make certain
fuel is shut off, and motor the gas generator.
This will blow out the fire. As soon as temper-
ature decreases to normal, discontinue
motoring.

U-31
GEK 97310
VOLUME I
ADDENDUM U
CAUTION
1. Conditions permitting, decelerate gas T5.4 drops below 400° F Manually shut off fuel
turbine to idle and close fuel valves (204° C) and NGG and supply
NPT decelerate
2. Observe T5.4 for 3 minutes after 700°F (371°C) max Motor gas turbine. Con-
shutdowns tinue motoring until
procedure.
of the 5 minute purge/motoring
accelerate to idle. Acceleration to
the desired power setting can then be
accomplished.

U-32
GEK 97310
VOLUME I
ADDENDUM U
CONSTRAINTS. supply pressure limits given in the limit tables
ditions, the gas turbines are constrained by the proper pressure is dependent on gas generator
operating limits published in the limits table. speed, oil type, oil temperature, and number of
shutdown or “trip” level should not be corrected oil pressure as directed on the appro-
practiced. priate pressure correction table in Chapter 5 to
assure the gas turbines continued normal oper- generator rotational speeds above 7500 rpm
ation. These events are either not detected or can result in high pressure compressor blade
not prevented by the customary protective fracture. The gas turbine can be operated after
devices of control systems. an inspection of the compressor stages 3
• Overtmperature During Starting not occurred. If tip clanging has occurred, fur-
from the spool.
• Starter Duty Cycle Gas.
• Re-Start Following High Power Trip a. With starter inlet air pressure set at
40 psig (276 kPa):
• No Power Turbine Rotation • 45 Seconds, on 2 minutes off for any
number of cycles,
or
acceleration to idle, cooling flows to compo- • 2 minutes on, 5 minutes off with two
nents of the gas turbine hot section are not suf- such cycles in any 30 minutes period.
ficient to protect the metals at T5.4 alarm and
b. With starter inlet air pressure set at
trip levels specified in the limits table. A lower 15 psig (103 kPa):
levels acceptable provided they exist for lim- • 5 minutes on, 2 minutes off with two
ited times as depicted on the curve titled such cycles in any 30 minute period.
“Transient Temperature Limits for Starts”.
This must be monitored by the operator. The or
into area B requires hot section disassembly • 10 minutes on, 20 minutes off for any
and inspection in a qualified facility. number of cycles.
U-33
GEK 97310
VOLUME I
ADDENDUM U
c. There is no duty cycle limit on the d. Refire and accel to 6000 rpm. Do not
hydraulic starter. exceed 6000 rpm. Power turbine should break
9-5.6 Re-Start Following High Power Trip. unlatched or shingled blades, or other cause.
In the event that re-start of the gas turbine is
required within two (2) hours following a trip 9-5.8 Windmilling.
minute cranking at 2000-2500 rpm should pre- a. Unlimited windmilling or cranking of
cede the fire up. The objective is to cool the the gas turbine is allowed at gas generator
high pressure turbine rotor, so that blade tips speeds above 1000 rpm provided the lube oil
maintain clearance with the more rapidly cool- temperature limits are not exceeded. At these
ing case. speeds, the lube supply and scavenge systems
9-5.7 No Power Turbine Rotation. A ther-
mally bound power turbine rotor could occur b. Below 1000 rpm gas generator speeds,
under extreme conditions following a rapid windmilling is allowed up to five (5) minutes,
shutdown from high power. Power turbine with successive periods allowed if preceded by
rotation should initiate during gas turbine normal gas turbine operation.
a. Remain at idle for 30 seconds and shut

down.

U-34
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VOLUME I
ADDENDUM U
TABLES 8 through 13. Deleted

U-35/(U-36 Blank)
GEK 97310
VOLUME I
ADDENDUM V
ADDENDUM
7LM2500GB101

GEK 97310
VOLUME I
ADDENDUM V
TABLE OF CONTENTS
1-0 INTRODUCTION....................................................................................... V-3

2-0 REFERENCE DATA .................................................................................. V-3
3-0 INSTALLATION DRAWINGS.................................................................. V-3
4-0 EQUIPMENT DESCRIPTION ................................................................. V-3
5-0 ACCESSORY DRIVE SECTION ............................................................. V-6
5-1.1 General .......................................................................................................... V-6
5-1.2 Accessory Drive Train .................................................................................. V-6
5-1.3 Inlet Gearbox................................................................................................. V-6
5-1.4 Radial Drive Shaft......................................................................................... V-6
5-1.5 Transfer and Accessory Gearbox .................................................................. V-6
5-1.6 Air-Oil Separator........................................................................................... V-11
6-0 IGNITION SYSTEM .................................................................................. V-11
7-0 EXHAUST GAS TEMPERATURE (T5.4) INDICATION ...................... V-18
8-0 LUBRICATION SYSTEM......................................................................... V-18
8-1.1 General .......................................................................................................... V-18
8-1.2 Lube Supply Subsystem................................................................................ V-18
8-1.3 Lube Scavenge Subsystem............................................................................ V-24
8-1.4 Oil Seal Pressurization Subsystem................................................................ V-24
8-1.5 Sump Vent Subsystem................................................................................... V-24
9-0 SERVICE REQUIREMENTS ................................................................... V-24
9-1.1 Natural Gas ................................................................................................... V-24
10-0 OPTIONAL HARDWARE KITS - LM2500GB101................................. V-25
11-0 GAS GENERATOR OPERATION ........................................................... V-26
11-1.1 Performance Ratings and Operating Limits.................................................. V-26
11-2.1 Initial Operation ............................................................................................ V-27
11-2.2 General .......................................................................................................... V-27
11-2.3 Special Instrumentation................................................................................. V-29
11-2.4 Preparation .................................................................................................... V-29
11-2.5 Gas Generator and Associated Equipment Check ........................................ V-29
11-2.6 Governor and Manual Control Check ........................................................... V-30
11-2.7 Start-up and Checkout................................................................................... V-30
11-2.8 Ignition Check............................................................................................... V-31
11-2.9 Motoring........................................................................................................ V-32
11-2.10 False Start...................................................................................................... V-32
11-2.11 Governor Check ............................................................................................ V-32
11-2.12 Wet Prestart ................................................................................................... V-32
11-2.13 Manual Start and Operation .......................................................................... V-32
11-2.14 Operation to Maximum Power...................................................................... V-38
11-3 AUTOMATIC OPERATION..................................................................... V-38
11-4 NORMAL OPERATION............................................................................ V-40
11-4.1 General .......................................................................................................... V-40

V-1
GEK 97310
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ADDENDUM V
TABLE OF CONTENTS (cont.)
11-4.2 Interlocks....................................................................................................... V-40

11-4.3 Operation....................................................................................................... V-40
11-5 EMERGENCY OPERATION ................................................................... V-41
11-5.1 Emergency Shutdown ................................................................................... V-41
11-5.2 Post Shutdown Fire ....................................................................................... V-41
Figure Title Page
1 Deleted
2 Deleted
3 Deleted
4 Deleted
5 Deleted
6 Deleted
7 Accessory Drive Section ............................................................................... V-8
8 Inlet Gearbox................................................................................................. V-9
9 Transfer and Accessory Gearbox .................................................................. V-10
10 Air-Oil Separator........................................................................................... V-12
11 Ignition System ............................................................................................. V-13
12 Thermocouple Schematic.............................................................................. V-19
13 Lubrication System Schematic...................................................................... V-20
14 Lube and Scavenge Pump ............................................................................. V-23
15 Acceleration Fuel Schedule .......................................................................... V-28
16 Fuel Manifold Pressure vs Fuel Flow ........................................................... V-36
17 Transient Temperature Limits ....................................................................... V-37
LIST OF TABLES
Table Title Page
1 INSTRUMENTATION CONNECTIONS - LM2500GB101 ....................... V-4

2 MECHANICAL SERVICE CONNECTIONS - LM2500GB101................. V-5
3 GAS GENERATOR OPERATING LIMITS ................................................ V-14
4 PRESTART CHECKS .................................................................................. V-31
5 START-UP AND OPERATION.................................................................... V-33
6 GAS GENERATOR SHUTDOWN .............................................................. V-39
7 EMERGENCY SHUTDOWN...................................................................... V-41
8 LUBE PRESSURE LIMITS FOR OIL, MIL-L-23699 ................................ V-42
9 CORRECTIONS FOR LUBE PRESSURE LIMITS USING
OIL, MIL-L-23699 ................................................................................ V-45
V-2
GEK 97310
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ADDENDUM V
1-0 INTRODUCTION. Wt-Lbs/(Kg)
This addendum provides information which High Pressure Turbine Nozzle, 127 ( 58)
applies specifically to the LM2500GB101 gas Stg 2
generator model, and may or may not be appli- Turbine Mid Frame 530 (240)
cable to other gas generator models covered by
Variable Stator Actuating 19 ( 9)
this manual. Reference data, instrumentation
Mech
and service connection information, special
servicing requirements, optional equipment Outside Piping and Bracketing 278 (126)
information, and complete operating instruc- Approx.
tions are included.
DRAWING LIST
2-0 REFERENCE DATA. Drawing No.
EQUIPMENT Gas Generator Installation
Gas Generator Assembly Drawing L31705
General Electric Co., Fuel System Flow Diagram L25152 or
Cincinnati, Ohio 45215 L24327
Model No. 7LM2500GB101 Lubrication System Flow
Dwg. No. L21380G01 or G05 Diagram L24007
Electrical Diagram L21892 or
PERFORMANCE RATING
L25596
Refer to paragraph 11-1.1. Ignition Units L21454P02
Gas Generator Assembly L21380G01
GAS GENERATOR WEIGHTS Drawing or G05
The average weights of the major gas genera-
tor components are:
Wt-Lbs/(Kg) been provided.
Transfer Gearbox 245 (111) a. The 7LM2500GB101 gas generator
Compressor Front Frame 517 ( 235) consists of:
Compressor Rotor 552 ( 250) 1 Inlet duct with water wash manifold
Compressor Stator, Front 307 ( 139) 1 Centerbody
Compressor Stator, Rear 93 ( 42) 30 Natural gas fuel nozzles and 1 fuel
manifold
Compressor Rear Frame 421 ( 191) 1 Lubrication system (less oil tank, cooler
Combustor 120 ( 54) and filters)
High Pressure Turbine Rotor 419 ( 190) 2 Ignition units
High Pressure Turbine Nozzle, 68 ( 31) 1 Set of instrumentation sensors
Stg 1

V-3
GEK 97310
VOLUME I
ADDENDUM V
Table 1. INSTRUMENTATION CONNECTIONS - LM2500GB101
or 364450
E2 Power turbine inlet temperature MS3106-14S-95
E3 A-sump scavenge oil temperature MS3106R12S-3S/W
E4 B-sump scavenge oil temperature MS3106R12S-3S/W
E5 C-sump scavenge oil temperature MS3106R12S-3S/W
E6 Accessory gearbox scavenge oil MS3106R12S-3S/W
temperature
E11 Oil supply temperature MS3106R12S-3S/W
F3 Natural gas fuel manifold pressure tap AN818-4C or MS9197-04
--Remote reading variable stator vane protractor
NOTE
For all other instrumentation connections, see the Installation Drawings, provided with gas
generator.

V-4
GEK 97310
VOLUME I
ADDENDUM V
Table 2. MECHANICAL SERVICE CONNECTIONS - LM2500GB101
CAUTION
MAL GROWTH OF GAS GENERATOR WITHOUT PLACING STRAIN ON LINES,
COMPONENT, OR ON GAS GENERATOR. IF EXCESSIVE FORCE IS REQUIRED
TO COMPLETE A CONNECTION, LOOSEN CONNECTION AND CHECK/ADJUST
F1 Natural gas supply 2 inch line from Fuel Control Unit to Gas Gen-
erator Fuel Manifold
AN818-24C or MS9197-24
ters AN818-16C or MS9197-16
AN818-20C or MS9197-20
L4 Lube supply inlet port 1 inch line from Oil Supply Filters to Gas Gen-
erator AN818-16C or MS9197-16
A2 Bleed air port 16th stage compressor bleed air lines if used
A11 CDP seal leakage No. 2 (is used) 2-inch line
A12 Air/Oil Separator 3 inch line from air/oil separator to atmospheric
A16 Aspirator Air Supply GE lube flange PN 9643M28P32 + V band
clamp PN 9014M45P32
D3 Oil drain, forward AN818-6C or MS9197-06
D5 Oil drain, aft AN818-6C or MS9197-06
or MS9197-12
S1A Waterwash manifold (Alternate)
NOTE
gas generator.

V-5
GEK 97310
VOLUME I
ADDENDUM V
5-0 ACCESSORY DRIVE SECTION. 5-1.4 Radial Drive Shaft. The radial drive
shaft, a hollow shaft externally splined on each
5-1.1 General. See figure 7. The accessory end, mates with the bevel gears in the inlet and
drive section consists of an inlet gearbox in the transfer gearboxes. Its function is to transmit
hub of the front frame, a radial drive shaft power from the inlet gearbox to the forward
inside the 6 o’clock strut of the front frame, section (bevel gearbox) of the transfer gear-
and a transfer gearbox bolt underneath the box. The shaft contains a shear section to pre-
front frame. The pneumatic starter, and the vent damage to the accessory drive system.
lube and scavenge pump are mounted on the
aft side of the transfer gearbox. The air-oil sep- 5-1.5 Transfer and Accessory Gearbox. See
arator and stator control are mounted on the figure 9. The transfer gearbox assembly con-
front of the gearbox. sists of a two-piece aluminum casing, air-oil
separator, gears, bearings, seals, oil nozzles,
5-1.2 Accessory Drive Train. Power to drive and accessory adapters. The forward section
the accessories is extracted from the compres- (bevel gearbox) contains a set of right-angle
sor rotor through a large-diameter hollow shaft bevel gears and a horizontal drive shaft which
which is spline-connected to the rotor front transmits the power to the gear train in the rear
shaft. A set of bevel gears in the inlet gearbox section (accessory gearbox). Each bevel gear is
transfers this power to the radial drive shaft, supported by a duplex ball bearing and a roller
which transmits the power to another set of bearing. An access cover in the bottom of the
bevel gears in the forward section of the trans- casing facilitates installation of the radial drive
fer gearbox. A short horizontal drive shaft shaft. The “plug-in” gear concept is used on all
transmits power to the accessory drive adapt- accessory adapters and idler gears in the aft
ers in the transfer gearbox. (accessory) section. This permits an entire
gear, bearing, seal, and adapter assembly to be
5-1.3 Inlet Gearbox. See figure 8. The inlet removed and replaced without disassembling
gearbox assembly consists of a cast aluminum the gearbox. Each spur gear is supported by a
casing, a shaft, a pair of bevel gears, bearings, casing-mounted roller bearing on one end and
and oil jets. The casing, which is bolted inside an adapter-mounted ball bearing on the other
the front frame hub, mounts two duplex ball end. The accessory drive spur gears are inter-
bearings and a roller bearing. It has internal oil nally splined. Internal tubes and oil nozzles
passages and jets to provide lubrication for the provide lubrication of the gears and bearings.
gears and bearings. The shaft, which rotates on Gearbox carbon face seals are retained from
a horizontal axis, is splined at the aft end to the outside of the gearbox and can be replaced
mate with the stage-2 disk of the compressor without disassembly of the gearbox.
rotor. The forward end of the shaft mounts the
upper bevel gear and is supported by a duplex
ball bearing. The lower bevel gear, which
rotates on a vertical axis, is supported at its
upper end by a roller bearing and at its lower
end by a duplex ball bearing. The lower end is
also splined to mate with the radial drive shaft.

V-6
GEK 97310
VOLUME I
ADDENDUM V

V-7
GEK 97310
VOLUME I
ADDENDUM V
Figure 7. Accessory Drive Section

V-8
GEK 97310
VOLUME I
ADDENDUM V
Figure 8. Inlet Gearbox

V-9
GEK 97310
VOLUME I
ADDENDUM V
Figure 9. Transfer and Accessory Gearbox

V-10
GEK 97310
VOLUME I
ADDENDUM V
5-1.6 Air-Oil Separator. See figure 10. The a. The ignition exciters are the capacitor
air-oil separator consists of a fabricated sheet discharge type. The exciters are off-engine
metal impeller with a cast aluminum housing. mounted. Design characteristics are as follows:
It is mounted on the front of the accessory sec-
tion of the transfer gearbox and is considered a Duty cycle................ Refer to Table 3 Gas
part of the gearbox. To prevent excessive oil (Normal) Generator Operating
loss from venting oil vapor overboard, all Limits
sumps are vented to the air-oil separator. The
sump air is discharged after passing through Power....................... 115v at 60 Hz
the separator. Oil is collected on the inside of Stored energy........... 14.5-16.0 joules
the impeller as the oil-laden sump air passes Spark rate................. 2/sec.
through the separator. Small holes in the seg-
Output voltage ......... 15-20 KV
ments of the impeller allow the collected oil to
be discharged to the separator outer housing. Output energy
Vanes on the housing wall are used to collect Total..................... 2.0 joules min.
and direct the oil to the gearbox. To prevent oil Duration............... 20 micro-seconds min.
and oil vapors from escaping past the end of Peak power .......... 100,000 watts min.
the impeller, the separator has two labyrinth
seals, with the cavity between the two seals Peak current......... 2000 amp. min.
pressurized with stage-8 ejector air.
b. The exciters operate on 115v, 60 Hz
6-0 IGNITION SYSTEM. input. The power is transformed, rectified, and
discharged in the form of capacitor discharge
See figure 11. During start, the ignition system energy pulses through the coaxial shielded
produces the high energy sparks that ignite the leads to the spark igniters.
fuel-air mixture in the combustor. It consists of
2 ignition exciters, 2 ignition leads, and 2 c. The ignition leads are low-loss connec-
spark igniters. tions between the ignition exciters and the
spark igniters. They are coaxial, having metal-
lic shielding which incorporates copper inner
braid, sealed flexible conduit, and nickel outer
braid.
d. The spark igniters are surface gap type.

They have internal passages for air-cooling
and air vents to prevent the accumulation of
carbon in interior passages.

V-11
GEK 97310
VOLUME I
ADDENDUM V

V-12
GEK 97310
VOLUME I
ADDENDUM V
Figure 11. Ignition System

V-13
GEK 97310
VOLUME I
ADDENDUM V
Table 3. GAS GENERATOR OPERATING LIMITS
Normal
Alarm/ Operating
NOTE
• Correct lube pressures in accordance with table 9.
Lubrication Gas Generator Lube Alarm 8 psig ± 1 psig 20 - 60 psig Bypass until
System - Supply Pressure (55 kPa ± 6.9 kPa) (138 - 413 kPa) 4500 rpm
Settings and below 8000 rpm
above 8000 rpm
Gas Generator Lube Trip 6 psig ± 1 psig 20 - 60 psig Bypass until
Supply Pressure (41 kPa ± 6.9 kPa) (138 - 413 kPa) 4500 rpm
Gas Generator Alarm 110 psig ± 10 psig 10 - 100 psig Scavenge Dis-
Scavenge Discharge (759 kPa ± 69 kPa (69 - 690 kPa) charge Pressure
Pressure shall not exceed
180 psig
(1242 kPa)
Gas Generator Lube Alarm 180° - 220°F 140° - 160°F Normal Operat-
Supply Temperature (82° - 104°C) (60° - 71°C) ing Range
reflects tempera-
ture expected
during operation
above idle speed
Gas Generator Lube Trip 330° - 350°F 215°- 275°F Normal Operat-
Scavenge (166° - 177°C) (102° - 135°C) ing Range
Temperatures reflects tempera-
ture expected
Alarm 290° - 310°F
during operation
(143° - 154°C)
above idle speed

V-14
GEK 97310
VOLUME I
ADDENDUM V
Table 3. GAS GENERATOR OPERATING LIMITS (Cont.)
Normal
Alarm/ Operating
Fuel Fuel Manifold 20-355 psig Supply Pressure
System Pressure (138-2448 kPa) as reflected at the
fuel manifold
inlet on the gas
generator
Fuel Supply Alarm 150°-170°F -65° to 150°F Starting Fuel
Temperature (66°-77°C) (-54° to 66°C) Flow Adjust-
ments may be
required to com-
pensate for fuel
temperature
variation
based on engine
starter torque
requirements
Application of Fuel 1200 ± 100 rpm
and Ignition
Application of Fuel 1700 ± 100 rpm 1700 ± 100 rpm
and Ignition (If for start after
purge cycle is used) purge cycle
simultaneously
with start
initiation
simultaneously
with application
of fuel and
ignition

V-15
GEK 97310
VOLUME I
ADDENDUM V
Normal
Alarm/ Operating
simultaneously
with start initia-
tion. De-ener-
gize ignition, fuel
system and
starter air supply
4500 rpm (If purge onds time delay
cycle is used) upon completion
of purge. De-
energize fuel and
ignition systems
and starter air
supply
Exhaust Failure to Trip 380° - 420°F 0 - 1600°F Trip if tempera-
Gas Light-Off (193° - 216°C) (18° - 871°C) ture does not
Temperature reach 400°F
(204°C) within
20 seconds after
fuel and ignition
are applied

V-16
GEK 97310
VOLUME I
ADDENDUM V
Normal
Alarm/ Operating
Overtemperature Trip 1450°F (788°C) 1378° - 1438°F Values given are
using constant
Alarm 1438°F (781°C) T5.4 control as
the power limit.
Installations
using constant
power control
mode should
consult the con-
tract documents
for determining
alarm and trip
settings, which
are unique to
each application,
but never to
exceed 1616°F
(880°C) (alarm)
and 1625°F
(885°C) (trip)
operation over
4 mils
Speed Gas Generator Trip 9950 ± 50 0-9850 rpm
valve upon loss
of flame

V-17
GEK 97310
VOLUME I
ADDENDUM V
7-0 EXHAUST GAS TEMPERATURE 8-1.2 Lube Supply Subsystem.
(T5.4) INDICATION.
a. The lube supply subsystem consists of
Gas generator exhaust gas temperature is the following components:
sensed by 11 thermocouples installed in the
turbine mid frame. See figure 12. There are (1) Oil tank (not General Electric Co.
four thermocouple harnesses, three of which supplied).
have three thermocouples each and one which
has two thermocouples. (2) Lube and scavenge pump supply
element and bypass valve.
a. A thermocouple junction is formed
when 2 dissimilar metals are joined. KP and (3) Lube supply duplex filter (not
KN are used as the dissimilar metals. A com- General Electric supplied).
plete circuit is formed when both ends of the
KP and KN wires are joined. The thermocou- (4) Lube supply anti-static check
ples generate an electrical signal which is pro- valve.
portional to the temperature of the turbine
discharge gas. This temperature is sometimes (5) C sump supply check valve.
referred to as T5.4.
b. Lube oil from the supply tank enters
8-0 LUBRICATION SYSTEM. the lube and scavenge pump through an inlet
screen which prevents particles larger than
8-1.1 General. See figure 13. The lubrication 0.030 inch (0.76 mm) in size from entering.
system provides the gas generator bearings, Output of the supply element is routed to the
gears, and splines with adequate cool oil to buyer provided lube supply filter. From the fil-
prevent excessive friction and heat. The single ter, the oil flows through an anti-static check
supply element of the pump forces the oil valve to the inlet gearbox, the stator vane
through tubes to components and areas requir- speed sensor, the transfer gearbox, and the gas
ing lubrication. Oil nozzles direct the oil onto generator sumps. Oil going to the C sump
bearings, gears, and splines. Four separate passes through an additional check valve in the
scavenge elements in the lube and scavenge C sump supply line. Lube discharge oil also is
pump remove oil from the B and C sumps and piped to a port near the forward end of the lube
the aft and forward transfer gearbox. (A sump and scavenge pump to lubricate the drive
drains to forward transfer gearbox.) The scav- spline.
enged oil is returned to the lube tank. The
lubrication system is divided into 3 subsystems
identified as lube supply, lube scavenge, and
sump vent.

V-18
GEK 97310
VOLUME I
ADDENDUM V

V-19
GEK 97310
VOLUME I
ADDENDUM V
Figure 13. Lubrication System Schematic (Sheet 1 of 2)

V-20
GEK 97310
VOLUME I
ADDENDUM V

V-21
GEK 97310
VOLUME I
ADDENDUM V
c. The lube and scavenge pump d. Oil enters the lube inlet port and passes
(figure 14) is a six element, positive displace- through a removable, non-bypassing inlet
ment, vane type pump. One element is used for screen which traps particles larger than
the lube supply, and 5 are used for lube scav- 0.030 inch (0. 76 mm). A lube supply pressure
enging. Within the pump are inlet screens, one limiting valve is provided to limit supply pres-
for each element, and a lube supply pressure sure. Scavenge oil enters the pump through 4
limiting valve. Design characteristics of the scavenge oil ports, passes through an inlet
pump are as follows: screen in each port, and enters the scavenge
Rotation Clockwise when viewed elements. The outputs of the 4 scavenge ele-
from drive end ments are connected inside the pump and dis-
charge through a common scavenge discharge
Shear section 1500-2000 lb in.
port.
(1730-2310 kg cm)
Pressure limit- e. The lube supply check valve is located
ing valve on the downstream side of the lube supply fil-
Cracking 300 psid (2070 kPa) min ter. It will open and flow 20 gpm (76 lpm) with
pressure a maximum differential pressure of 15 psid
Full flow 400 psid (2760 kPa) max (103 kPa). The purpose of the check valve is to
Reseat 275 psid (1898 kPa) min prevent the oil in the tank from draining into
Pumping All flows dependent upon the sumps and gearbox when the gas generator
capacity following conditions: is shut down.
6000 rpm, 150° ± 5°F
(66° + 3°C) oil temperature, f. A check valve is located in the lube oil
12-15 psia (83-103 kPa) oil supply line to the C sump. The check valve
inlet pressure, fluid per MIL- isolates the C sump from the gas generator
L-7808 or MIL-L-23699 lube oil system when an external lube supply
Lube supply 16.0-18.3 gpm (61-69 lpm) and scavenge system is used for the buyer fin-
TGB scav- 4.8-5.4 gpm (18-20 lpm) ished power turbine. The C sump scavenge
enge, fwd line and the C sump oil supply line are
equipped with access ports to facilitate the
TGB scav- 18.0-20.2 gpm
application of an external lube system for the
enge, aft (68-76 lpm)
power turbine. During normal engine opera-
B sump 10.6-12.1 gpm tion, lube oil is supplied from the lube pump,
scavenge (40-46 lpm) to the C sump. The check valve then opens at a
C sump 7.6-8.5 gpm (29-32 lpm) 2 psid (14 kPa) pressure differential.
scavenge
Discharge
pressure
Lube supply 25-75 psia (172-517 kPa)
normal, 75-100 psia
Scavenge 25-85 psia (172-586 kPa)
normal, 85-100 psia

V-22
GEK 97310
VOLUME I
ADDENDUM V

V-23
GEK 97310
VOLUME I
ADDENDUM V
8-1.3 Lube Scavenge Subsystem. See 8-1.5 Sump Vent Subsystem. See figure 13.
figure 13.
a. The sump vent subsystem consists of
a. The lube scavenge subsystem consists one major part, the air-oil separator, and the
of the following components: piping and tubing making up the subsystem.
(The air-oil separator is part of the transfer
(1) Lube and scavenge pump scav- gearbox.) For a detailed description of it, refer
enge elements. to paragraph 5-1.6.
(2) Lube scavenge duplex filter (not b. To prevent oil leakage, main bearing
supplied). oil seals use pressurization air to cause air to
flow across the seals into the sumps. Seal pres-
(3) Lube scavenge check valve. surizing air is extracted from the eighth stage
of the compressor and distributed to the oil
(4) Heat exchanger (oil cooler) (not seals. To remove the air which enters the
supplied). sumps through the oil seals and to maintain a
pressure drop across the oil seals, the sump air
b. The 4 scavenge elements of the lube is vented. Each sump area is connected to a
and scavenge pump scavenge oil from the B sump vent manifold through frame struts. The
and C sumps, and from 2 areas of the transfer manifold connects to the air-oil separator
gearbox. Oil from the air-oil separator drains which extracts oil from the air before venting
into the aft section of the transfer gearbox. Oil the air into the exhaust duct. Extracted oil is
from the inlet gearbox and the A sump drains returned to the transfer gearbox.
through the radial driveshaft sleeve into the
forward section of the transfer gearbox. Oil 9-0 SERVICE REQUIREMENTS.
from the 4 scavenge elements exits the pump
from a common discharge port. 9-1.1 Natural Gas.
c. The scavenge check valve is located in a. The required supply pressure to the
the lube and scavenge pump scavenge dis- fuel manifold on the gas turbine is 350 ± 5 psig
charge line. It will open and flow 20 gpm (2413 ± 34 kPa).
(76 lpm) with a maximum differential pressure
of 15 psid (103 kPa). The purpose of this b. The temperature of the gas must be in
check valve is to prevent the oil in the scav- the range of -65° to +150°F (-54 to +66°C). If
enge lines from draining back into the sumps the temperature is not repeatable on a day-to-
and gearbox when the gas generator is shut day basis it will be necessary to change the
down. starting fuel adjustment to adjust the supply
pressure to the engine to maintain a constant
8-1.4 Oil Seal Pressurization Subsystem. Btu-per-cubic-foot supply. Once started, the
Refer to paragraph 2-6. 2, Eight-Stage Bleed engine will accept variations in supply temper-
Air. ature of ±20°F (±11°C). The maximum fuel
flow required is 13,400 pph (6078 kg/h) with a

V-24
GEK 97310
VOLUME I
ADDENDUM V
10-0 OPTIONAL HARDWARE KITS - LM2500GB101.
Item Kit PN Nomenclature Qty
1 L24023 Flange, Customer 1
2 L24077 Stator Control 1
3 L25153 Fuel Control Installation 1
4 L28080G01 Fuel Control Assembly 1
5 106C7149G01 Container 1
6 536L298G01 Spad Drawing List 1
7 537L294G01 Kit/Installation (CIT) 1
8 537L365G03 Lead and Harness, T5.4 1
9 681L317G01 OEM Scheduled Inspection 1
10 681L461G01 Kit, Expendable 1
11 681L464G01 and G03-G06 Kit, On Engine Optional Equipment 1
12 681L465G01-G03 Kit, Off Engine Optional Equipment 1
13 681L468G01, G02 and G04 Kit, Ship With Engine 1
14 681L493G01 Compartment Separator Assembly 1
15 681L494G01 Kit, Machine Threaded Plugs 1

V-25
GEK 97310
VOLUME I
ADDENDUM V
11-0 GAS GENERATOR OPERATION. NOTE
a. These instructions contain the detailed The S. I. units shown in this chapter are
gas turbine operating procedures and limits direct mathematical conversions and
recommended by the General Electric Com- may be rounded off in most instances
pany for the 7LM2500GB101 Gas Generator. at the users discretion. Examples of
b. The instructions are intended to pro- utilized for temperatures, torque val-
vide operating personnel with the information ues, pressures, etc. Examples where
required to operate the gas generator. They S. I. units may not be rounded off are
pertain to routine and emergency conditions those utilized for drop checks, rigging
and procedures. When a fault exists, refer to adjustments, runouts, etc.
chapter 4, TROUBLESHOOTING.
11-1.1 Performance Ratings and Operating
c. It is possible that these instructions Limits.
equipment or contingency to be met in connec- a. Performance Ratings.
tion with the operation of the gas generator.
Refer requests for additional information to the (1) The rated performance of the
General Electric Company. Marine and Indus- 7LM2500GB101 gas generator in the new and
trial Projects Department, Cincinnati, Ohio clean condition is as follows:
45215.
Isentropic Gas 31,300
WARNING Horsepower
IF A QUESTIONABLE CONDITION Inlet Air Temperature 59°F (15°C)
EXISTS, DO NOT OPERATE THE Altitude Sea Level
GAS GENERATOR UNTIL A THOR-
OUGH INVESTIGATION HAS Inlet Losses 0” H2O
BEEN MADE. DO NOT REPEAT Relative Humidity 0%
STALLS, OR OTHER RECOGNIZED Fuel Lower Heating Value 19,000 Btu/lb
PROBLEMS WITHOUT PRIOR Compressor Bleed 0
FAILURE TO DO SO CAN RESULT Accessory Horsepower 0
IN UNDUE STRESS BEING Extraction
IMPOSED ON GAS GENERATOR Power Turbine Inlet Gas 1408°F (764°C)
COMPONENTS, WITH IMMEDI- Temperature (Avg)
ATE OR SUBSEQUENT DESTRUC-
Fuel, Natural Gas GE Specification
TIVE FAILURE OF THE GAS
GENERATOR AND INJURY TO MID-TD-0000-1
PERSONNEL.

V-26
GEK 97310
VOLUME I
ADDENDUM V
(2) Approximate starting fuel flow (7) For normal accelerations from
requirements based on applying fuel and igni- idle to power settings, the changes should be
tion at 1200 rpm are: made more slowly to enhance the time
between the hot section repairs and the life of
400 pph ± 37 pph (181 ± 17 kgh) at -65°F the gas generator; a time of 2 to 3 minutes is
(-54°C) Inlet Air Temperature reasonable.
480 pph ± 37 pph (218 ± 17 kgh) at 60°F (8) The maximum deceleration fuel
(16°C) Inlet Air Temperature flow rate should consist of a step fuel decrease
of 1500 pph (680 kg ph) ±10 percent followed
520 pph ± 37 pph (236 ± 17 kgh) at 130°F
by a rate change of 1330 pph (603 kg ph) ± 10
(54°C) Inlet Air Temperature based on
percent per second to idle fuel flow. Rates
19,000 btu/lb per cubic foot
greater than this can cause the gas generator to
lose fire. Normal decelerations from maximum
(3) Transient fuel flow requirements
are shown in Acceleration Fuel Schedule,
figure 15.
gas generator.
(4) The tolerance on the fuel sched-
ules is +4 percent of point. The schedule is
b. Operating Limits. Refer to table 3.
plotted against compressor discharge pressure.
NOTE
(5) Acceleration fuel rates greater
than those shown will result in over-tempera- If any operating limit is exceeded, ver-
ture and possible stall of the gas generator. ify instrumentation accuracy before
Acceleration fuel rates lower than those shown troubleshooting or inspecting gas
can result in “hung” starts in the below idle generator.
speed range.
11-2.1 Initial Operation.
(6) Above the idle speed point, low
acceleration fuel rates will not harm the gas 11-2.2 General. Initial operational period is
generator and will only result in slower accel-
gas generator replacement or major mainte-
eration times. nance on the system.

V-27
GEK 97310
VOLUME I
ADDENDUM V
Figure 15. Acceleration Fuel Schedule

V-28
GEK 97310
VOLUME I
ADDENDUM V
11-2.3 Special Instrumentation. Starter air supply pressure ..... 0-50 psig
a. Required for Operation.
11-2.4 Preparation. The gas generator and
Gas generator speed sensor.... 0-10,000 rpm
associated systems must be inspected and
Lube oil scavenge temper-..... 0-400°F checked out for proper installation and opera-
ature sensors (A-, B-, C- (-18 to 204°C) tion before normal operation can commence.
sumps and transfer gearbox)
Lube oil supply temper-......... 0-400°F 11-2.5 Gas Generator and Associated Equip-
ature sensor (-18 to 204°C) ment Check. Complete the following check
list.
Gas generator ...................... 0-4 in/sec or a. Gas Generator Assembly S/N _______
0-10 mil DA b. Mounting base secured to
Lube oil supply pressure........ 0-100 psig foundation _______
(0-690 kPa) c. Intake air and exhaust gas
Power turbine inlet gas tem- ducts in place and secured _______
perature (T5. 4) ..................... 0-2000°F d. Bonding straps in place and
(-18 to 1093°C) secure _______
Compressor Discharge 0-300 psig e. Gas generator support mounts
pressure ............................... (0-2070 kPa) and links in place and secure _______
Lube oil scavenge pressure.... 0-200 psig f. All service connections made
(0-1380 kPa) and secure _______
b. Required for Monitoring and packager’s manual _______
Troubleshooting: h. All instrumentation connec-
Fuel manifold pressure .......... 0-400 psi
sensor (0-2758 kPa)
Compressor inlet total pres-... 10-16 psia j. Gas generator assembly free of
sure sensor (69-110 kPa) loose objects and all lines/
Fuel supply pressure .............. 0-400 psig electrical leads connected _______
(0-2758 kPa) k. Gas generator inlet air area
Fuel supply temperature ........ -65-250°F free of foreign objects. Inlet
(-54 to 121°C) screen secure _______
Gas generator inlet air ........... -65-150°F l. Gas generator compressor rear
temperature (-54 to 66°C) frame leakage ports, struts 7
Power turbine inlet gas .......... 0-75 psia and 10, are open (not capped) _______
pressure (0-517.5 kPa) m. Starter is serviced per Pack-
Remote reading variable........ -5° to +45°
vane indicator n. Lube oil storage tank serviced

V-29
GEK 97310
VOLUME I
ADDENDUM V
o. Lube oil supply valves open _______ INACTIVE ACCORDING TO
p. All filters are serviced per THE CUSTOMER’S
Packager’s manual _______ PROCEDURES.
q. Fire alarm/extinguish system • SECONDARY AIR TO THE
ON and operative _______ ENCLOSURE SHALL BE SHUT
r. T5.4 thermocouple system OFF. HIGH SECONDARY AIR-
functioning properly _______ FLOW MAY PREVENT OPEN-
s. Ignition system operative _______ ING OR CLOSING THE
ENCLOSURE DOOR.
t. Compressor inlet total pres-
sure probe aligned properly • THE ENCLOSURE DOOR
and free of damage _______ SHALL BE KEPT OPEN. IF THE
u. Variable stator system secure _______ GAS TURBINE IS OPERATING,
y. Required checks and inspec- AN OBSERVER SHALL BE STA-
tions specified in Packager’s TIONED AT THE ENCLOSURE
manual for gas generator con- DOOR AND CONFINED SPACE
trol have been performed _______ ENTRY PROCEDURES SHALL
BE FOLLOWED.
11-2.7 Start-up and Checkout. TACT WITH HOT PARTS, AND
WARNING LATED GLOVES AS
NECESSARY.
MET: OPERATING.

ENTRY SHOULD BE
SENTATIVE WHO IS TRAINED b. Perform prestart checks per table 4.
UNDER SUCH CONDITIONS. c. Perform ignition checkout per

V-30
GEK 97310
VOLUME I
ADDENDUM V
d. Perform motoring procedure per 11-2.8 Ignition Check.
paragraph 11-2.10.
WARNING
f. Perform governor check per CONNECTING AND CONNECT-
packager’s manual. ING IGNITION EXCITER INPUT
g. Perform a wet prestart per SERVICE TO PRECLUDE INAD-
paragraph 11-2.12. VERTENT ACTIVATION.
h. Perform a manual start and operate per • ASSURE FUEL VALVES ARE
packager’s manual. CLOSED THROUGHOUT THIS
PROCEDURE.
paragraph 11-2.14.
fuel, motor gas generator for one minute:
allow gas generator to coast down.
paragraph 11-2.15.

Item Requirement
Fuel valves Closed
Ignition Off
Oil tank level Full
Fuel supply pressure temperature and flow 350 ± 5 psig
(2413 ± 34 kPa)
-65 to +150°F
(-54 to +66°C)
13,400 pph
(6078 kg) max

V-31
GEK 97310
VOLUME I
ADDENDUM V
b. Disconnect number one ignition exciter loosen oil fittings at lube pump to bleed air
input lead at exciter. Temporarily secure input from system. Starter should motor gas genera-
lead away from the exciter. tor to minimum of 2200 RPM.
c. Turn on electrical power to the ignition (4) Repeat motoring and bleeding
system (No. 2 ignition exciter energized). An procedure until an indication of oil pressure
audible report (approximately two sparks per appears.
igniter fires. 11-2.10 False Start.
d. Turn off electrical power to the ignition a. Perform false start as follows:
system. Reconnect input lead to exciter and (1) With ignition leads disconnected
safety-wire connector. and manual gas valve closed, make automatic
e. Repeat steps b, c, and d, disconnecting start of gas generator per packager’s manual.
the No. 2 exciter. (2) Gas generator should go through
f. If an audible report is not heard on normal start cycle and then abort because of
No. 1 and or No. 2 igniters, check out the sys- lack of flame.
tem to isolate the problem, and take appropri- 11-2.11 Governor Check. Check governor sys-
ate corrective action. tem per packager’s manual.
11-2.9 Motoring. 11-2.12 Wet Prestart.
a. After all preliminary checks have been a. Perform wet prestart as follows:
completed and lines flushed, gas generator can
be motored as follows: (1) With ignition lead disconnected,
but with manual gas valve open and governing
(1) Make ignition and natural-gas system operating, make automatic start of gas
supply systems inoperative as follows: generator per packager’s manual.
(a) Disconnect power supply to
ignition unit. (2) Gas generator should accelerate to
lightoff speed (1100 to 1300 rpm). Fuel valve
(b) Close natural-gas manual should open and fuel manifold pressure should
shutoff valve to fuel control unit. be approximately 3 psig (21 kPa). Adjust fuel
(2) Depress MOTORING pushbutton. because of lack of flame.
Gas generator will start to rotate. If it does,
refer to packager’s manual for supply pressure (3) Allow gas generator to coast to
to starter. stop; then motor it to purge any remaining nat-
ural gas from gas generator.
(3) Hold MOTORING pushbutton
11-2.13 Manual Start and Operation. Perform
check for oil pressure. If there is no indication
ton; while gas generator is coasting down,
Refer to table 5.

V-32
GEK 97310
VOLUME I
ADDENDUM V


are completed per table 4
CAUTION
IF T5.4 RAPIDLY APPROACHES OR EXCEEDS 1430°F (777°C), ABORT START
AUTOMATIC SHUTDOWN AT 1450°F (788°C). REFER TO FIGURE 17
NOTE
NOTE
3. At 1100 to 1300 RPM NGG
a. Ignition on
(21 kPa)
[T5.4 above 400°F shutdown
(204°C)]
1200 RPM
4. Note time to 4500 ± 200 90 seconds max Troubleshoot system and
RPM take corrective action if rpm
4300 RPM
5. At 4300 to 4700 RPM NGG
starter

V-33
GEK 97310
VOLUME I
ADDENDUM V


6. Note time to 5000 RPM NGG

a. Oil pressure 8 psig (55 kPa) min Shutdown if below 8 psig
(55 kPa)
b. NGG 5000 rpm ± 250 rpm Adjust
c. T5.4 1000°F (538°C) max Emergency shutdown

table 7
d. Gas generator vibration 0 to 3 mils DA Automatic normal shutdown
action
e. Compressor inlet tem- Approximately equal to out- Troubleshoot sensing and
as required
f. Check for fuel or oil No leaks allowed Correct as required
leaks
8. Set desired power setting. 1575°F (857°C) max Correct as required. Refer to
sient operation

V-34
GEK 97310
VOLUME I
ADDENDUM V


a. T5.4 1575°F (857°C) *
b. NGG 9850 rpm max corrected *
c. Oil pressure See table 9 Emergency or automatic

shutdown if 5 psig (34 kPa)
out of limits
d. Scavenge oil temperature 215°F to 275°F Automatic shutdown if
(102 to 135°C) above 340°F (171°C)
e. Gas generator vibration 3 mils max *
4 mils alarm Troubleshoot
7 mils max trip Emergency or automatic
Shutdown
f. Fuel inlet pressure 350 ± 5 psig **
(2415 ± 34 kPa) max
g. Fuel inlet temperature -65 to 150°F (-54 to 66°C) **
j. T2 Approximately equal to out- **
k. Stator vane angle See applicable figure in Correct as required per
WP 118 00 WP 118 00
shut down.

V-35
GEK 97310
VOLUME I
ADDENDUM V
Figure 16. Fuel Manifold Pressure vs Fuel Flow

V-36
GEK 97310
VOLUME I
ADDENDUM V

V-37
GEK 97310
VOLUME I
ADDENDUM V
11-2.14 Operation to Maximum Power. 11-3 AUTOMATIC OPERATION.
CAUTION a. Check automatic operation per pack-

ager’s manual.
ELIMINATE CERTAIN PROTEC- (1) Accelerate to idle.
ITS SHALL NOT BE EXCEEDED. (2) Accelerate to rated power.
a. Slowly increase manual control setting (3) Log all instrument readings.
generator speed. After each 500 rpm increase, (4) Decelerate to idle.
attention to variable stator vane position and (5) Check for fuel or lube oil leaks.
within limits, adjust it per WP 118 00. If vibra- (6) After a total of five minutes at
tions are not within limits, consult the local idle, shut down gas generator.
(7) Check lube oil and fuel filters and
b. Operate gas generator up to rated strainers: clean or replace as necessary.
power, if possible, but do not exceed exhaust
gas temperature (T5.4) limit. Hold at this (8) Correct any leaks observed.
If governing system is unstable, adjust per (9) Remove all temporary
packager’s manual. instrumentation.
c. Log all instrument readings once they (10) Check gas generator and mount-
stabilize. Refer to table 5, step 9. ing system for loose parts; tighten as
necessary.
instrument readings. Refer to table 6, step 2.

f. After gas generator has been stabilized

at idle for five minutes, make normal shut-
down. Refer to table 6, steps 3 and 4.

V-38
GEK 97310
VOLUME I
ADDENDUM V
Table 6. GAS GENERATOR SHUTDOWN

1. Set gas generator at idle Gas generator decelerates Emergency shutdown

power (unloaded)
following:
a. Oil pressure 8 psig (55 kPa) minimum Automatic normal shutdown
if below 8 psig (55 kPa)
c. T5.4 1000°F (538°C) maximum Troubleshoot and take cor-

rective action
d. Gas generator vibration 3 mils maximum Automatic normal shutdown
action
e. Fuel inlet temperature -65 to 150°F (-55 to 66°C)
f. Scavenge oil filter ∆P Refer to packager’s manual
g. Lube oil supply filter ∆P Refer to packager’s manual
5 minutes, close fuel valves (204°C) NGG decelerate and
stop
4. Observe T5.4 for 3 minutes 700°F (371°C) Motor gas generator and
after shutdown shut off fuel supply. Con-
tinue motoring until temper-
ature decreases

V-39
GEK 97310
VOLUME I
ADDENDUM V
ENCLOSURE DOOR.
tine operation of an installed gas generator. For • THE ENCLOSURE DOOR
directions in the use of manual or automatic SHALL BE KEPT OPEN. IF THE
operation for normal operation, refer to pack- GAS TURBINE IS OPERATING,
ager’s manual. AN OBSERVER SHALL BE STA-
11-4.2 Interlocks. Refer to paragraph 2-8. 9 DOOR AND CONFINED SPACE
for description of interlocks which affect gas ENTRY PROCEDURES SHALL
generator operation. BE FOLLOWED.
LATED GLOVES AS
NECESSARY.
OPERATING.
SHUT DOWN.
ENCLOSURE OR IN THE
ENTRY SHOULD BE
MOTORING THE GAS
TURBINE.
UNDER SUCH CONDITIONS. b. Start and operate the gas generator per
table 3. Do not exceed operating limits of
table 3.
c. Shut down the gas generator per
THE CUSTOMER’S
table 6.
PROCEDURES.
• SECONDARY AIR TO THE d. Emergency shut down the gas genera-
ENCLOSURE SHALL BE SHUT tor per table 7.
FLOW MAY PREVENT OPEN- e. Refer to table 8 and 9 for oil pressure
correction factors.

V-40
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ADDENDUM V
11-5 EMERGENCY OPERATION. 11-5.2 Post Shutdown Fire. During a normal
11-5.1 Emergency Shutdown. decrease. If during time gas generator is coast-
a. In an emergency, the gas generator may decreases, it indicates that combustion is still
be shut down from any power setting by clos- taking place because of a leaking fuel valve.
ing the fuel valve. However, this should only (A slight temperature increase after rotation
be done in an emergency, since rapid shutdown stops is normal.) Make certain fuel is shut off,
will decrease life of gas generator. and motor the gas generator. This will blow
out the fire. As soon as temperature decreases
b. Emergency shutdown shall be made to normal, discontinue motoring.
per table 7.
CAUTION
GENCY SHUTDOWN FROM HIGH POWER SETTINGS. SEIZURE OF GAS GEN-
ERATOR ROTOR MAY OCCUR DUE TO TIGHT CLEARANCES. NORMALLY
THE ROTOR WILL FREE ITSELF AFTER A COOLING PERIOD OF 3 TO 4 HOURS.
1. Conditions permitting, decelerate gas T5.4 drops below 400°F Manually shut off fuel
generator to idle and close fuel valves (204°C) and NGG and supply
NPT decelerate
2. Observe T5.4 for 3 minutes after 700°F (371°C) max Motor gas generator.
shutdown Continue motoring until
generator can be restarted within 1
procedure.

V-41
GEK 97310
VOLUME I
ADDENDUM V
b. If a “hot restart” is performed
motor the gas generator at
be accomplished.
Table 8. LUBE PRESSURE LIMITS FOR OIL, MIL-L-23699
NGG Lube Oil Temperature -°F

(RPM)
100 110 120 130 140 150 160 170 180 190 200
5000 23.9 22.1 20.8 19.9 19.3 18.9 18.7 18.7 18.8 19.1 19.6
5100 24.6 22.9 21.5 20.6 19.9 19.5 19.3 19.3 19.4 19.7 20.2
5200 25.4 23.6 22.2 21.2 20.5 20.1 19.9 19.9 20.1 20.4 20.9
5300 26.2 24.3 22.9 21.9 21.2 20.8 20.5 20.5 20.7 21.0 21.5
5400 27.1 25.1 23.6 22.6 21.9 21.4 21.2 21.2 21.3 21.7 22.2
5500 27.9 25.9 24.4 23.3 22.5 22.1 21.8 21.8 22.0 22.4 22.9
5600 28.7 26.6 25.1 24.0 23.2 22.7 22.5 22.5 22.7 23.0 23.6
5700 29.6 27.4 25.8 24.7 23.9 23.4 23.2 23.1 23.3 23.7 24.3
5800 30.5 28.2 26.6 25.4 24.6 24.1 23.8 23.8 24.0 24.4 25.0
5900 31.3 29.1 27.4 26.2 25.3 24.8 24.5 24.5 24.7 25.1 25.7
6000 32.2 29.9 28.1 26.9 26.0 25.5 25.2 25.2 25.4 25.8 26.4
6100 33.1 30.7 28.9 27.6 26.8 26.2 25.9 25.9 26.1 26.5 27.2
6200 34.0 31.6 29.7 28.4 27.5 26.9 26.6 26.6 26.8 27.3 27.9

V-42
GEK 97310
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ADDENDUM V
Table 8. LUBE PRESSURE LIMITS FOR OIL, MIL-L-23699 (Cont.)

(RPM)
100 110 120 130 140 150 160 170 180 190 200
6300 35.0 32.4 30.5 29.2 28.2 27.6 27.4 27.3 27.6 28.0 28.7
6400 35.9 33.3 31.4 30.0 29.0 28.4 28.1 28.1 28.3 28.8 29.5
6500 36.8 34.2 32.2 30.8 29.8 29.1 28.8 28.8 29.0 29.5 30.2
6600 37.8 35.1 33.0 31.6 30.5 29.9 29.6 29.6 29.8 30.3 31.0
6700 38.8 36.0 33.9 32.4 31.3 30.7 30.3 30.3 30.6 31.1 31.8
6800 39.8 36.9 34.7 33.2 32.1 31.4 31.1 31.1 31.3 31.9 32.6
6900 40.8 37.8 35.6 34.0 32.9 32.2 31.9 31.9 32.1 32.7 33.4
7000 41.8 38.7 36.5 34.9 33.7 33.0 32.7 32.7 32.9 33.5 34.3
7100 42.8 39.7 37.4 35.7 34.6 33.8 33.5 33.5 33.7 34.3 35.1
7200 43.8 40.6 38.3 36.6 35.4 34.7 34.3 34.3 34.5 35.1 36.0
7300 44.9 41.6 39.2 37.4 36.2 35.5 35.1 35.1 35.4 36.0 36.8
7400 45.9 42.6 40.1 38.3 37.1 36.3 35.9 35.9 36.2 36.8 37.7
7500 47.0 43.6 41.1 39.2 38.0 37.2 36.8 36.7 37.0 37.7 38.6
7600 48.1 44.6 42.0 40.1 38.8 38.0 37.6 37.6 37.9 38.5 39.4
7700 49.2 45.6 43.0 41.0 39.7 38.9 38.5 38.4 38.8 39.4 40.3
7800 50.3 46.6 43.9 42.0 40.6 39.8 39.3 39.3 39.6 40.3 41.3
7900 51.4 47.7 44.9 42.9 41.5 40.6 40.2 40.2 40.5 41.2 42.2
8000 52.5 48.7 45.9 43.8 42.4 41.5 41.1 41.1 41.4 42.1 43.1
8100 53.7 49.8 46.9 44.8 43.3 42.4 42.0 42.0 42.3 43.0 44.0
8200 54.8 50.8 47.9 45.7 44.3 43.3 42.9 42.9 43.2 43.9 45.0
8300 56.0 51.9 48.9 46.7 45.2 44.3 43.8 43.8 44.1 44.8 45.9
8400 57.1 53.0 49.9 47.7 46.2 45.2 44.7 44.7 45.1 45.8 46.9
8500 58.3 54.1 51.0 48.7 47.1 46.1 45.7 45.6 46.0 46.7 47.9
8600 59.5 55.2 52.0 49.7 48.1 47.1 46.6 46.6 46.9 47.7 48.9
8700 60.7 56.3 53.1 50.7 49.1 48.0 47.5 47.5 47.9 48.7 49.8
8800 62.0 57.5 54.1 51.7 50.1 49.0 48.5 48.5 48.9 49.7 50.9
8900 63.2 58.6 55.2 52.8 51.1 50.0 49.5 49.4 49.8 50.6 51.9

V-43
GEK 97310
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ADDENDUM V

(RPM)
100 110 120 130 140 150 160 170 180 190 200
9000 64.4 59.8 56.3 53.8 52.1 51.0 50.4 50.4 50.8 51.6 52.9
9100 65.7 60.9 57.4 54.8 53.1 52.0 51.4 51.4 51.8 52.7 53.9
9200 67.0 62.1 58.5 55.9 54.1 53.0 52.4 52.4 52.8 53.7 55.0
9300 68.3 63.3 59.6 57.0 55.1 54.0 53.4 53.4 53.8 54.7 56.0
9400 69.6 64.5 60.8 58.1 56.2 55.0 54.4 54.4 54.8 55.7 57.1
9500 70.9 65.7 61.9 59.2 57.2 56.0 55.5 55.4 55.9 56.8 58.2
9600 72.2 67.0 63.1 60.3 58.3 57.1 56.5 56.4 56.9 57.8 59.2
9700 73.5 68.2 64.2 61.4 59.4 58.1 57.5 57.5 58.0 58.9 60.3
9800 74.9 69.4 65.4 62.5 60.5 59.2 58.6 58.5 59.0 60.0 61.4
9900 76.2 70.7 66.6 63.6 61.6 60.3 59.6 59.6 60.1 61.1 62.5
10000 77.6 72.0 67.8 64.8 62.7 61.4 60.7 60.7 61.2 62.2 63.7

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ADDENDUM V
Table 9. CORRECTIONS FOR LUBE PRESSURE LIMITS USING
OIL, MIL-L-23699
NOTE
The following values are for corrections to 9000 RPM NGG and 150°F lube inlet temper-
ature. Read oil pressure and temperature then algebracially add the pressure additive (as
indicated for that particular rpm and lube temperature) to the observed lube pressure.
Corrected lube pressure limit is 46 to 57 psig.
NGG Lube Oil Temperature - °F
(RPM)
100 110 120 130 140 150 160 170 180 190 200
5000 27.1 28.9 30.2 31.1 31.7 32.1 32.3 32.3 32.2 31.9 31.4
5100 26.4 28.1 29.5 30.4 31.1 31.5 31.7 31.7 31.6 31.3 30.8
5200 25.6 27.4 28.8 29.8 30.5 30.9 31.1 31.1 30.9 30.6 30.1
5300 24.8 26.7 28.1 29.1 29.8 30.2 30.5 30.5 30.3 30.0 29.5
5400 23.9 25.9 27.4 28.4 29.1 29.6 29.8 29.8 29.7 29.3 28.8
5500 23.1 25.1 26.6 27.7 28.5 28.9 29.2 29.2 29.0 28.6 28.1
5600 22.3 24.4 25.9 27.0 27.8 28.3 28.5 28.5 28.3 28.0 27.4
5700 21.4 23.6 25.2 26.3 27.1 27.6 27.8 27.9 27.7 27.3 26.7
5800 20.5 22.8 24.4 25.6 26.4 26.9 27.2 27.2 27.0 26.6 26.0
5900 19.7 21.9 23.6 24.8 25.7 26.2 26.5 26.5 26.3 25.9 25.3
6000 18.8 21.1 22.9 24.1 25.0 25.5 25.8 25.8 25.6 25.2 24.6
6100 17.9 20.3 22.1 23.4 24.2 24.8 25.1 25.1 24.9 24.5 23.8
6200 17.0 19.4 21.3 22.6 23.5 24.1 24.4 24.4 24.2 23.7 23.1
6300 16.0 18.6 20.5 21.8 22.8 23.4 23.6 23.7 23.4 23.0 22.3
6400 15.1 17.7 19.6 21.0 22.0 22.6 22.9 22.9 22.7 22.2 21.5
6500 14.2 16.8 18.8 20.2 21.2 21.9 22.2 22.2 22.0 21.5 20.8
6600 13.2 15.9 18.0 19.4 20.5 21.1 21.4 21.4 21.2 20.7 20.0
6700 12.2 15.0 17.1 18.6 19.7 20.3 20.7 20.7 20.4 19.9 19.2
6800 11.2 14.1 16.3 17.8 18.9 19.6 19.9 19.9 19.7 19.1 18.4
6900 10.2 13.2 15.4 17.0 18.1 18.8 19.1 19.1 18.9 18.3 17.6
7000 9.2 12.3 14.5 16.1 17.3 18.0 18.3 18.3 18.1 17.5 16.7
7100 8.2 11.3 13.6 15.3 16.4 17.2 17.5 17.5 17.3 16.7 15.9

V-45
GEK 97310
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ADDENDUM V
OIL, MIL-L-23699 (Cont.)
(RPM)
100 110 120 130 140 150 160 170 180 190 200
7200 7.2 10.4 12.7 14.4 15.6 16.3 16.7 16.7 16.5 15.9 15.0
7300 6.1 9.4 11.8 13.6 14.8 15.5 15.9 15.9 15.6 15.0 14.2
7400 5.1 8.4 10.9 12.7 13.9 14.7 15.1 15.1 14.8 14.2 13.3
7500 4.0 7.4 9.9 11.8 13.0 13.8 14.2 14.3 14.0 13.3 12.4
7600 2.0 6.4 9.0 10.9 12.2 13.0 13.4 13.4 13.1 12.5 11.6
7700 1.8 5.4 8.0 10.0 11.3 12.1 12.5 12.6 12.2 11.6 10.7
7800 0.7 4.4 7.1 9.0 10.4 11.2 11.7 11.7 11.4 10.7 9.7
7900 -0.4 3.3 6.1 8.1 9.5 10.4 10.8 10.8 10.5 9.8 8.8
8000 -1.5 2.3 5.1 7.2 8.6 9.5 9.9 9.9 9.6 8.9 7.9
8100 -2.7 1.2 4.1 6.2 7.7 8.6 9.0 9.0 8.7 8.0 7.0
8200 -3.8 0.2 3.1 5.3 6.7 7.7 8.1 8.1 7.8 7.1 6.0
8300 -5.0 -0.9 2.1 4.3 5.8 6.7 7.2 7.2 6.9 6.2 5.1
8400 -6.1 -2.0 1.1 3.3 4.8 5.8 6.3 6.3 5.9 5.2 4.1
8500 -7.3 -3.1 0.0 2.3 3.9 4.9 5.3 5.4 5.0 4.3 3.1
8600 -8.5 -4.2 -1.0 1.3 2.9 3.9 4.4 4.4 4.1 3.3 2.1
8700 -9.7 -5.3 -2.1 0.3 1.9 3.0 3.5 3.5 3.1 2.3 1.2
8800 -11.0 -6.5 -3.1 -0.7 0.9 2.0 2.5 2.5 2.1 1.3 0.1
8900 -12.2 -7.6 -4.2 -1.8 -0.1 1.0 1.5 1.6 1.2 0.4 -0.9
9000 -13.4 -8.8 -5.3 -2.8 -1.1 0.0 0.6 0.6 0.2 -0.6 -1.9
9100 -14.7 -9.9 -6.4 -3.8 -2.1 -1.0 -0.4 -0.4 -0.8 -1.7 -2.9
9200 -16.0 -11.1 -7.5 -4.9 -3.1 -2.0 -1.4 -1.4 -1.8 -2.7 -4.0
9300 -17.3 -12.3 -8.6 -6.0 -4.1 -3.0 -2.4 -2.4 -2.8 -3.7 -5.0
9400 -18.6 -13.5 -9.8 -7.1 -5.2 -4.0 -3.4 -3.4 -3.8 -4.7 -6.1
9500 -19.9 -14.7 -10.9 -8.2 -6.2 -5.0 -4.5 -4.4 -4.9 -5.8 -7.2
9600 -21.2 -16.0 -12.1 -9.3 -7.3 -6.1 -5.5 -5.4 -5.9 -6.8 -8.2
9700 -22.5 -17.2 -13.2 -10.4 -8.4 -7.1 -6.5 -6.5 -7.0 -7.9 -9.3

V-46
GEK 97310
VOLUME I
ADDENDUM V
OIL, MIL-L-23699 (Cont.)
(RPM)
100 110 120 130 140 150 160 170 180 190 200
9800 -23.9 -18.4 -14.4 -11.5 -9.5 -8.2 -7.6 -7.5 -8.0 -9.0 -10.4
9900 -25.2 -19.7 -15.6 -12.6 -10.6 -9.3 -8.6 -8.6 -9.1 -10.1 -11.5
10000 -26.6 -21.0 -16.8 -13.8 -11.7 -10.4 -9.7 -9.7 -10.2 -11.2 -12.7
Example: Observed NGG 8900 RPM

Observed Oil Pressure 55 psig (379.5 KPa)
Pressure Additive -4.2 psig (29 KPa)
Corrected Pressure 55-4.2 = 50.8 psig (350.5 KPa)

V-47/(V-48 Blank)
GEK 97310
VOLUME I
ADDENDUM W
ADDENDUM
7LM2500GB104

GEK 97310
VOLUME I
ADDENDUM W
TABLE OF CONTENTS
1-0 INTRODUCTION....................................................................................... W-4

2-0 REFERENCE DATA .................................................................................. W-4
3-0 INSTALLATION DRAWINGS.................................................................. W-4
4-0 EQUIPMENT DESCRIPTION ................................................................. W-4
4-1 INSTRUMENTATION AND SUPPLY REQUIREMENTS ................... W-4
5-0 ACCESSORY DRIVE SECTION ............................................................. W-7
5-1.1 General .......................................................................................................... W-7
5-1.2 Accessory Drive Train .................................................................................. W-7
5-1.3 Inlet Gearbox................................................................................................. W-7
5-1.4 Radial Drive Shaft......................................................................................... W-11
5-1.5 Transfer and Accessory Gearbox .................................................................. W-11
5-1.6 Air-Oil Separator........................................................................................... W-11
6-0 IGNITION SYSTEM .................................................................................. W-14
7-0 EXHAUST GAS TEMPERATURE (T5.4) INDICATION ..................... W-14
8-0 LUBRICATION SYSTEM......................................................................... W-14
8-1.1 General .......................................................................................................... W-14
8-1.2 Lube Supply Subsystem................................................................................ W-19
8-1.3 Lube Scavenge Subsystem............................................................................ W-21
8-1.4 Oil Seal Pressurization Subsystem................................................................ W-21
8-1.5 Sump Vent Subsystem................................................................................... W-21
9-0 SERVICE REQUIREMENTS ................................................................... W-22
9-1.1 Natural Gas ................................................................................................... W-22
10-0 OPTIONAL HARDWARE KITS - LM2500GBI04 ................................. W-22
11-0 GAS GENERATOR OPERATION ........................................................... W-23
11-1.1 Performance Ratings and Operating Limits.................................................. W-23
11-2.1 Initial Operation ............................................................................................ W-24
11-2.2 General .......................................................................................................... W-24
11-2.3 Special Instrumentation................................................................................. W-30
11-2.4 Preparation .................................................................................................... W-30
11-2.5 Gas Generator and Associated Equipment Check ........................................ W-32
11-2.6 Governor and Manual Control Check ........................................................... W-33
11-2.7 Start-up and Checkout................................................................................... W-33
11-2.8 Ignition Check............................................................................................... W-34
11-2.9 Motoring........................................................................................................ W-34
11-2.10 False Start...................................................................................................... W-34
11-2.11 Governor Check ............................................................................................ W-35
11-2.12 Wet Prestart ................................................................................................... W-35
11-2.13 Manual Start and Operation .......................................................................... W-35
11-2.14 Operation to Maximum Power...................................................................... W-35

W-1
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ADDENDUM W
TABLE OF CONTENTS - CONTINUED
11-3 AUTOMATIC OPERATION..................................................................... W-35

11-4 NORMAL OPERATION............................................................................ W-47
11-4.1 General .......................................................................................................... W-47
11-4.2 Interlocks....................................................................................................... W-47
11-4.3 Operation....................................................................................................... W-47
11-5 ENERGENCY OPERATION .................................................................... W-48
11-5.1 Emergency Shutdown ................................................................................... W-48
11-5.2 Post Shutdown Fire ....................................................................................... W-48

W-2
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ADDENDUM W
Figure Title Page

1 Deleted
2 Deleted
3 Deleted
4 Deleted
5 Accessory Drive Section ............................................................................... W-9
6 Inlet Gearbox................................................................................................. W-10
7 Transfer and Accessory Gearbox .................................................................. W-12
8 Air-Oil Separator........................................................................................... W-13
9 Ignition System ............................................................................................. W-15
10 Thermocouple Schematic.............................................................................. W-16
11 Lubrication System Schematic...................................................................... W-17
12 Lube and Scavenge Pump ............................................................................. W-20
13 Acceleration Fuel Schedule .......................................................................... W-25
14 Fuel Manifold Pressure vs. Fuel Flow .......................................................... W-31
15 Transient Temperature Limits ....................................................................... W-39
LIST OF TABLES
Table Title Page
1 INSTRUMENTATION CONNECTIONS - 7LM2500GB104 ..................... W-5

2 MECHANICAL SERVICE CONNECTIONS - LM2500GB104................. W-6
3 OPTIONAL HARDWARE KITS ................................................................. W-22
4 GAS GENERATOR OPERATING LIMITS ................................................ W-26
5 PRESTART CHECKS .................................................................................. W-29
6 START-UP AND OPERATION.................................................................... W-36
7 GAS GENERATOR SHUTDOWN .............................................................. W-40
8 EMERGENCY SHUTDOWN...................................................................... W-41
9 LUBE PRESSURE LIMITS FOR OIL, MIL-L-23699 ................................ W-43
10 CORRECTIONS FOR LUBE PRESSURE LIMITS USING
OIL, MIL-L-23699 ............................................................................... W-45

W-3
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ADDENDUM W
1-0 INTRODUCTION. High Pressure Turbine Nozzle,
Stg 2 127 (58)
This addendum provides information which
applies specifically to the LM2500GB104 gas Turbine Mid Frame 530 (240)
generator model, and may or may not be appli- Variable Stator Actuating
cable to other gas generator models covered by Mech 19 (9)
this manual. Reference data, instrumentation Outside Piping and Bracketing
and service connection information, special Approx. 278 (126)
servicing requirements, optional equipment
information, and complete operating instruc- DRAWING LIST
tions are included.
Drawing No
2-0 REFERENCE DATA.
Gas Generator Installation
EQUIPMENT Drawing L31705
(General Electric Co., Cincinnati, Ohio) Lubrication System Flow
Model No. 7LM2500GB104 Diagram L24007
Drawing No. L21380G03 or G06 Electrical Diagram L25596
PERFORMANCE RATING
Refer to paragraph 11-1. 1 Drawing - Model L21380G03 or
7LM2500GB104 G06
GAS GENERATOR WEIGHTS
The average weights of the major gas genera- 3-0 INSTALLATION DRAWINGS.
tor components are: A complete set of installation drawings have
been provided.
Wt-Lbs/(Kg)
Gas Generator 4212 (1911) The 7LM2500GB104 gas generator consists
Inlet Gearbox 38 (17) of:
1 Inlet duct with water wash
Compressor Front Frame 517 (235) manifold
Compressor Rotor 552 (250) 1 Centerbody
Compressor Stator, Front 307 (139) 30 Natural gas fuel nozzles and 1 fuel
Compressor Stator, Rear 93 (42) manifold
1 Lubrication system (less oil tank,
Compressor Rear Frame 421 (191) cooler and filters)
Combustor 120 (54) 2 Ignition units
High Pressure Turbine Rotor 419 (190) 1 Set of instrumentation sensors
Stg 1 68 (31) 4-1 INSTRUMENTATION AND SUP-

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ADDENDUM W
Table 1. INSTRUMENTATION CONNECTIONS - 7LM2500GB104

Bell & Howell Electronics

E1 Vibration pickup, Gas Generator
Part No. 173960 or 364450

E6 Accessory gearbox scavenge oil temperature MS3106R12S-3S/W
--Remote reading variable stator vane
protractor
NOTE
gas turbine.

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ADDENDUM W
Table 2. MECHANICAL SERVICE CONNECTIONS - LM2500GB104
CAUTION
ALL LINES MUST BE FLEXIBLE ENOUGH TO ALLOW 3/4 INCH
(19MM) THERMAL GROWTH OF GAS GENERATOR WITHOUT
PLACING STRAIN ON LINES, COMPONENT, OR ON GAS GENERA-
TOR. IF EXCESSIVE FORCE IS REQUIRED TO COMPLETE A CON-
NECTION, LOOSEN CONNECTION AND CHECK/ADJUST ROUTING
AS REQUIRED.
Manifold
or MS9197-24
AN818-16C or MS9197-16
L3 Scavenge oil discharge 1-1/4inch line from Gas Generator Scavenge Pump to Oil
Scavenge Filter and Cooler AN818-20C or MS9197-20
AN818-16C or MS9197-16
A16 Aspirator Air Supply GE tube flange PN 9643M28P32 + V band clamp
PN 9014M45P32
Generator Inlet Duct AN818-12C or MS9197-12
S1A Waterwash manifold
(Alternate)
NOTE
For all other instrumentation connections, see the Installation Drawings,
provided with gas generator.

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ADDENDUM W
5-0 ACCESSORY DRIVE SECTION. 5-1.3 Inlet Gearbox. (See figure 6.) The inlet
gearbox assembly consists of a cast aluminum
5-1.1 General. (See figure 5.) The accessory casing, a shaft, a pair of bevel gears, bearings,
drive section consists of an inlet gearbox in the and oil jets. The casing, which is bolted inside
hub of the front frame, a radial drive shaft the front frame hub, mounts two duplex ball
inside the 6 o’clock strut of the front frame, bearings and a roller bearing. It has internal oil
and a transfer gearbox bolted underneath the passages and jets to provide lubrication for the
front frame. The optional pneumatic or gears and bearings. The shaft, which rotates on
hydraulic starter, optional hydraulic pump, and a horizontal axis, is splined at the aft end to
the lube and scavenge pump are mounted on mate with the stage-2 disk of the compressor
the aft side of the transfer gearbox. The air-oil rotor. The forward end of the shaft mounts the
separator and stator control are mounted on the upper bevel gear and is supported by a duplex
front of the gearbox. ball bearing. The lower bevel gear, which
5-1.2 Accessory Drive Train. Power to drive upper end by a roller bearing and at its lower
the accessories is extracted from the compres- end by a duplex ball bearing. The lower end is
sor rotor through a large-diameter hollow shaft also splined to mate with the radial drive shaft.
which is spline-connected to the rotor front
shaft. A set of bevel gears in the inlet gearbox
transfers this power to the radial drive shaft,
which transmits the power to another set of
bevel gears in the forward section of the trans-
fer gearbox. A short horizontal drive shaft
transmits power to the accessory drive adapt-
ers in the transfer gearbox.

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W-9
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ADDENDUM W
5-1.4 Radial Drive Shaft. The radial drive casing-mounted roller bearing on one end and
shaft, a hollow shaft externally splined on each an adapter-mounted ball bearing on the other
end, mates with the bevel gears in the inlet and end. The accessory drive spur gears are inter-
transfer gearboxes. Its function is to transmit nally splined. Internal tubes and oil nozzles
power from the inlet gearbox to the forward provide lubrication of the gears and bearings.
section (bevel gearbox) of the transfer gear- Gearbox carbon face seals are retained from
box. The shaft contains a shear section to pre- the outside of the gearbox and can be replaced
vent damage to the accessory drive system. without disassembly of the gearbox.
5-1.5 Transfer and Accessory Gearbox. See 5-1.6 Air-Oil Separator. See figure 8. The
figure 7. The accessory gearbox assembly con- air-oil separator consists of a fabricated sheet
sists of a two-piece aluminum casing, air-oil metal impeller with a cast aluminum housing.
separator, gears, bearings, seals, oil nozzles, It is mounted on the front of the accessory sec-
and accessory adapters. The forward section tion of the transfer gearbox and is considered a
(bevel gearbox) contains a set of right-angle part of the gearbox. To prevent excessive oil
bevel gears and a horizontal drive shaft which loss from venting oil vapor overboard, all
transmits the power to the gear train in the rear sumps are vented to the air-oil separator. The
section (accessory gearbox). Each bevel gear is sump air is discharged after passing through
supported by a duplex ball bearing and a roller the separator. Oil is collected on the inside of
bearing. An access cover in the bottom of the the impeller as the oil-laden sump air passes
casing facilitates installation of the radial drive through the separator. Small holes in the seg-
shaft. The “plug-in” gear concept is used on all ments of the impeller allow the collected oil to
accessory adapters and idler gears in the aft be discharged to the separator outer housing.
(accessory) section. This permits an entire Vanes on the housing wall are used to collect
gear, bearing, seal, and adapter assembly to be and direct the oil to the gearbox. To prevent oil
removed and replaced without disassembling and oil vapors from escaping past the end of
the gearbox. Each spur gear is supported by a the impeller, the separator has two labyrinth
seals, with the cavity between the two seals

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6-0 IGNITION SYSTEM. 7-0 EXHAUST GAS TEMPERATURE
(T5.4) INDICATION.
See figure 9. During start, the ignition system
produces the high energy sparks that ignite the Gas generator exhaust gas temperature is
fuel-air mixture in the combustor. It consists of sensed by 11 thermocouples installed in the
2 ignition exciters, 2 ignition leads, and 2 turbine mid frame. See figure 10. There are
spark igniters. four thermocouple harnesses, three of which
have three thermocouples each and one which
a. The ignition exciters are the capacitor has two thermocouples.
discharge type. The exciters are off-gas gener-
ator mounted. Design characteristics are as a. A thermocouple junction is formed
follows: when 2 dissimilar metals are joined. KP and
Duty cycle (Normal) . Refer to Table 4 Gas plete circuit is formed when both ends of the
Generator Operating KP and KN wires are joined. The thermocou-
Limits ples generate an electrical signal which is pro-
Power input ............... 115v at 60 Hz portional to the temperature of the gas
generator turbine discharge gas. This tempera-
Stored energy ............ 14.5-16.0 joules
ture is sometimes referred to as T5.4.
Spark rate .................. 2/sec.
Output energy 8-0 LUBRICATION SYSTEM.
Total...................... 2.0 joules min.
8-1.1 General. (See figure 11.) The lubrica-
Duration................ 20 micro-seconds min.
tion system provides the gas generator bear-
Peak power ........... 100,000 watts min. ings, gears, and splines with adequate cool oil
Peak current.......... 2000 amp. min. to prevent excessive friction and heat. The sin-
gle supply element of the pump forces the oil
b. The exciters operate on 115v, 60 Hz through tubes to components and areas requir-
input. The power is transformed, rectified, and ing lubrication. Oil nozzles direct the oil onto
discharged in the form of capacitor discharge bearings, gears, and splines. Four separate
energy pulses through the coaxial shielded scavenge elements in the lube and scavenge
leads to the spark igniters. pump remove oil from the B and C sumps and
the aft and forward transfer gearbox. (A sump
c. The ignition leads are low-loss connec- drains to forward transfer gearbox.) The scav-
tions between the ignition exciters and the enged oil is returned to the lube tank. The
spark igniters. They are coaxial, having metal- lubrication system is divided into 3 subsystems
lic shielding which incorporates copper inner identified as lube supply, lube scavenge, and
braid, sealed flexible conduit, and nickel outer sump vent.
braid.

and air vents to prevent the accumulation of

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8-1.2 Lube Supply Subsystem. Rotation..................... Clockwise when
view from drive end
Shear section ............. 1500-2000 lb in
the following components:
(1730-2310 kg cm)
(1) Oil tank (not General Electric Co. Pressure limiting valve
supplied). Cracking pressure.. 100 psid
(690 kPa) min
(2) Lube and scavenge pump supply Full flow ................ 200 psid
element and bypass valve. (1380 kPa) max
(3) Lube supply duplex filter (not Reseat .................... 90 psid (621 kPa) min
General Electric Co. supplied). Pumping capacity...... All flows dependent
upon following
(4) Lube supply anti-static check conditions:
valve. 6000 rpm, 150° ±
5°F (66° ± 3°C) oil
(5) C sump supply check valve. temperature,
12-15 psia 83-103
b. Lube oil from the supply tank enters kPa) oil inlet pres-
the lube and scavenge pump through an inlet sure, fluid per
screen which prevents particles larger than MIL-L-7808 or
0.030 inch (0.76 mm) in size from entering. MIL-L-23699
Output of the supply element is routed to the Lube supply ........... 16.0-18.3 gpm
buyer provided lube supply filter. From the fil- (61-69 lpm)
ter, the oil flows through an anti-static check
TGB scavenge, ...... 4.8-5.4 gpm
valve to the inlet gearbox, the stator vane
fwd (18-20 lpm)
speed sensor, the transfer gearbox, and the gas
generator sumps. Oil going to the C sump TGB scavenge, aft . 18.0-20.2 gpm
passes through an additional check valve in the (68-76 lpm)
C sump supply line. Lube discharge oil also is B sump scavenge... 10.6-12.1 gpm
piped to a port near the forward end of the lube (40-46 lpm)
and scavenge pump to lubricate the drive C sump scavenge... 7.6-8.5 gpm
spline. (29-32 lpm)
c. The lube and scavenge pump (figure Discharge pressure
12) is a six element, positive displacement, Lube supply ........... 25-75 psia (172-517
vane type pump. One element is used for the kPa) normal, 75-100
lube supply, and 5 are used for lube scaveng- psia (517-690 kPa)
ing. Within the pump are inlet screens, one for extreme
each element, and a lube supply pressure limit- Scavenge................ 25-85 psia (172-517
ing valve. Design characteristics of the pump kPa) normal, 85-100
are as follows: psia (586-690 kPa)
extreme

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d. Oil enters the lube inlet port and passes (2) Lube scavenge duplex filter (not
through a removable, non-bypassing inlet supplied).
screen which traps particles larger than
0.030 inch (0.76 mm). A lube supply pressure (3) Lube scavenge check valve.
limiting valve is provided to limit supply pres-
sure. Scavenge oil enters the pump through 4 (4) Heat exchanger (oil cooler) (not
scavenge oil ports, passes through an inlet supplied).
screen in each port, and enters the scavenge
elements. The outputs of the 4 scavenge ele- b. The scavenge elements of the lube and
ments are connected inside the pump and dis- scavenge pump scavenge oil from the B and C
charge through a common scavenge discharge sumps, and from 2 areas of the transfer gear-
port. box. Oil from the air-oil separator drains into
the aft section of the transfer gearbox. Oil from
e. The lube supply check valve is located the inlet gearbox and the A sump drains
on the downstream side of the lube supply fil- through the radial driveshaft sleeve into the
ter. It will open and flow 20 gpm (76 lpm) with forward section of the transfer gearbox. Oil
a maximum differential pressure of 15 psid from the 4 scavenge elements exits the pump
(103 kPa). The purpose of the check valve is to from a common discharge port.
prevent the oil in the tank from draining into
the sumps and gearbox when the gas generator c. The scavenge check valve is located in
is shut down. the lube and scavenge pump scavenge dis-
charge line. It will open and flow 20 gpm
f. A check valve is located in the lube oil (76 lpm) with a maximum differential pressure
supply line to the C sump. The check valve of 15 psid (103 kPa). The purpose of this
isolates the C sump from the gas generator check valve is to prevent the oil in the scav-
lube oil system when an external lube supply enge lines from draining back into the sumps
and scavenge system is used for the buyer fur- and gearbox when the gas generator is shut
nished power turbine. The C sump scavenge down.
line and the C sump oil supply line are
equipped with access ports to facilitate the 8-1.4 Oil Seal Pressurization Subsystem.
application of an external lube system for the Refer to paragraph 2-6.2
tion, lube oil is supplied from the lube pump, 8-1.5 Sump Vent Subsystem. See figure 11.
to the C sump. The check valve then opens at a
2 psid (14 kPa) pressure differential. a. The sump vent subsystem consists of
one major part, the air-oil separator, and the
8-1.3 Lube Scavenge Subsystem. See piping and tubing making up the subsystem.
figure 11. (The air-oil separator is part of the transfer
gearbox.) For a detailed description of it, refer
a. The lube scavenge subsystem consists to paragraph 5-1.6.
of the following components:
(1) Lube and scavenge pump scav-

enge elements.

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b. To prevent oil leakage, main bearing a. The required supply pressure to the
oil seals use pressurization air to cause air to fuel manifold on the gas generator is
flow across the seals into the sumps. Seal pres- 350 ± 5 psig (2413 ± 34 kPa).
surizing air is extracted from the eighth stage
of the compressor and distributed to the oil b. The temperature of the gas must be in
seals. To remove the air which enters the the range of -65° to +150°F (-54 + 66°C). If
sumps through the oil seals and to maintain a the temperature is not repeatable on a day-to-
pressure drop across the oil seals, the sump air day basis it will be necessary to change the
is vented. Each sump area is connected to a starting fuel adjustment to adjust the supply
sump vent manifold through frame struts. The pressure to the engine to maintain a constant
manifold connects to the air-oil separator Btu-per-cubic-foot supply. Once started, the
which extracts oil from the air before venting gas generator will accept variations in supply
the air into the exhaust duct. Extracted oil is temperature of ±20°F (±11°C). The maximum
returned to the transfer gearbox. fuel flow required is 13,400 pph (7068 kg/h)
with a lower heating value of 19, 000 Btu/1b.
10-0 OPTIONAL HARDWARE KITS -
9-1.1 Natural Gas. LM2500GBI04. See Table 3.
Table 3. OPTIONAL HARDWARE KITS
Item Kit PN Nomenclature Qty

1 L24023 Flange, Customer 1
2 L24077 Stator Control 1
3 106L7149G01 Container 1
4 536L298G01 Spad Drawing List 1
5 537L294G01 Kit/Installation (CIT) 1
6 537L365G03 Lead and Harness, T5. 4 1
7 681L317G01 OEM Scheduled Inspection 1
8 681L449G01 Starter Kit 1
9 681L459G01 Kit, Gas Starter 1
10 681L461G01 Kit, Expendable 1
11 681L464G0l and G04-G06 Kit, On Engine Optional Equipment 1
12 681L465G01 and G03 Kit, Off Engine Optional Equipment 1
13 681L468G01and G04-G05 Kit, Ship With Engine 1
14 681L493G01 Compartment Separator Assembly 1
15 681L494G01 Kit, Machine Threaded Plugs 1

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11-0 GAS GENERATOR OPERATION. NOTE
direct mathematical conversions and may
be rounded off in most instances at the
users discretion. Examples of units that
pany for the 7LM2500GB104 Gas Generator.
may be rounded off are those utilized for
b. The instructions are intended to pro- temperatures, torque values, pressures,
vide operating personnel with the information etc. Examples where S.I. units may not be
required to operate the gas turbine. They per- rounded off are those utilized for drop
tain to routine and emergency conditions and checks, rigging adjustments, runouts, etc.
procedures. When a fault exists, refer to chap-
11-1.1 Performance Ratings and Operating
ter 4, TROUBLESHOOTING.
Limits.
NOTE
equipment or contingency to be met in connec- Ratings published in this manual apply to
tion with the operation of the gas generator. the 7LM2500GB104 gas generator. The
Refer to requests for additional information to driven unit ratings/limits may be lower in
the General Electric Company, Marine and some cases and shall take precedence
Industrial Projects Department, Cincinnati, over the gas generator manual limits.
Ohio 45215.
a. Performance Ratings.
WARNING (1) The rated performance of the
IF A QUESTIONABLE CONDITION 7LM2500GBI04 gas generator in the new and
EXISTS, DO NOT OPERATE THE GAS clean condition is as follows:
GENERATOR UNTIL A THOROUGH
INVESTIGATION HAS BEEN MADE. Isentrophic Gas
DO NOT REPEAT HOT STARTS, Horsepower 31,300
COMPRESSOR STALLS, OR OTHER Inlet Air Temperature 59°F (15°C)
RECOGNIZED PROBLEMS WITH- Altitude Sea Level
OUT PRIOR THOROUGH INVESTI-
Inlet Losses O″ H2O
GATION. FAILURE TO DO SO CAN
RESULT IN UNDUE STRESS BEING Relative Humidity 0%
IMPOSED ON GAS GENERATOR Fuel Lower Heating
COMPONENTS, WITH IMMEDIATE Value 19,000 Btu/lb
OR SUBSEQUENT DESTRUCTIVE
Compressor Bleed 0 lbs/Sec
FAILURE OF THE GAS GENERATOR
AND INJURY TO PERSONNEL. Accessory Horsepower
Extraction 0
Power Turbine Inlet Gas
Fuel, Natural Gas GE Specification
MID-TD-0000-1
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(2) Approximate starting fuel flow (7) For normal accelerations from
requirements based on applying fuel and igni- idle to power settings the changes should be
tion at 1200 rpm are: made more slowly to enhance the time
400 pph ± 37 pph (181 ± 17 kgh) at the gas generator; a time of 2 to 3 minutes is
-65°F (-54°C) Inlet Air Temperature reasonable.
480 pph ± 37 pph (218 ± 17 kgh) at (8) The maximum deceleration fuel
60°F (16°C) Inlet Air Temperature flow rate should consist of a step fuel decrease
of 1500 pph (680 kgh) ± 10 percent followed
520 pph ± 37 pph (236 ± 17 kgh) at by a rate change of 1330 pph (603 kgh) ± 10
130°F (54°C) Inlet Air Temperature percent per second to idle fuel flow. Rates
based on 19,000 btu/lb per cubic foot greater than this can cause the gas generator to
lose fire. Normal decelerations from maximum
(3) Transient acceleration fuel flow power to idle should be made in approximately
requirements are shown in Acceleration Fuel 2 to 3 minutes - this will enhance the time
Schedule, figure 13. between hot section repairs and the life of the
gas generator.
(4) The tolerance on the fuel sched-
ules is +4 percent of point. The schedule is b. Operating Limits. Refer to Table 4.
plotted against compressor discharge pressure.
NOTE
(5) Acceleration fuel rates greater If any operating limit is exceeded, ver-
than those shown will result in over-tempera- ify instrumentation accuracy before
ture and possible stall of the gas generator. troubleshooting or inspecting gas
Acceleration fuel rates lower than those shown generator.
can result in “hung” starts in the below idle
speed range. 11-2.1 Initial Operation.
(6) Above the idle speed point, low 11-2.2 General. Initial operational period is
acceleration fuel rates will not harm the gas that period of operation immediately following
generator and will only result in slower accel- gas generator replacement or major mainte-
eration times. nance on the system.

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Normal
Alarm/ Operating
NOTE
• Continuous operation should not take place with any parameter indi-
cating between the alarm and trip levels. If an alarm level is not
shown, the trip level is the operating limit.
• Correct lube pressures in accordance with Table 10.
Lubrication Gas Alarm 8 psig ± 1 psig 20 - 60 psig Bypass until
System - Generator (55 kPa ± 6.9 kPa) (138 - 413 kPa) 4500 rpm
Settings and Lube Supply below 8000 rpm
above 8000 rpm
Gas Trip 6 psig ± 1 psig 20 - 60 psig Bypass until
Generator (41 kPa ± 6.9 kPa) (138 - 413 kPa) 4500 rpm
Lube Supply
Pressure
Gas Alarm 110 psig ± 10 psig 10 - 100 psig Scavenge Discharge
Generator (759 kPa ± 69 kPa) (69 - 690 kPa) Pressure shall not
Scavenge exceed 180 psig
Discharge (1242 kPa)
Pressure
Gas Alarm 180° - 220°F 140° - 160°F Normal Operating
Generator (82° - 104°C) (60° - 71°C) Range reflects tem-
Lube Alarm perature expected
Supply during operation
Temperature above idle speed
Gas Trip 330° - 350°F 215° - 275°F Normal Operating
Generator (166° - 177°C) (102° - 135°C) Range reflects tem-
Lube perature expected
Scavenge during operation
Temperatures Alarm 290° - 310°F above idle speed
(143° - 154°C)
System Manifold (138-2448 kPa) reflected at the fuel
(Natural Pressure manifold inlet on the
Gas) gas generator

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Normal
Alarm/ Operating
Fuel Supply Alarm 150°-170°F -65° to 150°F Starting Fuel Flow
Temperature (66°-77°C) (-54° to 66°C) Adjustments may be
required to compen-
ture variation
System Supply (276 kPa) Requirement based
Pressure on engine starter
torque requirements
of Fuel and
Ignition
of Fuel Igni- start after purge
tion (If purge cycle
cycle is used)
to time delay simulta-
initiation
Failure to Trip 380° - 420°F Activate 20 seconds
Light-Off (193° - 216°C) time delay simulta-
tion of fuel and
ignition
to time delay simulta-
gize ignition, fuel
system and starter air
supply

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Normal
Alarm/ Operating
(If purge completion of purge.
cycle is used) De-energize fuel and
starter air supply
Exhaust Gas Failure to Trip 380° - 420°F 0 - 1600°F Trip if temperature
Tempera- Light-Off (193° - 216°C) (18° - 871°C) does not reach 400°F
ture (204°C) within 20
seconds after fuel
and ignition are
applied
Overtemper- Trip 1450°F (788°C) 1378° - 1438°F Values given are for
ature (748° - 781°C) installations using
as the power limit.
Alarm 1438°F (781°C) Installations using
constant power con-
trol mode should
mining alarm and
are unique to each
application, but
never to exceed
1616°F (880°C)
(alarm) and 1625°F
(885°C) (trip)
Generator operation over 4 mils
Speed Gas Trip 9950 ± 50 rpm 0-9850 rpm
Generator
upon loss of flame

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Item Requirement
Fuel valves Closed
Ignition Off
Oil tank level Full
Lube oil temperature 140°F to 160°F (60° to 71°C)
Fuel manifold pressure 3 psig
(21 kPa)

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11-2.3 Special Instrumentation. b. Required for Monitoring and
Troubleshooting:
a. Required for Operation.
Gas generator speed sensor .........................(0-2758 kPa)
sensor ......................... 0-10,000 rpm Compressor inlet total 10-16 psia
Lube oil scavenge ......... 0-400°F pressure sensor........... (69-110.4 kPa)
temperature (-18 to 204°C) Fuel supply pressure ...... 0-400 psig
sensors (A-, B-, C- (0-2758 kPa)
sumps and transfer
Fuel supply temperature. -65-250°F
gearbox)
(-54 to 121°C)
Lube oil supply
Gas generator inlet air.... -65-150°F
temperature ................ 0-400°F
temperature ................ (-54 to 66°C)
sensor ......................... (-18 to 204°C)
Power turbine inlet gas
Vibration indicators gas 0-4 in/sec or
generator .................... 0-10 mil DA pressure ...................... 0-75 psia
(0-517.5 kPa)
Remote reading variable
pressure ...................... (0-690 kPa)
vane Indicator ............ -5° to ±45°
Starter air supply
temperature (T5.4)....... (-18 to 1093°C)
pressure (optional) .....
Compressor discharge 0-300 psig 0-50 psig
pressure ...................... (0-2070 kPa) (0-345 kPa)
Lube oil scavenge 0-200 psig
pressure ...................... (0-1380 kPa) 11-2.4 Preparation. The gas generator and
associated systems must be inspected and
checked out for proper installation and opera-

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Figure 14. Fuel Manifold Pressure vs. Fuel Flow

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11-2.5 Gas Generator and Associated Equip- k. Gas generator compressor
ment Check. Complete the following check rear frame leakage ports,
list. struts 7 and 10, are open
(not capped) ______
a. Gas Generator Assembly
S/N ______ l. Starter is serviced per
Packager’s manual ______
foundation ______ m. Lube oil storage tank serviced
to full level ______
ducts in place and secured ______ n. Lube oil supply valves open ______
d. Gas generator support mounts o. All filters are serviced per

and links in place and secure ______ Packager’s manual ______
e. All service connections made p. T5.4 thermocouple system

and secure ______ functioning properly ______
f. All lines have been flushed per q. Ignition system operative ______
r. Compressor inlet total
g. All instrumentation connections pressure probe aligned properly
made and secure ______ and free of damage ______
h. All accessories are secure per s. Variable stator system secure ______
t. Required checks and
i. Gas generator assembly free inspections specified in
of loose objects and all lines/ Packager’s manual for gas
electrical leads connected ______ generator control have been
performed ______
j. Gas generator inlet air area
screen secure ______

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Check. Refer to Packager’s manual. COOL DOWN. AVOID CON-
LATED GLOVES AS
WARNING NECESSARY.
OPERATING.
MET:
ENCLOSURE OR IN THE
SHUT DOWN.
ENTRY SHOULD BE
THE CUSTOMER’S e. Perform false start per
PROCEDURES. paragraph 11-2. 10.
• SECONDARY AIR TO THE f. Perform governor check per

SHALL BE KEPT OPEN. IF THE i. Operate to maximum power per
DOOR AND CONFINED SPACE paragraph 11-3.
BE FOLLOWED.

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11-2.8 Ignition Check. 11-2.9 Motoring.
WARNING a. After all preliminary checks have been

• ASSURE POWER TO IGNITION be motored as follows:
CONNECTING AND CONNECT- (1) Make ignition and natural-gas
ING IGNITION EXCITER INPUT supply systems inoperative as follows:
SERVICE TO PRECLUDE INAD- (a) Disconnect power supply to
VERTENT ACTIVATION. ignition unit.
• ASSURE FUEL VALVES ARE (b) Close natural-gas manual

CLOSED THROUGHOUT THIS shutoff valve to fuel control unit.
PROCEDURE. (2) Depress MOTORING pushbutton.
a. To clear combustor of any residual Gas generator will start to rotate. If it does not,
fuel, motor gas generator for one minute; refer to packager’s manual for supply pressure
allow gas generator to coast down. to starter.
b. Disconnect number one ignition exciter (3) Hold MOTORING pushbutton

input lead at exciter. Temporarily secure input closed until gas generator speed stabilizes, and
lead away from the exciter. check for oil pressure. If there is no indication
c. Turn on electrical power to the ignition ton; while gas generator is coasting down,
system (No. 2 ignition exciter energized). An loosen oil fittings at lube pump to bleed air
audible report (approximately two sparks per from system. Starter should motor gas genera-
second) should be heard when the No. 2 spark tor to minimum of 2200 RPM.
igniter fires.
(4) Repeat motoring and bleeding
d. Turn off electrical power to the ignition procedure until an indication of oil pressure
system. Reconnect input lead to exciter and appears.
safetywire connector.
11-2.10 False Start.
the No. 2 exciter. a. Perform false start as follows:
f. If an audible report is not heard on (1) With ignition leads disconnected

No. 1 and/or No. 2 igniters, check out the sys- and manual gas valve closed, make automatic
tem to isolate the problem, and take appropri- start of gas generator per packager’s manual.
ate corrective action. (2) Gas generator should go through
normal start cycle and then abort because of
lack of flame.

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11-2.11 Governor Check. Check governor b. Operate gas generator up to rated
system per packager’s manual. power, if possible, but do not exceed exhaust
gas temperature (T5.4) limit. Hold at this power
11-2.12 Wet Prestart.
setting until all temperatures stabilize. If gov-
a. Perform wet prestart as follows: erning system is unstable, adjust per pack-
ager’s manual.
(1) With ignition lead disconnected,
but with manual gas valve open and governing c. Log all instrument readings once they
system operating, make automatic start of gas stabilize. Refer to Table 6, step 9.
(2) Gas generator should accelerate to After stabilizing for three minutes, record all
lightoff speed (1100 to 1300 rpm). Fuel valve instrument readings. Refer to Table 7, step 2.
because of lack of flame. f. After gas generator has been stabilized
(3) Allow gas generator to coast to
down. Refer to Table 7, steps 3 and 4.
stop; then motor it to purge any remaining nat-
ural gas from gas generator. 11-3 AUTOMATIC OPERATION.
11-2.13 Manual Start and Operation. a. Check automatic operation per pack-
Perform manual start per packager’s manual ager’s manual.
with fuel system normal and with ignition lead
connected. Refer to Table 6. (1) Accelerate to idle.
11-2.14 Operation to Maximum Power. (2) Accelerate to rated power.
CAUTION (3) Log all instrument readings.
MANUAL OPERATION MAY (4) Decelerate to idle.

(5) Check for fuel or lube oil leaks.
ITS SHALL NOT BE EXCEEDED. (6) After a total of five minutes at
idle, shut down gas generator.
(refer to packager’s manual) to increase gas (7) Check lube oil and fuel filters and
generator speed. After each 500 rpm increase, strainers; clean or replace as necessary.
attention to variable stator vane position and (8) Correct any leaks observed.
vibration. If variable stator system is not (9) Remove all temporary
within limits, adjust it per WP 118 00. If vibra- instrumentation.
tions are not within limits, consult the local
General Electric Company representative. (10) Check gas generator and mount-
ing system for loose parts; tighten as
necessary.

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ADDENDUM W

CAUTION
IF T5.4 RAPIDLY APPROACHES OR EXCEEDS 1430°F (777°C), ABORT
START. AUTOMATIC SHUTDOWN AT 1450°F (788°C). REFER TO
FIGURE 15.
NOTE
A start may be aborted at any time by closing fuel valve,
allowing gas generator to motor for 60 seconds, then closing
starter shutoff valve.
NOTE
3. At 1100 to 1300 rpm NGG
a. Ignition on
(21 kPa)
[T5.4 above 400°F shutdown
(204°C)] 1200 rpm
4. Note time to 4500 ± 200 90 seconds max Troubleshoot system and
rpm take corrective action if
rpm stops accelerating
or it takes longer than
90 sec. to reach
4300 rpm
5. At 4300 to 4700 rpm NGG
a. Starter shutoff valve, Valve closed Close fuel valve and
close automatically allow gas generator to
motor for 60 seconds,
then shutoff starter

W-36
GEK 97310
VOLUME I
ADDENDUM W

a. Oil pressure 8 psig (55 kPa) min. Shutdown if below
6 psig (41 kPa)
Table 8
d. Gas generator 0 to 3 mils DA Automatic normal shut-
vibration down if above 7 mils.
corrective action
e. Compressor inlet tem- Approximatley equal to Troubleshoot sensing
perature (T2) outside air temperature and indicating system.
Correct as required
leaks
8. Set desired power setting. 1575°F (857°C) max Correct as required.
Observe T5.4 during tran- Refer to figure 15
sient operation
a. T5.4 1575°F (857°C) *
b. NGG 9850 rpm max corrected *
c. Oil pressure See Table 9 Emergency or auto-
matic shutdown if 5 psig
d. Scavenge oil 215°F to 275°F Automatic shutdown if
temperature (102 to 135°C) above 340°F (171°C)

W-37
GEK 97310
VOLUME I
ADDENDUM W

7 mils max trip Emergency or auto-
matic shutdown
f. Fuel inlet pressure 350 ± 5 psig (2415 ± **
34 kPa) maximum
g. Fuel inlet temperature -65 to 150°F (-54 to 66°C) **
h. Scavenge oil filter ∆P Refer to packager’s
manual
i. Lube oil supply filter Refer to packager’s
∆P manual
j. T2 Approximately equal to **
k. VSV schedule See applicable figures in Correct as required per
WP 118 00 WP 118 00
shut down.

W-38
GEK 97310
VOLUME I
ADDENDUM W

W-39
GEK 97310
VOLUME I
ADDENDUM W

power (unloaded)
following:
a. Oil pressure 8 psig (55 kPa) min Automatic normal
shutdown if below
8 psig (55 kPa)
c. T5.4 1000°F (538°C) max Troublshoot and take
corrective action
d. Gas generator vibration 3 mils max Automatic normal
shutdown if above
f. Scavenge oil filter ∆P Refer to packager’s
manual
g. Lube oil supply filter Refer to packager’s
∆P manual
5 minutes, close fuel valves (204°C) NGG decelerate
and stop
4. Observe T5.4 for 3 min. 700°F (371°C) Motor gas generator and

W-40
GEK 97310
VOLUME I
ADDENDUM W

CAUTION
ASSURE FREEDOM OF ROTATION OF GAS GENERATOR AFTER AN
EMERGENCY SHUTDOWN FROM HIGH POWER SETTINGS. SEI-
ZURE OF GAS GENERATOR ROTOR MAY OCCUR DUE TO TIGHT
CLEARANCES. NORMALLY THE ROTOR WILL FREE ITSELF AFTER
A COOLING PERIOD OF 3 TO 4 HOURS. CHECK FOR FREEDOM OF
ROTATION BY TURNING ROTOR BY HAND.
1. Conditions permitting, decel- T5.4 drops below 400°F Manually shut off fuel
erate gas generator to idle (204°C) and NGG and NPT supply
2. Observe T5.4 for 3 minutes 700°F (371°C) max Motor gas generator. Con-
after shutdown tinue motoring until tem-
perature decreases
ceed as follows:
generator can be restarted
within 1 minute follow-
HPC rotor, acceptable
restarts can be made
procedure.

W-41
GEK 97310
VOLUME I
ADDENDUM W

b. If a “hot restart” is per-
formed between 1 minute
and 2 hours following the
emergency shutdown,
motor the gas generator
at 2000-2500 rpm NGG
for 5 minutes. At the end
of the 5 minute motoring/
purge cycle, perform nor-
mal restart and acceler-
ate to idle. Acceleration
to the desired power set-
ting can then be accom-
plished.
procedure.

W-42
GEK 97310
VOLUME I
ADDENDUM W
(RPM)
100 110 120 130 140 150 160 170 180 190 200
5000 23.9 22.1 20.8 19.9 19.3 18.9 18.7 18.7 18.8 19.1 19.6
5100 24.6 22.9 21.5 20.6 19.9 19.5 19.3 19.3 19.4 19.7 20.2
5200 25.4 23.6 22.2 21.2 20.5 20.1 19.9 19.9 20.1 20.4 20.9
5300 26.2 24.3 22.9 21.9 21.2 20.8 20.5 20.5 20.7 21.0 21.5
5400 27.1 25.1 23.6 22.6 21.9 21.4 21.2 21.2 21.3 21.7 22.2
5500 27.9 25.9 24.4 23.3 22.5 22.1 21.8 21.8 22.0 22.4 22.9
5600 28.7 26.6 25.1 24.0 23.2 22.7 22.5 22.5 22.7 23.0 23.6
5700 29.6 27.4 25.8 24.7 23.9 23.4 23.2 23.1 23.3 23.7 24.3
5800 30.5 28.2 26.6 25.4 24.6 24.1 23.8 23.8 24.0 24.4 25.0
5900 31.3 29.1 27.4 26.2 25.3 24.8 24.5 24.5 24.7 25.1 25.7
6000 32.2 29.9 28.1 26.9 26.0 25.5 25.2 25.2 25.4 25.8 26.4
6100 33.1 30.7 28.9 27.6 26.8 26.2 25.9 25.9 26.1 26.5 27.2
6200 34.0 31.6 29.7 28.4 27.5 26.9 26.6 26.6 26.8 27.3 27.9
6300 35.0 32.4 30.5 29.2 28.2 27.6 27.4 27.3 27.6 28.0 28.7
6400 35.9 33.3 31.4 30.0 29.0 28.4 28.1 28.1 28.3 28.8 29.5
6500 36.8 34.2 32.2 30.8 29.8 29.1 28.8 28.8 29.0 29.5 30.2
6600 37.8 35.1 33.0 31.6 30.5 29.9 29.6 29.6 29.8 30.3 31.0
6700 38.8 36.0 33.9 32.4 31.3 30.7 30.3 30.3 30.6 31.1 31.8
6800 39.8 36.9 34.7 33.2 32.1 31.4 31.1 31.1 31.3 31.9 32.6
6900 40.8 37.8 35.6 34.0 32.9 32.2 31.9 31.9 32.1 32.7 33.4
7000 41.8 38.7 36.5 34.9 33.7 33.0 32.7 32.7 32.9 33.5 34.3
7100 42.8 39.7 37.4 35.7 34.6 33.8 33.5 33.5 33.7 34.3 35.1
7200 43.8 40.6 38.3 36.6 35.4 34.7 34.3 34.3 34.5 35.1 36.0
7300 44.9 41.6 39.2 37.4 36.2 35.5 35.1 35.1 35.4 36.0 36.8
7400 45.9 42.6 40.1 38.3 37.1 36.3 35.9 35.9 36.2 36.8 37.7
7500 47.0 43.6 41.1 39.2 38.0 37.2 36.8 36.7 37.0 37.7 38.6
7600 48.1 44.6 42.0 40.1 38.8 38.0 37.6 37.6 37.9 38.5 39.4
7700 49.2 45.6 43.0 41.0 39.7 38.9 38.5 38.4 38.8 39.4 40.3
7800 50.3 46.6 43.9 42.0 40.6 39.8 39.3 39.3 39.6 40.3 41.3
7900 51.4 47.7 44.9 42.9 41.5 40.6 40.2 40.2 40.5 41.2 42.2
8000 52.5 48.7 45.9 43.8 42.4 41.5 41.1 41.1 41.4 42.1 43.1
8100 53.7 49.8 46.9 44.8 43.3 42.4 42.0 42.0 42.3 43.0 44.0
8200 54.8 50.8 47.9 45.7 44.3 43.3 42.9 42.9 43.2 43.9 45.0
8300 56.0 51.9 48.9 46.7 45.2 44.3 43.8 43.8 44.1 44.8 45.9
8400 57.1 53.0 49.9 47.7 46.2 45.2 44.7 44.7 45.1 45.8 46.9
8500 58.3 54.1 51.0 48.7 47.1 46.1 45.7 45.6 46.0 46.7 47.9
8600 59.5 55.2 52.0 49.7 48.1 47.1 46.6 46.6 46.9 47.7 48.9
8700 60.7 56.3 53.1 50.7 49.1 48.0 47.5 47.5 47.9 48.7 49.8
8800 62.0 57.5 54.1 51.7 50.1 49.0 48.5 48.5 48.9 49.7 50.9
8900 63.2 58.6 55.2 52.8 51.1 50.0 49.5 49.4 49.8 50.6 51.9

W-43
GEK 97310
VOLUME I
ADDENDUM W
(RPM)
100 110 120 130 140 150 160 170 180 190 200
9000 64.4 59.8 56.3 53.8 52.1 51.0 50.4 50.4 50.8 51.6 52.9
9100 65.7 60.9 57.4 54.8 53.1 52.0 51.4 51.4 51.8 52.7 53.9
9200 67.0 62.1 58.5 55.9 54.1 53.0 52.4 52.4 52.8 53.7 55.0
9300 68.3 63.3 59.6 57.0 55.1 54.0 53.4 53.4 53.8 54.7 56.0
9400 69.6 64.5 60.8 58.1 56.2 55.0 54.4 54.4 54.8 55.7 57.1
9500 70.9 65.7 61.9 59.2 57.2 56.0 55.5 55.4 55.9 56.8 58.2
9600 72.2 67.0 63.1 60.3 58.3 57.1 56.5 56.4 56.9 57.8 59.2
9700 73.5 68.2 64.2 61.4 59.4 58.1 57.5 57.5 58.0 58.9 60.3
9800 74.9 69.4 65.4 62.5 60.5 59.2 58.6 58.5 59.0 60.0 61.4
9900 76.2 70.7 66.6 63.6 61.6 60.3 59.6 59.6 60.1 61.1 62.5
10000 77.6 72.0 67.8 64.8 62.7 61.4 60.7 60.7 61.2 62.2 63.7

W-44
GEK 97310
VOLUME I
ADDENDUM W
Table 10. CORRECTIONS FOR LUBE PRESSURE LIMITS
USING OIL, MIL-L-23699
NOTE
The following values are for corrections to 9000 RPM NGG and 150°F
(66°C) lube inlet temperature. Read oil pressure and temperature then
algerbracially add the pressure additive (as indicated for that particu-
lar rpm and lube temperature) to the observed lube pressure. Cor-
rected lube pressure limit is 46 to 57 psig (317-393 kPa).
(RPM) 100 110 120 130 140 150 160 170 180 190 200
5000 27.1 28.9 30.2 31.1 31.7 32.1 32.3 32.3 32.2 31.9 31.4
5100 26.4 28.1 29.5 30.4 31.1 31.5 31.7 31.7 31.6 31.3 30.8
5200 25.6 27.4 28.8 29.8 30.5 30.9 31.1 31.1 30.9 30.6 30.1
5300 24.8 26.7 28.1 29.1 29.8 30.2 30.5 30.5 30.3 30.0 29.5
5400 23.9 25.9 27.4 28.4 29.1 29.6 29.8 29.8 29.7 29.3 28.8
5500 23.1 25.1 26.6 27.7 28.5 28.9 29.2 29.2 29.0 28.6 28.1
5600 22.3 24.4 25.9 27.0 27.8 28.3 28.5 28.5 28.3 28.0 27.4
5700 21.4 23.6 25.2 26.3 27.1 27.6 27.8 27.9 27.7 27.3 26.7
5800 20.5 22.8 24.4 25.6 26.4 26.9 27.2 27.2 27.0 26.6 26.0
5900 19.7 21.9 23.6 24.8 25.7 26.2 26.5 26.5 26.3 25.9 25.3
6000 18.8 21.1 22.9 24.1 25.0 25.5 25.8 25.8 25.6 25.2 24.6
6100 17.9 20.3 22.1 23.4 24.2 24.8 25.1 25.1 24.9 24.5 23.8
6200 17.0 19.4 21.3 22.6 23.5 24.1 24.4 24.4 24.2 23.7 23.1
6300 16.0 18.6 20.5 21.8 22.8 23.4 23.6 23.7 23.4 23.0 22.3
6400 15.1 17.7 19.6 21.0 22.0 22.6 22.9 22.9 22.7 22.2 21.5
6500 14.2 16.8 18.8 20.2 21.2 21.9 22.2 22.2 22.0 21.5 20.8
6600 13.2 15.9 18.0 19.4 20.5 21.1 21.4 21.4 21.2 20.7 20.0
6700 12.2 15.0 17.1 18.6 19.7 20.3 20.7 20.7 20.4 19.9 19.2
6800 11.2 14.1 16.3 17.8 18.9 19.6 19.9 19.9 19.7 19.1 18.4
6900 10.2 13.2 15.4 17.0 18.1 18.8 19.1 19.1 18.9 18.3 17.6
7000 9.2 12.3 14.5 16.1 17.3 18.0 18.3 18.3 18.1 17.5 16.7
7100 8.2 11.3 13.6 15.3 16.4 17.2 17.5 17.5 17.3 16.7 15.9
7200 7.2 10.4 12.7 14.4 15.6 16.3 16.7 16.7 16.5 15.9 15.0
7300 6.1 9.4 11.8 13.6 14.8 15.5 15.9 15.9 15.6 15.0 14.2
7400 5.1 8.4 10.9 12.7 13.9 14.7 15.1 15.1 14.8 14.2 13.3
7500 4.0 7.4 9.9 11.8 13.0 13.8 14.2 14.3 14.0 13.3 12.4
7600 2.0 6.4 9.0 10.9 12.2 13.0 13.4 13.4 13.1 12.5 11.6
7700 1.8 5.4 8.0 10.0 11.3 12.1 12.5 12.6 12.2 11.6 10.7
7800 0.7 4.4 7.1 9.0 10.4 11.2 11.7 11.7 11.4 10.7 9.7
7900 -0.4 3.3 6.1 8.1 9.5 10.4 10.8 10.8 10.5 9.8 8.8
8000 -1.5 2.3 5.1 7.2 8.6 9.5 9.9 9.9 9.6 8.9 7.9
8100 -2.7 1.2 4.1 6.2 7.7 8.6 9.0 9.0 8.7 8.0 7.0
8200 -3.8 0.2 3.1 5.3 6.7 7.7 8.1 8.1 7.8 7.1 6.0

W-45
GEK 97310
VOLUME I
ADDENDUM W
Table 10. CORRECTIONS FOR LUBE PRESSURE LIMITS
USING OIL, MIL-L-23699 (Cont.)
(RPM) 100 110 120 130 140 150 160 170 180 190 200
8300 -5.0 -0.9 2.1 4.3 5.8 6.7 7.2 7.2 6.9 6.2 5.1
8400 -6.1 -2.0 1.1 3.3 4.8 5.8 6.3 6.3 5.9 5.2 4.1
8500 -7.3 -3.1 0.0 2.3 3.9 4.9 5.3 5.4 5.0 4.3 3.1
8600 -8.5 -4.2 -1.0 1.3 2.9 3.9 4.4 4.4 4.1 3.3 2.1
8700 -9.7 -5.3 -2.1 0.3 1.9 3.0 3.5 3.5 3.1 2.3 1.2
8800 -11.0 -6.5 -3.1 -0.7 0.9 2.0 2.5 2.5 2.1 1.3 0.1
8900 -12.2 -7.6 -4.2 -1.8 -0.1 1.0 1.5 1.6 1.2 0.4 -0.9
9000 -13.4 -8.8 -5.3 -2.8 -1.1 0.0 0.6 0.6 0.2 -0.6 -1.9
9100 -14.7 -9.9 -6.4 -3.8 -2.1 -1.0 -0.4 -0.4 -0.8 -1.7 -2.9
9200 -16.0 -11.1 -7.5 -4.9 -3.1 -2.0 -1.4 -1.4 -1.8 -2.7 -4.0
9300 -17.3 -12.3 -8.6 -6.0 -4.1 -3.0 -2.4 -2.4 -2.8 -3.7 -5.0
9400 -18.6 -13.5 -9.8 -7.1 -5.2 -4.0 -3.4 -3.4 -3.8 -4.7 -6.1
9500 -19.9 -14.7 -10.9 -8.2 -6.2 -5.0 -4.5 -4.4 -4.9 -5.8 -7.2
9600 -21.2 -16.0 -12.1 -9.3 -7.3 -6.1 -5.5 -5.4 -5.9 -6.8 -8.2
9700 -22.5 -17.2 -13.2 -10.4 -8.4 -7.1 -6.5 -6.5 -7.0 -7.9 -9.3
9800 -23.9 -18.4 -14.4 -11.5 -9.5 -8.2 -7.6 -7.5 -8.0 -9.0 -10.4
9900 -25.2 -19.7 -15.6 -12.6 -10.6 -9.3 -8.6 -8.6 -9.1 -10.1 -11.5
10000 -26.6 -21.0 -16.8 -13.8 -11.7 -10.4 -9.7 -9.7 -10.2 -11.2 -12.7

Observed Oil Pressure 55 psig (379.5 kPa)
Corrective Pressure 55-4.2 = 50.8 psig (350.5 kPa)

W-46
GEK 97310
VOLUME I
ADDENDUM W
tine operation of an installed gas generator. For FLOW MAY PREVENT OPEN-
ager’s manual.
gas generator operation. AN OBSERVER SHALL BE STA-
BE FOLLOWED.
WARNING
LATED GLOVES AS
SHUT DOWN.
• THE FIRE EXTINGUISHING ear protection.
INACTIVE ACCORDING TO b. Start and operate the gas generator per
THE CUSTOMER’S Table 6. Do not exceed operating limits of
PROCEDURES. Table 4.

Table 7.

W-47
GEK 97310
VOLUME I
ADDENDUM W
d. Emergency shut down the gas genera- 11-5 ENERGENCY OPERATION.
tor per Table 8.
e. Refer to Table 10 for oil pressure cor-
rection factors. a. In an emergency, the gas generator may
(200 kPa) maximum after five (5) minutes be done in an emergency, since rapid shutdown
stablization. will decrease life of gas generator.
g. The operating pressure of the lube oil b. Emergency shut-down shall be made
shall be 40 to 50 psig (276-345 kPa) at stan- per Table 8.
dard conditions of 9000 rpm gas generator
speed and 150°F (66°C) at lube pump dis- 11-5.2 Post Shutdown Fire. During a normal
charge temperature. Oil pressure measured at shutdown, exhaust gas temperature should
conditions other than standard shall be cor- decrease. If during time gas generator is coast-
rected to standard conditions using Table 9. ing to stop, temperature increases instead of
decreases, it indicates that combustion is still
taking place because of a leaking fuel valve.
(A slight temperature increase after rotation
stops is normal.) Make certain fuel is shut off,
and motor the gas generator. This will blow
out the fire. As soon as temperature decreases
to normal, discontinue motoring.

W-48
GEK 97310
VOLUME I
ADDENDUM X
ADDENDUM
7LM2500-20GB104

GEK 97310
VOLUME I
ADDENDUM X
TABLE OF CONTENTS
1-0 INTRODUCTION....................................................................................... X-3

2-0 REFERENCE DATA .................................................................................. X-3
3-0 INSTALLATION DRAWINGS.................................................................. X-3
4-0 EQUIPMENT DESCRIPTION ................................................................. X-3
4-1 INSTRUMENTATION AND SUPPLY REQUIREMENTS ................... X-3
5-0 ACCESSORY DRIVE SECTION ............................................................. X-6
5-1.1 General .......................................................................................................... X-6
5-1.2 Accessory Drive Train .................................................................................. X-6
5-1.3 Inlet Gearbox................................................................................................. X-6
5-1.4 Radial Drive Shaft......................................................................................... X-6
5-1.5 Transfer and Accessory Gearbox .................................................................. X-9
5-1.6 Air-Oil Separator........................................................................................... X-9
6-0 IGNITION SYSTEM .................................................................................. X-12
7-0 EXHAUST GAS TEMPERATURE T5.4 INDICATION ........................ X-12
8-0 LUBRICATION SYSTEM......................................................................... X-12
8-1.1 General .......................................................................................................... X-12
8-1.2 Lube Supply Subsystem................................................................................ X-14
8-1.3 Lube Scavenge Subsystem............................................................................ X-18
8-1.4 Oil Seal Pressurization Subsystem................................................................ X-18
8-1.5 Sump Vent Subsystem................................................................................... X-18
9-0 SERVICE REQUIREMENTS ................................................................... X-18
9-1.1 Natural Gas ................................................................................................... X-18
10-0 OPTIONAL HARDWARE KITS - 7LM2500-20GB104 ......................... X-20
11-0 GAS GENERATOR OPERATION ........................................................... X-20
11-1.1 Performance Ratings and Operating Limits.................................................. X-21
11-2.1 Initial Operation ............................................................................................ X-25
11-2.2 General .......................................................................................................... X-25
11-2.3 Special Instrumentation................................................................................. X-25
11-2.4 Preparation .................................................................................................... X-25
11-2.5 Gas Generator and Associated Equipment Check ........................................ X-26
11-2.6 Governor and Manual Control Check ........................................................... X-28
11-2.7 Start-up and Checkout................................................................................... X-28
11-2.8 Ignition Check............................................................................................... X-29
11-2.9 Motoring........................................................................................................ X-30
11-2.10 False Start...................................................................................................... X-30
11-2.11 Governor Check ............................................................................................ X-30
11-2.12 Wet Prestart ................................................................................................... X-30
11-2.13 Manual Start and Operation .......................................................................... X-30
11-2.14 Operation to Maximum Power...................................................................... X-30
11-3 AUTOMATIC OPERATION..................................................................... X-37
11-4 NORMAL OPERATION............................................................................ X-37

X-1
GEK 97310
VOLUME I
ADDENDUM X
11-4.1 General .......................................................................................................... X-37

11-4.2 Interlocks....................................................................................................... X-37
11-4.3 Operation....................................................................................................... X-38
11-5 EMERGENCY OPERATION ................................................................... X-39
11-5.1 Emergency Shutdown ................................................................................... X-39
11-5.2 Post Shutdown Fire ....................................................................................... X-39
Figure Title Page
1 Deleted
2 Deleted
3 Accessory Drive Section ............................................................................... X-8
4 Inlet Gearbox................................................................................................. X-9
5 Transfer and Accessory Gearbox .................................................................. X-10
6 Air-Oil Separator........................................................................................... X-11
7 Ignition System ............................................................................................. X-13
8 Thermocouple Schematic.............................................................................. X-14
9 Lubrication System Schematic...................................................................... X-16
10 Lube and Scavenge Pump ............................................................................. X-19
11 Acceleration Fuel Schedule .......................................................................... X-22
12 Fuel Manifold Pressure vs Fuel Flow ........................................................... X-27
13 Transient Temperature Limits ....................................................................... X-36
LIST OF TABLES
Table Title Page
1 INSTRUMENTATION CONNECTIONS - LM2500-20GB104.................. X-4

2 MECHANICAL SERVICE CONNECTIONS - LM2500-20GB104 ........... X-5
3 GAS GENERATOR OPERATING LIMITS ................................................ X-23
4 PRESTART CHECKS .................................................................................. X-29
5 START-UP AND OPERATION.................................................................... X-31
6 GAS GENERATOR SHUTDOWN .............................................................. X-34
7 EMERGENCY SHUTDOWN...................................................................... X-35
8 LUBE PRESSURE LIMITS FOR OIL, MIL-L-23699 ................................ X-39
9 CORRECTIONS FOR LUBE PRESSURE LIMITS USING OIL,
MIL-L-23699 ...................................................................................... X-41

X-2
GEK 97310
VOLUME I
ADDENDUM X
1-0 INTRODUCTION. Wt-Lbs/(Kg)
This addendum provides information which High Pressure Turbine Nozzle, 127(58)
applies specifically to the LM2500-20GB104 Stg 2
gas generator model, and may or may not be
applicable to other gas generator models cov-
ered by this manual. Reference data, instru- Variable Stator Actuating 19 (9)
mentation and service connection information, Mech
special servicing requirements, optional equip- Outside Piping and Bracketing 278 (126)
ment information, and complete operating Approx.
instructions are included.
DRAWING LIST
2-0 REFERENCE DATA.
Drawing No.
EQUIPMENT
Gas Generator Installation L31705
Gas Generator Assembly Drawing
General Electric Co., Fuel System Flow Diagram L24327
Model No. 7LM2500-20GB104
Diagram
Dwg. No. L21380G07
PERFORMANCE RATING Ignition Units L21454P02
Refer to paragraph 11-1.1 Gas Generator Assembly L21380G07
Drawing - Model
GAS GENERATOR WEIGHTS 7LM2500-20GB104
generator components are: 3-0 INSTALLATION DRAWINGS.
Wt-Lbs/(Kg) been provided.
Transfer Gearbox 245 (111) The 7LM2500-20GB104 gas generator con-
sists of:
Compressor Rotor 552 (250) 1 Inlet duct with water wash manifold
1 Centerbody
30 Natural gas fuel nozzles and 1 fuel
Compressor Stator, Rear 93 (42) manifold
Compressor Rear Frame 421(191) 1 Lubrication system (less oil tank,
Combustor 120 (54) cooler and filters)
2 Ignition units
High Pressure Turbine Rotor 419 (190)
1 Set of instrumentation sensors
High Pressure Turbine Nozzle, 68 (31)
Stg 1 4-1 INSTRUMENTATION AND SUP-
X-3
GEK 97310
VOLUME I
ADDENDUM X
Table 1. INSTRUMENTATION CONNECTIONS - LM2500-20GB104

Part No. 173960 or 364450
E6 Accessory gearbox scavenge oil temperature MS3106R12S-3S/W
NOTE
gas generator.

X-4
GEK 97310
VOLUME I
ADDENDUM X
Table 2. MECHANICAL SERVICE CONNECTIONS - LM2500-20GB104

CAUTION
Manifold
or MS9197-24
L2 Lube pump discharge 1 inch line from Lube Pump to Oil Supply Filters AN818-16C
or MS9197-16
Scavenge Filter and Cooler AN818-20C or MS9197-20
AN818-16C or MS9197-16
A16 Aspirator Air Supply GE tube flange PN 9643M28P32 + V band clamp
PN 9014M45P32
S1 Waterwash manifold 1 inch line - hot water line to waterwash manifold on Gas Gen-
erator Inlet Duct AN818-12C or MS9197-12
S1A Waterwash manifold
(Alternate)
NOTE
For all other instrumentation connections, see the Installation Drawings, provided with gas
generator.

X-5
GEK 97310
VOLUME I
ADDENDUM X
5-0 ACCESSORY DRIVE SECTION. 5-1.3 Inlet Gearbox. See figure 4. The inlet
gearbox assembly consists of a cast aluminum
5-1.1 General. See figure 3. The accessory casing, a shaft, a pair of bevel gears, bearings,
drive section consists of an inlet gearbox in the and oil jets. The casing, which is bolted inside
hub of the front frame, a radial drive shaft the front frame hub, mounts two duplex ball
inside the 6 o’clock strut of the front frame, bearings and a roller bearing. It has internal oil
and a transfer gearbox bolted underneath the passages and jets to provide lubrication for the
front frame. The optional pneumatic or gears and bearings. The shaft, which rotates on
hydraulic starter, optional hydraulic pump, and a horizontal axis, is splined at the aft end to
the lube and scavenge pump are mounted on mate with the stage-2 disk of the compressor
the aft side of the transfer gearbox. The air-oil rotor. The forward end of the shaft mounts the
separator and stator control are mounted on the upper bevel gear and is supported by a duplex
front of the gearbox. ball bearing. The lower bevel gear, which
5-1.2 Accessory Drive Train. Power to drive upper end by a roller bearing and at its lower
the accessories is extracted from the compres- end by a duplex ball bearing. The lower end is
sor rotor through a large-diameter hollow shaft also splined to mate with the radial drive shaft.
which is spline-connected to the rotor front
shaft. A set of bevel gears in the inlet gearbox 5-1.4 Radial Drive Shaft. The radial drive
transfers this power to the radial drive shaft, shaft, a hollow shaft externally splined on each
which transmits the power to another set of end, mates with the bevel gears in the inlet and
bevel gears in the forward section of the trans- transfer gearboxes. Its function is to transmit
fer gearbox. A short horizontal drive shaft power from the inlet gearbox to the forward
transmits power to the accessory drive adapt- section (bevel gearbox) of the transfer gear-
ers in the transfer gearbox. box. The shaft contains a shear section to pre-
vent damage to the accessory drive system.

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Figures 1 and 2. Deleted

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5-1.5 Transfer and Accessory Gearbox. See box and can be replaced without disassembly
figure 5. The accessory gearbox assembly of the gearbox.
consists of a two-piece aluminum casing, air-
oil separator, gears, bearings, seals, oil noz- 5-1.6 Air-Oil Separator. See figure 6. The
zles, and accesssory adapters. The forward air-oil separator consists of a fabricated sheet
section (bevel gearbox) contains a set of right- metal impeller with a cast aluminum housing.
angle bevel gears and a horizontal drive shaft It is mounted on the front of the accessory sec-
which transmits the power to the gear train in tion of the transfer gearbox and is considered a
the rear section (accessory gearbox). Each part of the gearbox. To prevent excessive oil
bevel gear is supported by a duplex ball bear-
ing and a roller bearing. An access cover in loss from venting oil vapor overboard, all
the bottom of the casing facilitates installation sumps are vented to the air-oil separator. The
of the radial drive shaft. The “plug-in” gear sump air is discharged after passing through
concept is used on all accessory adapters and the separator. Oil is collected on the inside of
idler gears in the aft (accessory) section. This the impeller as the oil-laden sump air passes
permits an entire gear, bearing, seal, and through the separator. Small holes in the seg-
adapter assembly to be removed and replaced
without disassembling the gearbox. Each spur ments of the impeller allow the collected oil to
gear is supported by a casing-mounted roller be discharged to the separator outer housing.
bearing on one end and an adapter-mounted Vanes on the housing wall are used to collect
ball bearing on the other end. The accessory and direct the oil to the gearbox. To prevent
drive spur gears are internally splined. Inter- oil and oil vapors from escaping past the end
nal tubes and oil nozzles provide lubrication of of the impeller, the separator has two labyrinth
the gears and bearings. Gearbox carbon face
seals are retained from the outside of the gear- seals, with the cavity between the two seals

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6-0 IGNITION SYSTEM. and air vents to prevent the accumulation of
See figure 7. During start, the ignition system
produces the high energy sparks that ignite the
7-0 EXHAUST GAS TEMPERATURE
fuel-air mixture in the combustor. It consists of
T5.4 INDICATION.
2 ignition exciters, 2 ignition leads, and 2
spark igniters.
Gas generator exhaust gas temperature is
sensed by 11 thermocouples installed in the
a. The ignition exciters are the capacitor
turbine mid frame. See figure 8. There are four
discharge type. The exciters are off-gas gener-
thermocouple harnesses, three of which have
ator mounted. Design characteristics are as
three thermocouples each and one which has
follows:
two thermocouples.
Duty cycle.............. Refer to Table 3
a. A thermocouple junction is formed
(Normal) Gas Generator
when 2 dissimilar metals are joined. KP and
Operating Limits
Power input ........... 115v at 60 Hz plete circuit is formed when both ends of the
Stored energy ......... 14. 5-16. 0 joules KP and KN wires are joined. The thermocou-
Spark rate .............. 2/sec. ples generate an electrical signal which is pro-
portional to the temperature of the gas
Output voltage ...... 15-20 KV generator turbine discharge gas. This tempera-
Output energy ture is sometimes referred to as T5.4.
Total ................ 2. 0 joules min.
8-0 LUBRICATION SYSTEM.
Duration ........... 20 micro-seconds
min. 8-1.1 General. See figure 9. The lubrication
Peak power ...... 100, 000 watts min. system provides the gas generator bearings,
Peak current ..... 2000 amp. min. gears, and splines with adequate cool oil to
prevent excessive friction and heat. The single
b. The exciters operate on 115v, 60 Hz supply element of the pump forces the oil
input. The power is transformed, rectified, and through tubes to components and areas requir-
discharged in the form of capacitor discharge ing lubrication. Oil nozzles direct the oil onto
energy pulses through the coaxial shielded bearings, gears, and splines. Four separate
leads to the spark igniters. scavenge elements in the lube and scavenge
pump remove oil from the B and C sumps and
c. The ignition leads are low-loss connec- the aft and forward transfer gearbox. (A sump
tions between the ignition exciters and the drains to forward transfer gearbox.) The scav-
spark igniters. They are coaxial, having metal- enged oil is returned to the lube tank. The
lic shielding which incorporates copper inner lubrication system is divided into 3 subsystems
braid, sealed flexible conduit, and nickel outer identified as lube supply, lube scavenge, and
braid. sump vent.

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8-1.2 Lube Supply Subsystem.

the following components:
(1) Oil tank (not General Electric Co.
supplied).
(2) Lube and scavenge pump supply
element and bypass valve.
(3) Lube supply duplex filter (not
General Electric Co. supplied).
(4) Lube supply anti-static check
valve.
(5) C sump supply check valve.
b. Lube oil from the supply tank enters
the lube and scavenge pump through an inlet
screen which prevents particles larger than
0. 030 inch (0. 76 mm) in size from entering.
Output of the supply element is routed to the
buyer provided lube supply filter. From the fil-
ter, the oil flows through an anti-static check
valve to the inlet gearbox, the stator vane
speed sensor, the transfer gearbox, and the gas
generator sumps. Oil going to the C sump
passes through an additional check valve in the
C sump supply line. Lube discharge oil also is
piped to a port near the forward end of the lube
and scavenge pump to lubricate the drive
spline.

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ADDENDUM X
c. The lube and scavenge pump (figure d. Oil enters the lube inlet port and passes
10) is a six element, positive displacement, through a removable, non-bypassing inlet
vane type pump. One element is used for the screen which traps particles larger than
lube supply, and 5 are used for lube scaveng- 0. 030 inch (0. 76 mm). A lube supply pressure
ing. Within the pump are inlet screens, one for limiting valve is provided to limit supply pres-
each element, and a lube supply pressure limit- sure. Scavenge oil enters the pump through 4
ing valve. Design characteristics of the pump scavenge oil ports, passes through an inlet
are as follows: screen in each port, and enters the scavenge
elements. The outputs of the 4 scavenge ele-
Rotation Clockwise when viewed ments are connected inside the pump and dis-
from drive end charge through a common scavenge discharge
Shear section 1500-2000 lb in (1730- port.
2310 kg cm)
Pressure limiting e. The lube supply check valve is located
valve on the downstream side of the lube supply fil-
Cracking pressure 100 psid (690 kPa) min ter. It will open and flow 20 gpm (76 lpm) with
Full flow 200 psid (1380 kPa) max a maximum differential pressure of 15 psid
Reseat 90 psid (621 kPa) min (103 kPa). The purpose of the check valve is to
Pumping capacity All flows dependent upon prevent the oil in the tank from draining into
following conditions: the sumps and gearbox when the gas generator
6000 rpm, 150° ± 5°F is shut down.
(66° ± 3°C) oil tempera-
ture, 12-15 psia
(83-103 kPa) oil inlet pres
sure, fluid per
MIL-L-7808 or
MIL-L-23699
Lube supply 16.0-18.3 gpm
(61-69 lpm)
TGB scavenge, 4.8-5.4 gpm
fwd (18-20 1pm)
TGB scavenge, aft 18.0-20.2 gpm
(68-76 lpm)
B sump scavenge 10. 6-12. 1 gpm
(40-46 lpm)
C sump scavenge 7.6-8.5 gpm (29-32 lpm)
Discharge pressure
Lube supply 25-75 psia (172-517 kPa)
normal, 75-100 psia
Scavenge 25-85 psia (172-586 kPa)
normal, 85-100 psia

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f. A check valve is located in the lube oil and gearbox when the gas generator is shut
supply line to the C sump. The check valve down.
isolates the C sump from the gas generator
8-1.4 Oil Seal Pressurization Subsystem.
lube oil system when an external lube supply
Refer to paragraph 2-6.2, Volume I, Basic
and scavenge system is used for the buyer fin-
Manual.
ished power turbine. The C sump scavenge
line and the C sump oil supply line are 8-1.5 Sump Vent Subsystem. See figure 9.
equipped with access ports to facilitate the
a. The sump vent subsystem consists of
application of an external lube system for the
one major part, the air-oil separator, and the
piping and and tubing making up the sub-
tion, lube oil is supplied from the lube pump,
system. (The air-oil separator is part of the
to the C sump. The check valve then opens at a
transfer gearbox.) For a detailed description of
2 psid (14 kPa) pressure differential.
it, refer to paragraph 5-1.6.
8-1.3 Lube Scavenge Subsystem. See
b. To prevent oil leakage, main bearing
figure 9.
oil seals use pressurization air to cause air to
flow across the seals into the sumps. Seal pres-
a. The lube scavenge subsystem consists
surizing air is extracted from the eighth stage
of the following components:
of the compressor and distributed to the oil
(1) Lube and scavenge pump scav- seals. To remove the air which enters the
enge elements. sumps through the oil seals and to maintain a
(2) Lube scavenge duplex filter (not pressure drop across the oil seals, the sump air
supplied). is vented. Each sump area is connected to a
sump vent manifold through frame struts. The
(3) Lube scavenge check valve. manifold connects to the air-oil separator
(4) Heat exchanger (oil cooler) (not which extracts oil from the air before venting
supplied). the air into the exhaust duct. Extracted oil is
returned to the transfer gearbox.
b. The 4 scavenge elements of the lube
and scavenge pump scavenge oil from the B 9-0 SERVICE REQUIREMENTS.
and C sumps, and from 2 areas of the transfer 9-1.1 Natural Gas.
gearbox. Oil from the air-oil separator drains
into the aft section of the transfer gearbox. Oil a. The required supply pressure to the
from the inlet gearbox and the A sump drains fuel manifold on the gas generator is
through the radial driveshaft box. Oil from the 350 ± 5 psig (2413 ± 34 kPa).
4 scavenge elements exits the pump from a b. The temperature of the gas must be in
common discharge port. the range of -65° to +150°F (-54 to +66°C). If
c. The scavenge check valve is located in the temperature is not repeatable on a day-to-
the lube and scavenge pump scavenge dis- starting fuel adjustment to adjust the supply
charge line. It will open and flow 20 gpm pressure to the engine to maintain a constant
(76 lpm) with a maximum differential pressure Btu-per-cubic-foot supply. Once started, the
of 15 psid (103 kPa). The purpose of this gas generator will accept variations in supply
check valve is to prevent the oil in the scav- temperature of ±20°F (±11°C). The maximum
enge lines from draining back into the sumps fuel flow required is 13,400 pph (7068 kg/h)
with a lower heating value of 19,000 Btu/lb.

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10-0 OPTIONAL HARDWARE KITS - Refer requests for additional information to the
7LM2500-20GB104. General Electric Company, Marine and Indus-
trial Projects Department, Cincinnati, Ohio
Item Kit PN Nomenclature 45215.
1 L24023 Flange, Customer
2 L24077 Stator Control WARNING
3 106C7149G01 Container IF A QUESTIONABLE CONDITION
4 536L298G01 Spad Drawing List EXISTS, DO NOT OPERATE THE
5 681L316G01 JV Scheduled OUGH INVESTIGATION HAS
Inspection BEEN MADE. DO NOT REPEAT
6 681L461G01 Kit, Expendable HOT STARTS, COMPRESSOR
7 681L464G01 and Kit, On Engine STALLS, OR OTHER RECOGNIZED
G03 Option-Equipment PROBLEMS WITHOUT PRIOR
8 681L465G01 and Kit, Off Engine
G02 Optional Equip-
ment
IMPOSED ON GAS GENERATOR
9 681L468G01 and Kit, Ship With COMPONENTS, WITH IMMEDI-
G02 Engine ATE OR SUBSEQUENT DESTRUC-
10 681L493G01 Compartment Sep- TIVE FAILURE OF THE GAS
arator Assembly GENERATOR AND INJURY TO
11 681L494G01 Kit, Machine PERSONNEL.
Threaded Plugs
NOTE
11-0 GAS GENERATOR OPERATION. The S.I. units shown in this chapter are
a. These instructions contain the detailed may be rounded off in most instances
gas turbine operating procedures and limits at the users discretion. Examples of
recommended by the General Electric Com- units that may be rounded off are those
pany for the 7LM2500-20GB104 Gas Genera- utilized for temperatures, torque val-
tor. ues, pressures, etc. Examples where
b. The instructions are intended to pro- those utilized for drop checks, rigging
vide operating personnel with the information adjustments, runouts, etc.
procedures. When a fault exists, refer to chap-
ter 4, TROUBLESHOOTING.
tion with the operation of the gas generator.

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ADDENDUM X
11-1.1 Performance Ratings and Operating (3) Transient acceleration fuel flow
Limits. requirements are shown in Acceleration Fuel
Schedule, figure 11.
NOTE
Ratings published in this manual apply (4) The tolerance on the fuel sched-
to the 7LM2500-20GB104 gas genera- ules is +4 percent of point. The schedule is
tor. The driven unit ratings/limits may plotted against compressor discharge pressure.
be lower in some cases and shall take
precedence over the gas generator (5) Acceleration fuel rates greater
manual limits. than those shown will result in over-tempera-
ture and possible stall of the gas generator.
a. Performance Ratings.
Acceleration fuel rates lower than those shown
(1) The rated performance of the can result in “hung” starts in the below idle
7LM2500-20GB104 gas generator in the new speed range.
and clean condition are as follows:
(6) Above the idle speed point, low
acceleration fuel rates will not harm the gas
Isentropic Gas Horsepower 20,000
generator and will only result in slower accel-
Inlet Air Temperature 59°F (15°C) eration times.
Altitude Sea Level
(7) For normal accelerations from
Inlet Losses 0” H2O idle to power settings the changes should be
Relative Humidity 0% made more slowly to enhance the time
Fuel Lower Heating Value 19,000 Btu/lb
the gas generators; a time of 2 to 3 minutes is
Compressor Bleed 0 lbs/Sec reasonable.
Accessory Horsepower (8) The maximum deceleration fuel
Extraction 0 flow rate should consist of a step fuel decrease
Power Turbine Inlet Gas Tem- 1145°F of 1500 pph (680 kgh) ± 10 percent followed
perature (618°C) by a rate change of 1330 pph (603 kgh) ± 10
Fuel, Natural Gas GE Specifica- percent per second to idle fuel flow. Rates
tion MID-TD- greater than this can cause the gas generator to
0000-1 lose fire. Normal decelerations from maximum
(2) Approximate starting fuel flow 2 to 3 minutes - this will enhance the time
requirements based on applying fuel and igni- between hot section repairs and the life of the
tion at 1200 RPM are: gas generator.
400 pph ± 37 pph (181 ± 17 kgh) at b. Operating Limits. Refer to Table 3.

-65°F (-54°C) Inlet Air Temperature
NOTE
480 pph ± 37 pph (218 ± 17 kgh) at
60°F (16°C) Inlet Air Temperature If any operating limit is exceeded, ver-
520 pph ± 37 pph (236 ± 17 kgh) at troubleshooting or inspecting gas gen-
130°F (54°C) Inlet Air Temperature erator.
based on 19, 000 btu/lb per cubic foot.

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Item Requirements Remarks
1. Idle RPM, Gas Generator 4950 + 50 RPM 6800 RPM max
2. Maximum RPM, Gas 10,050 RPM, max full power Trip set point 10,120 rpm
Generator corrected (uncorrected)
3. Power Turbine Inlet 1285°F (696°C) max 1000°F Trip set point 1300°F
(T5.4) (Gas Generator (538°C) max idle Starts (See (704°C)
Exhaust) Temperature figure 13) Operation (See
figure 13)
NOTE
Vibration may be read as either displacement (mils) or velocity [inches (mm)/second].
4. Vibration, Gas Generator
a. Displacement 3 mils DA maximum Trip point set at 7 + 1 mils
DA
b. Velocity Alarm at 1.5 in (38 mm)/ sec at Trip point set at 2.5 in.
84-125 hz, and at 1.75 in (63 mm)/sec at 84-125 hz,
(44.5 mm)/ sec above 125 hz and at 3.0 in (76 mm)/sec
above 125 hz
5. Lube Oil Consumption 0.2 lbs (0.1 kg)/hr. (avg.)
2.0 lbs (0.9 kg)/hr. max
6. Lube Oil Supply Pressure 8 psig (55 kPa) min at Idle 46 to Trip set point at 6 psig +
57 psig (317-393 kPa) @ 9000 1 psig
RPM and 150°F (66°C) Oil Inlet
Temp. (See Table 9)
7. Lube Oil Supply 140°F to 160°F (60°C to 71.1°C) 200°F (93°C) max
Temperature operating + 20°F (-7°C) min.,
starting
8. Lube Oil Scavenge 110 psig (758 kPa). max. Alarm at 100 + 10 psig (689
Pressure + 69 kPA)
9. Lube Oil Scavenge 275°F (135°C) max. Alarm at 300°F + 5°F
Temperature (150°C + 3°C)
10. Fuel Manifold Pressure 350 + 5 psig (2413 + 34 kPa) Supply pressure as reflected
at maximum power at the fuel manifold inlet on
the gas generator
11. Stator Vane Schedule See applicable figure in Correct as required per
WP 118 00 WP 118 00

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ADDENDUM X
Table 3. GAS GENERATOR OPERATING LIMITS - Continued
Item Requirements Remarks
12. Fuel Flow 13,400 lb (6078 kg)/hour
max at 19,000 Btu/lb
13. Ignition Duty Cycle 75 sec. on, 90 sec. off
75 sec. on, 90 sec. off
75 sec. on, 30 min. off
or
45 sec. on, 120 sec. off for 4
cycles, followed by 30 min. off
14. Gas Generator Starting
a. Light-off 20 sec. max. after initiation of If gas generator does not fire
ignition and fuel in 20 sec., terminate igni-
tion and fuel and continue
motoring for 60 sec. to clear
gas generator of residual
fuel.
b. Fuel manifold pressure 3 psig (21 kPa) (approx.) (See
figure 13)
c. Time to reach gas gen- 60 seconds approx. with starter Abort start if NGG does not
erator idle RPM operating within limits of Pack- reach 4500 + 200 rpm in
ager’s manual 90 seconds
15. Compressor Discharge 250 psig (1724 kPa), max
Pressure (CDP, Ps3)
16. Lube Oil Leakage
a. Drive pads (lube pump 7 cc/hour max. combined
and starter) (5 cc/hour/pad)
b. Sump oil seal drain 5 cc/hour/sump
c. Vane actuators 2 cc/minute max per actuator
17. Shut-Down Time 2-3 minutes down to idle, Normal shutdown
idle for 5 minutes
18. Loss of Flame Combustor flame Close and lock out fuel shut-
off valve upon loss of flame

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ADDENDUM X
11-2.1 Initial Operation. b. Required for Monitoring and Trouble-
shooting:.
that period of operation immediately following Fuel Manifold pressure . . . . . . 0-400 psi
gas generator replacement or major mainte- sensor (0-2758 kpa)
nance on the system. Compressor inlet total . . . . . . . 10-16 psia
pressure sensor (69-110.4
11-2.3 Special Instrumentation. kpa)
a. Required for Operation. Fuel supply pressure . . . . . . . . 0-400 psig
(0-2758 kpa)
Gas Generator speed. . . . . . . . 0-10,000 rpm Fuel supply temperature . . . . . -65-250°F
sensor (-54 to
121°C)
Lube oil scavenge temper- . . . 0-400°F
ature sensors (A-, B-, (-18 to Gas generator inlet air . . . . . . . -65-150°F
C-sumps and transfer 204°C) temperature (-54 to 66°C)
gearbox) Power turbine inlet gas . . . . . . 0-75 psia
Lube oil supply . . . . . . . . . . . . 0- 400°F pressure (0-517. 5 kpa)
temperature sensor . . . . . . . (-18 to Remote reading variable . . . . . 5° to +45°
204°C) vane indicator
Vibration indicators Starter air supply pressure . . . . 0-50 psig
gas generator . . . . . . . . . . 0-4 in/sec or (optional) (0-345 kpa)
0-10 mil DA
Lube oil supply pressure. . . . . 0-100 psig 11-2.4 Preparation. The gas generator and
(0-690 kPa) associated systems must be inspected and
Power turbine inlet gas checked out for proper installation and opera-
temperature (T5.4) . . . . . . . . 0-2000°F tion before normal operation can commence.
(-18 to
1093°C)
Compressor discharge
pressure. . . . . . . . . . . . . . . . 0-300 psig
(0-2070 kpa)
Lube oil scavenge pressure. . . 0-200 psig
(0-1380 kpa)

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ADDENDUM X
11-2.5 Gas Generator and Associated Equip- k. Gas generator compressor _________
ment Check. Complete the following check rear frame leakage ports,
list. struts 7 and 10, are open
(not capped)
a. Gas Generator Assembly _________ l. Starter is serviced per Pack- _________
S/N ager’s manual
b. Mounting base secure to _________ m. Lube oil storage tank ser- _________
foundation viced to full level
c. Intake air and exhaust gas _________ n. Lube oil supply valves open _________
o. All filters are serviced per _________
d. Gas generator support _________ Packager’s manual
mounts and links in place
and secure p. T5.4 thermocouple system _________
e. All service connections _________ functioning properly
made and secure q. Ignition system operative _________
f. All lines have been flushed _________ r. Compressor inlet total pres- _________
per Packager’s manual sure probe aligned properly
g. All instrumentation connec- _________ and free of damage
tions made and secure s. Variable stator system _________
h. All accessories are secure _________ secure
per Packager’s manual t. Required checks and _________
i. Gas generator assembly _________ inspections specified in
free of loose objects and all Packager’s manual for gas
lines/electrical leads generator control have been
connected performed
j. Gas turbine inlet air area _________
screen secure

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ADDENDUM X
Figure 12. Fuel Manifold Pressure vs Fuel Flow

X-27
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ADDENDUM X
Refer to Packager’s manual. BE FOLLOWED.

MET:
SHUT DOWN.
• THE FIRE EXTINGUISHING paragraph 11.2-8.
SYSTEM SHALL BE MADE d. Perform motoring procedure per
INACTIVE ACCORDING TO paragraph 11.2-9.
THE CUSTOMER’S
PROCEDURES. e. Perform flase start per
• SECONDARY AIR TO THE paragraph 11-2. 10.
SHALL BE KEPT OPEN. IF THE paragraph 11-2. 13.
paragraph 11-3.

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ADDENDUM X
Item Requirements
Fuel valves Closed
Ignition Off
Oil tank level Full
Lube oil temperature 140° F to 160° F
(60° to 71° C)
Fuel manifold pressure 3 psig (21 kPa)
11-2.8 Ignition Check. c. Turn on electrical power to the ignition

WARNING
• ASSURE POWER TO IGNITION igniter fires.
CONNECTING AND CONNECT- d. Turn off electrical power to the ignition
ING IGNITION EXCITER INPUT system. Reconnect input lead to exciter and
LEAD. TAG SWITCH OUT OF safetywire connector.
VERTENT ACTIVATION. e. Repeat steps b, c, and d, disconnecting
• ASSURE FUEL VALVES ARE the No. 2 exciter.
PROCEDURE. f. If an audible report is not heard on
a. To clear combustor of any residual tem to isolate the problem, and take appropri-
fuel, motor gas generator for one minute; ate corrective action.
allow gas generator to coast down.


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ADDENDUM X
11-2.9 Motoring. 11-2.12 Wet Prestart.
a. After all preliminary checks have been a. Perform wet prestart as follows:
be motored as follows: (1) With ignition lead disconnected,
but with manual gas valve open and governing
(1) Make ignition and natural-gas
supply systems inoperative as follows:
(a) Disconnect power supply to
ignition unit. (2) Gas generator should accelerate to
lightoff speed (1100 to 1300 rpm). Fuel valve
(b) Close natural-gas manual
shutoff valve to fuel control unit.
(2) Depress MOTORING pushbutton. supply if required. Start will then abort
Gas generator will start to rotate. If it does not, because of lack of flame.
to starter. (3) Allow gas generator to coast to
stop; then motor it to purge any remaining nat-
(3) Hold MOTORING pushbutton ural gas from gas generator.
check for oil pressure. If there is no indication 11-2.13 Manual Start and Operation. Perform
of oil pressure, release MOTORING pushbut- manual start per packager’s manual with fuel
ton; while gas generator is coasting down, system normal and with ignition lead con-
loosen oil fittings at lube pump to bleed air nected. Refer to Table 5.
from system. Starter should motor gas genera-
tor to minimum of 2200 RPM. 11-2.14 Operation to Maximum Power.
(4) Repeat motoring and bleeding
CAUTION
procedure until an indication of oil pressure
appears. MANUAL OPERATION MAY
11-2.10 False Start. TIVE CIRCUITS. OPERATING LIM-
a. Perform false start as follows:
(1) With ignition leads disconnected (refer to packager’s manual) to increase gas
and manual gas valve closed, make automatic generator speed. After each 500 rpm increase,
start of gas generator per packager’s manual. log all instrument readings, paying particular
(2) Gas generator should go through vibration. If variable stator system is not
normal start cycle and then abort because of within limits, adjust it per WP 118 00. If vibra-
lack of flame. tions are not within limits, consult the local
11-2.11 Governor Check.Check governor sys-

X-30
GEK 97310
VOLUME I
ADDENDUM X
b. Operate gas generator up to rated d. Reduce gas generator speed to idle.
power, if possible, but do not exceed exhaust After stabilizing for three minutes, record all
gas temperature (T5.4) limit. Hold at this instrument readings. Refer to Table 6, step 2.
If governing system is unstable, adjust per e. Check fail-safe section of control sys-
packager’s manual. tem per packager’s manual.
c. Log all instrument readings once they f. After gas generator has been stabilized
stabilize. Refer to Table 5, step 9. at idle for five minutes, make normal shut-

CAUTION
IF T5.4 RAPIDLY APPROACHES OR EXCEEDS 1430°F (777°C) ABORT
START. AUTOMATIC SHUTDOWN AT 1450°F (788°C). REFER TO
FIGURE 13.
NOTE
A start may be aborted at any time by closing fuel valve, allowing gas genera-
tor to motor for 60 seconds, then closing starter shutoff valve
NOTE
3. At 1100 to 1300 rpm NGG
a. Ignition on
approximately
3 psig (21 kPa)
c. Note time to lightoff 20 seconds max. Abort start-automatic shutdown at
[T5.4 above 1285°F (696°C) 1360°F (738°C)
400°F (204°C)]
1200 RPM

X-31
GEK 97310
VOLUME I
ADDENDUM X
4. Note time to 4500 ± 200 rpm 90 seconds max Troubleshoot system and take cor-
rective action if rpm stops accelerat-
ing or it takes longer than 90 sec. to
reach 4300 rpm
5. At 4300 to 4700 rpm NGG
a. Starter shutoff valve, Valve closed Close fuel valve and allow gas gener-
close automatically ator to motor for 60 seconds, then
shutoff starter
a. Oil pressure 8 psig (55 kPa) min. Shutdown if below 6 psig (41 kPa)
c. T5.4 950°F (510°C) max Emergency shutdown Table 7
d. Gas generator 0 to 3 mils DA Automatic normal shutdown if above
vibration 7 mils. Troubleshoot and take cor-
rective action
e. Compressor inlet temper- Approximately equal Troubleshoot sensing and indicating
ature (T2) to outside air system. Correct as required
temperature
leaks
8. Set desired power setting. 1285°F (696°C) Correct as required. Refer to
Observe T5.4 during transient figure 13
operation
a. T5.4 1285°F (696°C)
b. NGG 10,050 rpm max
corrected
c. Oil pressure See Table 8 Emergency or automatic shutdown if
5 psig (34 kPa) out of limits

X-32
GEK 97310
VOLUME I
ADDENDUM X
d. Scavenge oil 215°F to 275°F Automatic shutdown if above 340°F
temperature (102 to 135°C) (171°C)
7 mils max trip Emergency or automatic shutdown
f. Fuel inlet pressure 350 ± 5 psig **
(2415 ± 34 kPa)
maximum
g. Fuel inlet temperature -65 to 150°F **
(-54 to 66°C)
manual
i. Lube oil supply filter ∆P Refer to packager’s
manual
j. T2 Approximately equal **
to outside air
temperature
k. Stator vane angle See applicable figure Correct as required per WP 118 00
in WP 118 00
limits, shutdown.

X-33
GEK 97310
VOLUME I
ADDENDUM X

power (unloaded)
following:
a. Oil pressure 8 psig (55 kPa) min Automatic normal shut-
down if below 8 psig
(55.2 kPa)
c. T5.4 1000°F (538°C) max Troubleshoot and take
corrective action
d. Gas generator vibration 3 mils max Automatic normal shut-
down if above 7 mils. Trou-
bleshoot and take corrective
action
f. Scavenge oil filter ∆P Refer to packager’s manual
g. Lube oil supply filter ∆P Refer to packager’s manual
5 minutes, close fuel valves (204°C) NGG decelerate and
stop
4. Observe T5.4 for 3 minutes 700°F (371°C) Motor gas generator and
after shutdown shut off fuel supply. Con-
tinue motoring until temper-
ature decreases

X-34
GEK 97310
VOLUME I
ADDENDUM X
CAUTION
SHUTDOWN FROM HIGH POWER SETTINGS. SEIZURE OF GAS GENERATOR
1. Conditions permitting, decelerate gas T5.4 drops below 400°F Manually shut off
generator to idle and close fuel valves (204°C) and NGG and fuel supply
NPT decelerate
until temperature
decreases
generator can be restarted within 1
procedure.
the gas generator at 2000-2500 rpm
NGG for 5 minutes. At the end of the
accomplished.

X-35
GEK 97310
VOLUME I
ADDENDUM X

X-36
GEK 97310
VOLUME I
ADDENDUM X
11-3 AUTOMATIC OPERATION. (10) Check gas generator and mount-
ing system for loose parts; tighten as
a. Check automatic operation per pack- necessary.
ager’s manual.
(1) Accelerate to idle.
(2) Accelerate to rated power. 11-4.1 General. Normal operation is the rou-
tine operation of an installed gas generator. For
(3) Log all instrument readings.
(4) Decelerate to idle. operation for normal operation, refer to pack-
ager’s manual.
(5) Check for fuel or lube oil leaks.
(6) After a total of five minutes at 11-4.2 Interlocks. Refer to packager’s manual
idle, shut down gas generator. for description of interlocks which affect gas
generator operation.
(7) Check lube oil and fuel filters and
(8) Correct any leaks observed.
(9) Remove all temporary instrumen-
tation.

X-37
GEK 97310
VOLUME I
ADDENDUM X
WARNING
SHUT DOWN.
UNDER SUCH CONDITIONS. b. Start and operate the gas generator per
INACTIVE ACCORDING TO c. Shut down the gas generator per
THE CUSTOMER’S Table 6.
PROCEDURES. d. Emergency shut down the gas genera-
tor per Table 7.
ENCLOSURE SHALL BE SHUT e. Refer to Table 9 for oil pressure correc-
OFF. HIGH SECONDARY AIR- tion factors.
FLOW MAY PREVENT OPEN- f. Idle lube oil pressure is 29 psig
ING OR CLOSING THE (200 kPa) maximum after five (5) minutes
ENCLOSURE DOOR. stabilization.
• THE ENCLOSURE DOOR g. The operating pressure of the lube oil

SHALL BE KEPT OPEN. IF THE shall be 40 to 50 psig (276-345 kPa) at stan-
GAS TURBINE IS OPERATING, dard conditions of 9000 rpm gas generator
AN OBSERVER SHALL BE STA- speed and 150° F (66° C) at lube pump dis-
TIONED AT THE ENCLOSURE charge temperature. Oil pressure measured at
DOOR AND CONFINED SPACE conditions other than standard shall be cor-
ENTRY PROCEDURES SHALL rected to standard conditions using Table 9.
BE FOLLOWED.

X-38
GEK 97310
VOLUME I
ADDENDUM X
11-5 EMERGENCY OPERATION. 11-5.2 Post Shutdown Fire. During a normal
11-5.1 Emergency Shutdown. decrease. If during time gas generator is coast-
a. In an emergency, the gas generator may decreases, it indicates that combustion is still
be shut down from any power setting by clos- taking place because of a leaking fuel valve.
ing the fuel valve. However, this should only (A normal.) Make certain fuel is shut off, and
be done in an emergency, since rapid shutdown motor the gas generator. This will blow out the
will decrease life of gas generator. fire. As soon as temperature decreases to nor-
mal, discontinue motoring.
per Table 7.

(RPM)
100 110 120 130 140 150 160 170 180 190 200
5000 23.9 22.1 20.8 19.9 19.3 18.9 18.7 18.7 18.8 19.1 19.6
5100 24.6 22.9 21.5 20.6 19.9 19.5 19.3 19.3 19.4 19.7 20.2
5200 25.4 23.6 22.2 21.2 20.5 20.1 19.9 19.9 20.1 20.4 20.9
5300 26.2 24.3 22.9 21.9 21.2 20.8 20.5 20.5 20.7 21.0 21.5
5400 27.1 25.1 23.6 22.6 21.9 21.4 21.2 21.2 21.3 21.7 22.2
5500 27.9 25.9 24.4 23.3 22.5 22.1 21.8 21.8 22.0 22.4 22.9
5600 28.7 26.6 25.1 24.0 23.2 22.7 22.5 22.5 22.7 23.0 23.6
5700 29.6 27.4 25.8 24.7 23.9 23.4 23.2 23.1 23.3 23.7 24.3
5800 30.5 28.2 26.6 25.4 24.6 24.1 23.8 23.8 24.0 24.4 25.0
5900 31.3 29.1 27.4 26.2 25.3 24.8 24.5 24.5 24.7 25.1 25.7
6000 32.2 29.9 28.1 26.9 26.0 25.5 25.2 25.2 25.4 25.8 26.4
6100 33.1 30.7 28.9 27.6 26.8 26.2 25.9 25.9 26.1 26.5 27.2
6200 34.0 31.6 29.7 28.4 27.5 26.9 26.6 26.6 26.8 27.3 27.9
6300 35.0 32.4 30.5 29.2 28.2 27.6 27.4 27.3 27.6 28.0 28.7
6400 35.9 33.3 31.4 30.0 29.0 28.4 28.1 28.1 28.3 28.8 29.5
6500 36.8 34.2 32.2 30.8 29.8 29.1 28.8 28.8 29.0 29.5 30.2
6600 37.8 35.1 33.0 31.6 30.5 29.9 29.6 29.6 29.8 30.3 31.0
6700 38.8 36.0 33.9 32.4 31.3 30.7 30.3 30.3 30.6 31.1 31.8
6800 39.8 36.9 34.7 33.2 32.1 31.4 31.1 31.1 31.3 31.9 32.6
6900 40.8 37.8 35.6 34.0 32.9 32.2 31.9 31.9 32.1 32.7 33.4
7000 41.8 38.7 36.5 34.9 33.7 33.0 32.7 32.7 32.9 33.5 34.3
7100 42.8 39.7 37.4 35.7 34.6 33.8 33.5 33.5 33.7 34.3 35.1
7200 43.8 40.6 38.3 36.6 35.4 34.7 34.3 34.3 34.5 35.1 36.0
7300 44.9 41.6 39.2 37.4 36.2 35.5 35.1 35.1 35.4 36.0 36.8
7400 45.9 42.6 40.1 38.3 37.1 36.3 35.9 35.9 36.2 36.8 37.7
7500 47.0 43.6 41.1 39.2 38.0 37.2 36.8 36.7 37.0 37.7 38.6

X-39
GEK 97310
VOLUME I
ADDENDUM X
Table 8. LUBE PRESSURE LIMITS FOR OIL, MIL-L-23699 - Continued
(RPM)
100 110 120 130 140 150 160 170 180 190 200
7600 48.1 44.6 42.0 40.1 38.8 38.0 37.6 37.6 37.9 38.5 39.4
7700 49.2 45.6 43.0 41.0 39.7 38.9 38.5 38.4 38.8 39.4 40.3
7800 50.3 46.6 43.9 42.0 40.6 39.8 39.3 39.3 39.6 40.3 41.3
7900 51.4 47.7 44.9 42.9 41.5 40.6 40.2 40.2 40.5 41.2 42.2
8000 52.5 48.7 45.9 43.8 42.4 41.5 41.1 41.1 41.4 42.1 43.1
8100 53.7 49.8 46.9 44.8 43.3 42.4 42.0 42.0 42.3 43.0 44.0
8200 54.8 50.8 47.9 45.7 44.3 43.3 42.9 42.9 43.2 43.9 45.0
8300 56.0 51.9 48.9 46.7 45.2 44.3 43.8 43.8 44.1 44.8 45.9
8400 57.1 53.0 49.9 47.7 46.2 45.2 44.7 44.7 45.1 45.8 46.9
8500 58.3 54.1 51.0 48.7 47.1 46.1 45.7 45.6 46.0 46.7 47.9
8600 59.5 55.2 52.0 49.7 48.1 47.1 46.6 46.6 46.9 47.7 48.9
8700 60.7 56.3 53.1 50.7 49.1 48.0 47.5 47.5 47.9 48.7 49.8
8800 62.0 57.5 54.1 51.7 50.1 49.0 48.5 48.5 48.9 49.7 50.9
8900 63.2 58.6 55.2 52.8 51.1 50.0 49.5 49.4 49.8 50.6 51.9
9000 64.4 59.8 56.3 53.8 52.1 51.0 50.4 50.4 50.8 51.6 52.9
9100 65.7 60.9 57.4 54.8 53.1 52.0 51.4 51.4 51.8 52.7 53.9
9200 67.0 62.1 58.5 55.9 54.1 53.0 52.4 52.4 52.8 53.7 55.0
9300 68.3 63.3 59.6 57.0 55.1 54.0 53.4 53.4 53.8 54.7 56.0
9400 69.6 64.5 60.8 58.1 56.2 55.0 54.4 54.4 54.8 55.7 57.1
9500 70.9 65.7 61.9 59.2 57.2 56.0 55.5 55.4 55.9 56.8 58.2
9600 72.2 67.0 63.1 60.3 58.3 57.1 56.5 56.4 56.9 57.8 59.2
9700 73.5 68.2 64.2 61.4 59.4 58.1 57.5 57.5 58.0 58.9 60.3
9800 74.9 69.4 65.4 62.5 60.5 59.2 58.6 58.5 59.0 60.0 61.4
9900 76.2 70.7 66.6 63.6 61.6 60.3 59.6 59.6 60.1 61.1 62.5
10000 77.6 72.0 67.8 64.8 62.7 61.4 60.7 60.7 61.2 62.2 63.7

X-40
GEK 97310
VOLUME I
ADDENDUM X
Table 9. CORRECTIONS FOR LUBE PRESSURE LIMITS USING OIL,
MIL-L-23699
NOTE
The following values are for corrections to 9000 RPM NGG and 150°F (66°C) lube inlet
temperature. Read oil pressure and temperature then algebracially add the pressure addi-
tive (as indicated for that particular rpm and lube temperature) to the observed lube pres-
sure. Corrected lube pressure limit is 46 to 57 psig (317-393 kPa).
(RPM)
100 110 120 130 140 150 160 170 180 190 200
5000 27.1 28.9 30.2 31.1 31.7 32.1 32.3 32.3 32.2 31.9 31.4
5100 26.4 28.1 29.5 30.4 31.1 31.5 31.7 31.7 31.6 31.3 30.8
5200 52.6 27.4 28.8 29.8 30.5 30.9 31.1 31.1 30.9 30.6 30.1
5300 24.8 26.7 28.1 29.1 29.8 30.2 30.5 30.5 30.3 30.0 29.5
5400 23.9 25.9 27.4 28.4 29.1 29.6 29.8 29.8 29.7 29.3 28.8
5500 23.1 25.1 26.6 27.7 28.5 28.9 29.2 29.2 29.0 28.6 28.1
5600 22.3 24.4 25.9 27.0 27.8 28.3 28.5 28.5 28.3 28.0 27.4
5700 21.4 23.6 25.2 26.3 27.1 27.6 27.8 27.9 27.7 27.3 26.7
5800 20.5 22.8 24.4 25.6 26.4 26.9 27.2 27.2 27.0 26.6 26.0
5900 19.7 21.9 23.6 24.8 25.7 26.2 26.5 26.5 26.3 25.9 25.3
6000 18.8 21.1 22.9 24.1 25.0 25.5 25.8 25.8 25.6 25.2 24.6
6100 17.9 20.3 22.1 23.4 24.2 24.8 25.1 25.1 24.9 24.5 23.8
6200 17.0 19.4 21.3 22.6 23.5 24.1 24.4 24.4 24.2 23.7 23.1
6300 16.0 18.6 20.5 21.8 22.8 23.4 23.6 23.7 23.4 23.0 22.3
6400 15.1 17.7 19.6 21.0 22.0 22.6 22.9 22.9 22.7 22.2 21.5
6500 14.2 16.8 18.8 20.2 21.2 21.9 22.2 22.2 22.0 21.5 20.8
6600 13.2 15.9 18.0 19.4 20.5 21.1 21.4 21.4 21.2 20.7 20.0
6700 12.2 15.0 17.1 18.6 19.7 20.3 20.7 20.7 20.4 19.9 19.2
6800 11.2 14.1 16.3 17.8 18.9 19.6 19.9 19.9 19.7 19.1 18.4
6900 10.2 13.2 15.4 17.0 18.1 18.8 19.1 19.1 18.9 18.3 17.6
7000 9.2 12.3 14.5 16.1 17.3 18.0 18.3 18.3 18.1 17.5 16.7
7100 8.2 11.3 13.6 15.3 16.4 17.2 17.5 17.5 17.3 16.7 15.9
7200 7.2 10.4 12.7 14.4 15.6 16.3 16.7 16.7 16.5 15.9 15.0
7300 6.1 9.4 11.8 13.6 14.8 15.5 15.9 15.9 15.6 15.0 14.2
7400 5.1 8.4 10.9 12.7 13.9 14.7 15.1 15.1 14.8 14.2 13.3
7500 4.0 7.4 9.9 11.8 13.0 13.8 14.2 14.3 14.0 13.3 12.4
7600 2.0 6.4 9.0 10.9 12.2 13.0 13.4 13.4 13.1 12.5 11.6
7700 1.8 5.4 8.0 10.0 11.3 12.1 12.5 12.6 12.2 11.6 10.7
7800 0.7 4.4 7.1 9.0 10.4 11.2 11.7 11.7 11.4 10.7 9.7
7900 -0.4 3.3 6.1 8.1 9.5 10.4 10.8 10.8 10.5 9.8 8.8
8000 -1.5 2.3 5.1 7.2 8.6 9.5 9.9 9.9 9.6 8.9 7.9
8100 -2.7 1.2 4.1 6.2 7.7 8.6 9.0 9.0 8.7 8.0 7.0
8200 -3.8 0.2 3.1 5.3 6.7 7.7 8.1 8.1 7.8 7.1 6.0

X-41
GEK 97310
VOLUME I
ADDENDUM X
Table 9. CORRECTIONS FOR LUBE PRESSURE LIMITS USING OIL,
MIL-L-23699 - Continued
(RPM)
100 110 120 130 140 150 160 170 180 190 200
8300 -5.0 -0.9 2.1 4.3 5.8 6.7 7.2 7.2 6.9 6.2 5.1
8400 -6.1 -2.0 1.1 3.3 4.8 5.8 6.3 6.3 5.9 5.2 4.1
8500 -7.3 -3.1 0.0 2.3 3.9 4.9 5.3 5.4 5.0 4.3 3.1
8600 -8.5 -4.2 -1.0 1.3 2.9 3.9 4.4 4.4 4.1 3.3 2.1
8700 -9.7 -5.3 -2.1 0.3 1.9 3.0 3.5 3.5 3.1 2.3 1.2
8800 -11.0 -6.5 -3.1 -0.7 0.9 2.0 2.5 2.5 2.1 1.3 0.1
8900 -12.2 -7.6 -4.2 -1.8 -0.1 1.0 1.5 1.6 1.2 0.4 -0.9
9000 -13.4 -8.8 -5.3 -2.8 -1.1 0.0 0.6 0.6 0.2 -0.6 -1.9
9100 -14.7 -9.9 -6.4 -3.8 -2.1 -1.0 -0.4 -0.4 -0.8 -1.7 -2.9
9200 -16.0 -11.1 -7.5 -4.9 -3.1 -2.0 -1.4 -1.4 -1.8 -2.7 -4.0
9300 -17.3 -12.3 -8.6 -6.0 -4.1 -3.0 -2.4 -2.4 -2.8 -3.7 -5.0
9400 -18.6 -13.5 -9.8 -7.1 -5.2 -4.0 -3.4 -3.4 -3.8 -4.7 -6.1
9500 -19.9 -14.7 -10.9 -8.2 -6.2 -5.0 -4.5 -4.4 -4.9 -5.8 -7.2
9600 -21.2 -16.0 -12.1 -9.3 -7.3 -6.1 -5.5 -5.4 -5.9 -6.8 -8.2
9700 -22.5 -17.2 -13.2 -10.4 -8.4 -7.1 -6.5 -6.5 -7.0 -7.9 -9.3
9800 -23.9 -18.4 -14.4 -11.5 -9.5 -8.2 -7.6 -7.5 -8.0 -9.0 -10.4
9900 -25.2 -19.7 -15.6 -12.6 -10.6 -9.3 -8.6 -8.6 -9.1 -10.1 -11.5
10000 -26.6 -21.0 -16.8 -13.8 -11.7 -10.4 -9.7 -9.7 -10.2 -11.2 -12.7
Corrected Pressure 55-4.2 = 50.8 psig (350.5 kPa)

X-42
GEK 97310
VOLUME I
ADDENDUM Y
ADDENDUM
7LM2500-GE-MG

GEK 97310
VOLUME I
ADDENDUM Y
TABLE OF CONTENTS
1-0 INTRODUCTION....................................................................................... Y-3

2-0 REFERENCE DATA .................................................................................. Y-3
3-0 INSTALLATION DRAWINGS.................................................................. Y-3
4-0 EQUIPMENT DESCRIPTION ................................................................. Y-4
5-0 INSTRUMENTATION AND SUPPLY REQUIREMENTS ................... Y-4
6-0 SERVICE REQUIREMENTS ................................................................... Y-4
6-1.1 Natural Gas ................................................................................................... Y-4
7-0 OPTIONAL HARDWARE KITS - 7LM2500-GE-MG ........................... Y-6
8-0 GAS GENERATOR OPERATION ........................................................... Y-6
8-1.1 Performance Ratings and Operating Limits.................................................. Y-6
8-1.2 Performance Ratings ..................................................................................... Y-7
8-1.3 Operating Limits ........................................................................................... Y-15
8-2 INITIAL OPERATION .............................................................................. Y-15
8-2.1 General .......................................................................................................... Y-15
8-2.2 Special Instrumentation................................................................................. Y-15
8-2.3 Preparation .................................................................................................... Y-19
8-2.4 Gas Generator and Associated Equipment Check List ................................. Y-19
8-2.5 Governor and Manual Control Check........................................................... Y-19
8-2.6 Start-Up and Checkout.................................................................................. Y-20
8-2.7 Ignition Check............................................................................................... Y-21
8-2.8 Motoring........................................................................................................ Y-21
8-2.9 False Start...................................................................................................... Y-23
8-2.10 Governor Check ............................................................................................ Y-23
8-2.11 Gas Prestart ................................................................................................... Y-23
8-2.12 Manual Start and Operation .......................................................................... Y-23
8-2.13 Operation to Maximum Power...................................................................... Y-23
8-2.14 Automatic Operation..................................................................................... Y-24
8-3 NORMAL OPERATION............................................................................ Y-24
8-3.1 General .......................................................................................................... Y-24
8-3.2 Interlocks....................................................................................................... Y-29
8-3.3 Operation....................................................................................................... Y-29
8-4 EMERGENCY OPERATION ................................................................... Y-30
8-4.1 Emergency Shutdown ................................................................................... Y-30
8-4.2 Post Shutdown Fire ....................................................................................... Y-30
8-5 SPECIAL GAS GENERATOR CONSTRAINTS.................................... Y-30
8-5.1 General .......................................................................................................... Y-30
8-5.2 Overtemperature............................................................................................ Y-30

Y-1
GEK 97310
VOLUME I
ADDENDUM Y
8-5.3 Lube Oil Supply Pressure ............................................................................. Y-31

8-5.4 High Speed Stall............................................................................................ Y-31
8-5.5 Starter Duty Cycle - Air, Natural Gas, or Hydraulic..................................... Y-31
8-5.6 Re-Start Following High Power Trip ............................................................ Y-31
8-5.7 Windmilling .................................................................................................. Y-31
Figure Title Page
1 Transient Temperature Limits (Typical) ....................................................... Y-8

2 Lube Pump Discharge Pressure vs. Gas Generator Speed using Lube Oil,
MIL-L-23699, for Gas Generators Equipped with L21808 Speed Sensor.......... Y-9
3 Deleted
4 Deleted
5 Deleted
6 Deleted
7 Speed Sensor Output Scale Reading - L21808P06 ....................................... Y-11
8 7LM2500-GE Acceleration and Deceleration
Fuel Flow Requirements (Sheet 1 of 3) ........................................................ Y-12
LIST OF TABLES
Table Title Page
1 INSTRUMENTATION CONNECTIONS-7LM2500-GE-MG .................... Y-4

2 SUPPLY SERVICE CONNECTIONS - 7LM2500-GE-MG........................ Y-5
3 GAS GENERATOR OPERATING LIMITS ................................................ Y-16
4 PRESTART CHECKS .................................................................................. Y-22
5 START-UP AND OPERATION.................................................................... Y-24
6 GAS GENERATOR SHUTDOWN .............................................................. Y-28
7 EMERGENCY SHUTDOWN...................................................................... Y-32
8 DELETED
9 DELETED
10 DELETED
11 DELETED

Y-2
GEK 97310
VOLUME I
ADDENDUM Y
The information contained herein describes the High Pressure Turbine Nozzle, 68 (31)
7LM2500-GE-MG model gas generator basic Stg 1
configuration and control system differences. High Pressure Turbine Nozzle, 127 (58)
In addition, the coverage of reference data, Stg 2
instrumentation and supply connections, spe- Turbine Mid Frame 530 (240)
kits and the complete gas generator operating Variable Stator Actuating 19 (9)
instructions for the 7LM2500-GE-MG model Mech
are included. Outside Piping and Bracketing 278 (126)
2-0 REFERENCE DATA. DRAWING LIST

Drawing No.
EQUIPMENT
Gas Generator Installation L31705
Gas Generator Assembly Drawing
(General Electric Co., Cincinnati, Ohio) Fuel System Flow Diagram L24327
Model No. 7LM2500-GE-MG Lubrication System Flow Dia- L24007
Dwg. No. L25250G17 or G26 gram
PERFORMANCE RATING
Refer to paragraph 8-1.1 Gas Generator Assembly L25250G17
Drawing or G26
GAS GENERATOR WEIGHTS
The average weights of the major gas genera-
tor components are: A complete set of installation drawings has
been provided for initial installation. For addi-
Component Wt-Lbs/(Kg) tional information contact General Electric
Gas Generator 4212 (1911) Company, M&I CS/PS.
Combustor 120 (54)

Y-3
GEK 97310
VOLUME I
ADDENDUM Y
4-0 EQUIPMENT DESCRIPTION. b. The temperature of the gas must be in
the range of 20°F (-6.7°C) above the saturated
The 7LM2500-GE-MG is a natural gas fueled, vapor temperature as a minimum, and 350°F
marinized gas generator. (177°C) as a maximum. If the temperature is
5-0 INSTRUMENTATION AND SUP- not repeatable on a day-to-day basis, it will be
PLY REQUIREMENTS. (See Tables 1 and necessary to change the starting fuel adjust-
2.) ment to adjust the supply pressure to the
engine to maintain a constant BTU-per-cubic-
6-0 SERVICE REQUIREMENTS. foot supply. The maximum fuel flow required
6-1.1 Natural Gas. is 13,500 pph (6123 kg/h) with a lower heating
value of 19,000 Btu/lb
natural gas fuel manifold on the gas generator
is 355±5 psig (2448±35 kPa) maximum.
Table 1. INSTRUMENTATION CONNECTIONS-7LM2500-GE-MG

E2 Power turbine inlet temperature MS3106R-14S-9S
E-3 A-sump RTD/TC MS3106R12S-3S/W
E4 B-sump RTD/TC MS3106R12S-3S/W
E5 C-sump RTD/TC MS3106R12S-3S/W
E6 Accessory gearbox RTD/TC MS3106R12S-3S/W
E10 Starter speed switch (optional) MS3106R-10SL-4S
E11 Lube supply RTD/TC MS3106R12S-3S/W
A23 CDP pressure tap .500-20UNJF-3B
L7 Lube scavenge pressure tap AN818-4C or MS9197-D4
-- Remote reading variable stator vane position indicator*
NOTE
For all other instrumentation connections, refer to applicable Installation Drawings, pro-
vided with gas generator.
*There is no mechanical interface for VSV position indicator

Y-4
GEK 97310
VOLUME I
ADDENDUM Y
Table 2. SUPPLY SERVICE CONNECTIONS - 7LM2500-GE-MG

CAUTION
F1 Natural gas supply 2 inch line from Fuel Control Unit to Gas Generator
Fuel Manifold
AN818-24C or MS9197-24
AN818-16C or MS9197-16
MS9197-20
AN818-16C or MS9197-16
A4 Inlet duct seal flange (if used)
A10 CDP seal leakage port No. 1 (if used) 2-inch line
A11 CDP seal leakage port No. 2 (if used) 2-inch line
A12 Air/Oil Separator discharge port 3 inch line from air/oil separator to atmospheric vent
A26A Aspirator Air Supply GE Tube flange PN 9643M28P32 and V band clamp
PN 9014M45P32
Gas Generator Inlet Duct AN818-12C or MS9197-12
NOTE
For all other supply connections needed refer to applicable Installation Drawings, pro-
vided with gas generator.

Y-5
GEK 97310
VOLUME I
ADDENDUM Y
7LM2500-GE-MG.
detailed list of optional kits available for this GAS GENERATOR UNTIL A THOR-
particular gas generator model. OUGH INVESTIGATION HAS
8-0 GAS GENERATOR OPERATION. HOT STARTS, COMPRESSOR
gas generator operating procedures and limits THOROUGH INVESTIGATION.
pany for the 7LM2500-GE-MG Gas IN UNDUE STRESS BEING
Generator. IMPOSED ON GAS GENERATOR
b. The instructions are intended to ATE OR SUBSEQUENT DESTRUC-
provide operating personnel with the TIVE FAILURE OF THE GAS
information required to operate the gas GENERATOR AND INJURY TO
generator. They pertain to routine and emer- PERSONNEL.
gency conditions and procedures. When a
fault exists, refer to Volume I, Chapter 5, 8-1.1 Performance Ratings and Operating
TROUBLESHOOTING. Limits.

equipment or contingency to be met in connec- to the gas generator. The driven unit
tion with the operation of the gas generator. ratings/limits may be lower in some
Refer requests for additional information to the cases and shall take precedence over
General Electric Company; Marine and Indus- the gas generator manual limits.
trial Engines and Service Division; Cincinnati,
Ohio 45215-6301.

Y-6
GEK 97310
VOLUME I
ADDENDUM Y
8-1.2 Performance Ratings. c. Typical transient fuel flow require-
a. The rated performance of the ule, figure 8.
7LM2500-GE-MG gas generator in the new
and clean condition is as follows: NOTE
The acceleration fuel schedule shown
Isentropic Gas Horsepower
in figure 8 is provided as an example
- Continuous 33700 transient fuel flow curve only. Refer to
- Maximum 36600 packager’s manual for the LM2500-
GE-MG gas model transient fuel flow
Heat Rate, BTU/IGHP-Hr requirements.
- Average, Continuous 6060
- Average, Maximum 6054 d. Acceleration fuel rates greater than
those shown in Figure 8 may result in over-
temperature and possible stall of the gas gener-
Inlet Air Temperature 59°F (15°C) ator. Acceleration fuel rates lower than those
Altitude Sea Level shown can result in “hung” starts in the below
Inlet Losses 0” H2s idle speed range.
Exhaust Losses 0” H2s e. Above the idle speed point, low accel-
Relative Humidity 0% eration fuel rates wi11 not harm the gas gener-
ator and will only result in slower acceleration
Compressor Bleed 0
times.
Accessory Power Extraction 0
Hot Effective Exhaust Area 208.5 sq in f. For normal accelerations from idle to
Exhaust Gas Temperature power settings the changes should be made
T5.4 Avg @ 1461°F section repairs and the life of the gas genera-
Continuous Rating (793.9°C) tor; a time of 2 to 3 minutes is reasonable.
T5.4 Avg @ 1547°F
Maximum Rating (841.7°C) g. The fuel rates shown on the curve will
give starting times to 5000 rpm idle of 60 to
90 seconds and accelerations from idle to max-
b. Starting fuel flow for the
imum power of 15 seconds.
7LM2500-GE-MG model gas generator is nor-
mally set by the minimum stop on the gas fuel
h. Normal decelerations from maximum
metering valve. The proper fuel flow setting
2 to 3 minutes; this will enhance the time
basis, is 10.45 X 106 +0.46 x 106 BTU/ hour between hot section repairs and the life of the
for ambient temperatures of -65°F (-54°C) to gas generator.
+130°F (54°C), and is based on commencing
fuel and ignition at 1200 ± 100 rpm.

Y-7
GEK 97310
VOLUME I
ADDENDUM Y
Figure 1. Transient Temperature Limits (Typical)

Y-8
GEK 97310
VOLUME I
ADDENDUM Y
Figure 2. Lube Pump Discharge Pressure vs. Gas Generator Speed using Lube Oil,
MIL-L-23699, for Gas Generators Equipped with L21808 Speed Sensor

Y-9
GEK 97310
VOLUME I
ADDENDUM Y

Y-10
GEK 97310
VOLUME I
ADDENDUM Y
Figure 7. Speed Sensor Output Scale Reading - L21808P06

Y-11
GEK 97310
VOLUME I
ADDENDUM Y
Figure 8. 7LM2500-GE Acceleration and Deceleration Fuel Flow Requirements (Sheet 1 of 3)

Y-12
GEK 97310
VOLUME I
ADDENDUM Y

Y-13
GEK 97310
VOLUME I
ADDENDUM Y

Y-14
GEK 97310
VOLUME I
ADDENDUM Y
8-1.3 Operating Limits. Refer to Table 3. b. Required for Monitoring and
Troubleshooting:
NOTE
If any operating limit is exceeded, ver- Fuel Manifold pressure sensor 0-400 psig
ify instrumentation accuracy before (0-2758 kPa)
troubleshooting or inspecting gas Compressor inlet total pres- 10-16 psia
generator. sure sensor (69-110 kPa)
8-2 INITIAL OPERATION. (0-2758 kPa)
Fuel supply temperature -65-250°F
(-54 to 121°C)
gas generator replacement or major mainte- Gas generator inlet air -65-150°F
nance on the system. temperature (-54 to 66°C)
8-2.2 Special Instrumentation. pressure (0-517 kPa)
Remote reading variable vane -5° to +45°
a. Required for Operation. indicator
Gas generator speed sensor 0-11,000 rpm Starter air supply pressure 0-50 psig
Lube oil scavenge temperature 0-400°F
sensors (A-, B-, C-sumps (-18 to 204°C) High pressure recoup pressure 0-150 psig
and accessory gearbox) (0-1035 kPa)
Vibration indicators gas 0-4 in/sec or
generator 0-10 mil DA
(0-690 kPa)
perature (T5.4) (-18 to 1093°C)
(0-1380 kPa)

Y-15
GEK 97310
VOLUME I
ADDENDUM Y
Alarm/ Normal
NOTE
Lubrication Gas generator Alarm 8 psig ± 1 psig 20-60 psig Bypass until
System - lube supply (55 kPa ± 6.9 kPa) (138-414 kPa) 4500 rpm
Settings and pressure below 8000 rpm
above 8000 rpm
(41 kPa ± 6.9 kPa) (138-414 kPa) 4500 rpm
Gas generator Alarm 110 psig ± 10 psig 10-100 psig Scavenge dis-
charge pressure shall not exceed
180 psig
(1242 kPa)
Gas generator Alarm 180°-220°F 140°-160°F Normal Operat-
lube supply tem- (82°-104°C) (60°-71°C) ing range reflects
perature temperature
expected during
operation above
idle speed
Gas generator Alarm 290°-310°F 160°-275°F Normal operating
lube scavenge (143°-154°C) (71°-135°C) range reflects tem-
temperatures- perature expected
four sensors Trip 330°-350°F during operation
Fuel System Fuel manifold 350 psig Supply pressure as
Natural Gas pressure (2413 kPa) reflected at the
fuel manifold in-
let on the gas
generator

Y-16
GEK 97310
VOLUME I
ADDENDUM Y
Alarm/ Normal
Starting Starter 38-42 psig Starting pressure
System supply pressure (262-290 kPa) requirement based
on gas generator
starter torque
requirements
fuel and ignition
fuel and ignition for start after
used)
simultaneously
with start
initiation
Starting time to Trip 4500 ± 200 rpm Activate 90 sec-
simultaneously
with start initia-
tion. De-energize
ignition, fuel sys-
tem and starter air
supply
gize fuel and igni-
tion systems and
starter air supply

Y-17
GEK 97310
VOLUME I
ADDENDUM Y
Alarm/ Normal
Exhaust Gas Failure to Trip 380-420°F 0-900°F Trip if tempera-
Tempera- light-off (193-216°C) (18°-482°C) ture does not
ture T54) reach 400°F
(204°C) within
10 seconds after
fuel and ignition
are applied
Overtemperature Control 1510°F (821°C) 0-1510°F
limit (0-821°C)
Alarm 1515°F (824°C)
Trip 1575°F (857°C)
NOTE
The above T5.4 control limit is the basic field operation control parameter or value to be
used in the control system design. An alarm value or limit is given only to provide margin
so that the alarm will not annunciate when operating at the control limit. The trip value or
limit is considered a safety limit above which the gas generator should never be operated.
All values or limits are for a gas generator rated at 33,700 IGHP and having an AE8 of
208.5 in2.
Loss of Combustor Close and
Flame flame lock out fuel shut-
off valve upon
loss of flame
Vibration Gas Alarm 4±1 mil DA 0-3 mils Continuous opera-
Generator tion above 4 mils
Trip 7±1 mil DA DA
is to be avoided
Thrust Recoup Recoup pressure Preferred operat-
Balance Pressure 0-150 psig ing range depicted
Pressure (0-1035 kPa) as corrected
P5.4: 0-60 psig recoup pressure vs
(0-414 kPa) corrected exhaust
gas total pressure
(P54) (See Vol-
ume I Chapter 5)

Y-18
GEK 97310
VOLUME I
ADDENDUM Y
8-2.3 Preparation. The gas generator and j. Gas Generator inlet air area ________
associated systems must be inspected and free of foreign objects. Inlet
checked out for proper installation and opera- screen secure
k. Gas Generator compressor ________
8-2.4 Gas Generator and Associated Equip- rear frame leakage ports, struts
ment Check List. Complete the following 7 and 10, are open (not
checklist. capped)
a. Gas Generator Assembly S/N ________ 1. Continuous lube supply starter ________
is initially serviced per Pack-
b. Mounting base secured to ________
ager’s manual
foundation
m. Lube oil storage tank serviced ________
c. Intake air and exhaust gas ________
to full level
n. Lube oil supply valves open ________
d. Gas generator support mounts ________
and links in place and secure o. All filters are serviced per ________
e. All service connections made ________ Packager’s manual
and secure p. T5.4 thermocouple system ________
f. All lines have been flushed ________ functioning properly
per Packager’s manual q. Ignition system operative ________
g. All instrumentation connec- ________ r. Compressor inlet total pres- ________
tions made and secure sure probe aligned properly
h. All accessories are secure per ________ and free of damage
Packager’s manual s. Variable stator system secure ________
i. Gas Generator assembly free ________ t. Required checks and inspec- ________
of loose objects and all lines/ tions specified in Packager’s
electrical leads connected manual for gas generator con-
trol have been performed

Refer to Packagers manual.

Y-19
GEK 97310
VOLUME I
ADDENDUM Y
LATED GLOVES AS
NECESSARY.
OPERATING.
SHUT DOWN.
ENCLOSURE OR IN THE
ENTRY SHOULD BE
MOTORING THE GAS
TURBINE.
FIELD SERVICE FOR A REPRE- a. When entering enclosure during gas
SENTATIVE WHO IS TRAINED generator operation wear proper ear protection.

PROCEDURES.
e. Perform false start per paragraph 8-2.9.
ENCLOSURE SHALL BE SHUT f. Perform governor check per
ENCLOSURE DOOR.
GAS TURBINE IS OPERATING, i. Operate to maximum power per
BE FOLLOWED.

Y-20
GEK 97310
VOLUME I
ADDENDUM Y
8-2.7 Ignition Check. f. If an audible report is not heard on
WARNING tem to isolate the problem, and take appropri-
• ASSURE POWER TO IGNITION ate corrective action.
SYSTEMS IS OFF WHEN DIS- 8-2.8 Motoring. After all preliminary checks
CONNECTING IGNITION have been completed and lines flushed, gas
EXCITER INPUT LEAD. TAG generator can be motored as follows:
SWITCH OUT OF SERVICE TO
PRECLUDE INADVERTENT a. Make ignition and natural-gas supply
ACTIVATION. systems inoperative as follows:
• ASSURE FUEL VALVES ARE (1) Disconnect power supply to igni-

CLOSED THROUGHOUT THIS tion unit.
PROCEDURE. (2) Close natural-gas manual shutoff
a. To clear combustor of any residual valve to fuel control unit.
fuel, motor gas generator for one minute; b. Depress MOTORING pushbutton. Gas
allow gas generator to coast down. generator will start to rotate. If it does not,
b. Disconnect number one ignition exciter refer to Packager’s manual for supply pressure
input lead at exciter. Temporarily secure input to starter.
lead away from the exciter. c. Hold MOTORING pushbutton closed
until gas generator speed stabilizes and check
c. Turn on electrical power to the ignition for oil pressure. If there is no indication of oil
system (No. 2 ignition exciter energized). An pressure, release MOTORING pushbutton;
audible report (approximately two sparks per while gas generator is coasting down, loosen
second) should be heard when the No. 2 spark oil fittings at lube pump to bleed air from sys-
igniter fires. tem. Starter should motor gas generator to
system. Reconnect input lead to exciter and d. Repeat motoring and bleeding proce-
safety-wire connector. dure until an indication of oil pressure appears.
e. Repeat steps b, c and d, disconnecting
the No. 2 exciter.

Y-21
GEK 97310
VOLUME I
ADDENDUM Y
Item Requirements
Fuel valves Closed
Ignition Off
Oil tank level Full
Lube oil temperature Above +20°F (-7°C) for MIL-L-23699
pressure at manifold inlet 0
flow 0

Y-22
GEK 97310
VOLUME I
ADDENDUM Y
8-2.9 False Start. Perform false start as 8-2.13 Operation to Maximum Power.
follows:
CAUTION
manual gas valve closed, make automatic start MANUAL OPERATION MAY
of gas generator per Packager’s manual. ELIMINATE CERTAIN PROTEC-
b. Gas generator should go through nor- ITS SHALL NOT BE EXCEEDED.
of flame. a. Slowly increase manual control setting
(refer to Packager’s manual) to increase gas
8-2.10 Governor Check. Check governor sys- generator speed. After each 500 RPM increase,
tem per Packager’s manual. log all instrument readings, paying particular
8-2.11 Gas Prestart. Perform gas prestart as vibration. If variable stator system is not
follows: within limits, adjust it per work package
a. With ignition system disabled, but with sult the local General Electric Company repre-
manual gas valve open and governing system sentative.
operating, make automatic start of gas genera-
tor per Packager’s manual. b. Operate gas generator up to rated
power, if possible, but do not exceed exhaust
b. Gas generator should accelerate to gas temperature (T5.4) limit or corrected speed
light-off speed (1100 to 1300 rpm). Fuel valve limit (10,050 RPM). Hold at this power setting
should open and fuel manifold pressure should until all temperatures stabilize. If governing
be approximately 3 psig (21 kPa). Adjust fuel system is unstable, adjust per Packager’s
supply if required. Start will then abort manual.
c. Allow gas generator to coast to stop; stabilize. Refer to Table 5, step 9.
gas from gas generator. Continue to motor for d. Reduce gas generator speed to idle.
60 seconds to purge fuel from the gas After stabilizing for three minutes, record all
generator. instrument readings. Refer to Table 6, step 2.
8-2.12 Manual Start and Operation. Perform e. Check fail-safe section of control sys-
manual start per Packager’s manual with fuel tem per Packager’s manual.
Refer to Table 5. f. After gas generator has been stabilized

Y-23
GEK 97310
VOLUME I
ADDENDUM Y
8-2.14 Automatic Operation. Check automatic h. Correct any leaks observed.
operation per Packager’s manual.
j. Check gas generator and mounting sys-
b. Accelerate to rated power. tem for loose parts; tighten as necessary.
c. Log all instrument readings. 8-3 NORMAL OPERATION.
d. Decelerate to idle. 8-3.1 General. Normal operation is the rou-

e. Check for fuel or lube oil leaks. directions in the use of manual or automatic
operation for normal operation refer to Pack-
f. After a total of five minutes at idle, ager’s manual.
shut down gas generator.


1. Assure that prestart checks Installations using constant

are completed per Table 4 power control mode should
consult the contract docu-
ments or the General Elec-
tric Company for
determining alarm and trip
settings which are unique to
each application
CAUTION
IF T5.4 RAPIDLY APPROACHES OR EXCEEDS SPECIFIED LIMITS (CONTRACT
DOCUMENTS) ABORT START.
NOTE
2. Open starter shutoff valve Gas generator rotation Close valve, determine fault
and correct

Y-24
GEK 97310
VOLUME I
ADDENDUM Y

CAUTION
IF PURGE CYCLE IS REQUIRED, NGG IN STEP 3 MAY BE REVISED. (REFER TO
8.2-11C FOR PURGE CYCLE.)
3. At 1100 to 1300 RPM NGG
a. Ignition on
(21 kPa). See paragraph
8-2.11, step b
c. Note time to lightoff 10 seconds maximum Abort start-automatic shut-
204°C) cause
4. Note time to 4500 ± 200 90 seconds maximum from Troubleshoot system and
RPM starter initiation take corrective action if
to reach 4300 RPM
5. At 4300 to 4700 RPM NGG

should close supply
automatically
c. Check lube discharge Indication Recheck at idle
pressure
6. Note time to 5000 RPM NGG 60 to 90 seconds typical

Y-25
GEK 97310
VOLUME I
ADDENDUM Y


a. Oil Pressure See applicable figures in Alarm at 8 ± 1 psig
Chapter 5 (55 ± 6.9 kPa).
Trip at 6 ± 1 psig
(41 ± 6.9 kPa)
b. NGG 5000 + 50 RPM Adjust

Table 7
d. Gas generator vibration 0 to 3 mils DA Alarm set at 4 mils. Auto-
e. Compressor inlet tem- Approximately equal to out- Troubleshoot sensing and
as required
leaks
sient operation
b. NGG 0 - 10,000 RPM *
NOTE
c. Oil Pressure See applicable table and fig- Shutdown and investigate
ure in Chapter 5
d. Scavenge oil temperature 160°F - 275°F Shutdown and investigate
(71°C - 135°C)

Y-26
GEK 97310
VOLUME I
ADDENDUM Y

e. Gas generator vibration 0-3 mils DA Shutdown and investigate

f. Fuel manifold pressure 360 psig (2483 kPa) max **
g. Fuel inlet temperature -65° to 150°F (-54° to 66°C) *
j. T2 Approximately equal to out- **
k. Stator vane angle See applicable figure in Correct as required per
WP 118 00 and per figure 7 WP 118 00
its, shutdown, and investigate.

Y-27
GEK 97310
VOLUME I
ADDENDUM Y


following:
a. Lube discharge pressure See applicable figure in Alarm at 8 ± 1 psig
Trip at 6 ± 1 psig
(41 ± 6.9 kPa)
b. Lube supply temperature 140° - 160°F Alarm at 180° - 220°F
(60° - 71°C) (82° - 104°C)
c. NGG 4950 - 5050 RPM Adjust
d. T5.4 1000°F (538°C) maximum Troubleshoot and take cor-

rective action
e. Gas generator vibration 0-3 mils (DA) Alarm set at 4 mils. Auto-
f. Fuel inlet temperature -65° to 150°F
(-54° to 66°C)
g. Scavenge oil filter ∆P Refer to packager’s manual
h. Lube oil supply filter ∆P Refer to packager’s manual
i. Lube scavenge tempera- 160-275°F Alarm at 290°-310°F
tures (A, B, C, and AGB) (71-135°C) (143-154°C)
Trip at 330-350°F
(166-177°C)
5 minutes, close fuel valves (204°C); NGG decelerates supply
and stops
4. Observe T5.4 for 3 minutes 700°F (371°C) maximum Motor gas generator. Con-
ature decreases

Y-28
GEK 97310
VOLUME I
ADDENDUM Y
8-3.2 Interlocks. Refer to Packager’s manual • THE ENCLOSURE DOOR
for description of interlocks which affect gas SHALL BE KEPT OPEN. IF THE
generator operation. GAS TURBINE IS OPERATING,
8-3.3 Operation. TIONED AT THE ENCLOSURE
WARNING
BE FOLLOWED.
BINE ENCLOSURE, THE FOLLOW- • ALLOW THE GAS TURBINE TO
ING REQUIREMENTS SHALL BE COOL DOWN. AVOID CON-
MET: TACT WITH HOT PARTS, AND
• THE GAS TURBINE SHALL BE LATED GLOVES AS NECES-
SHUT DOWN. SARY.

ENTRY SHOULD BE
REQUIRED DURING ENGINE • DO NOT REMAIN IN THE
OPERATION, CONTACT GE ENCLOSURE OR IN THE
FIELD SERVICE FOR A REPRE- PLANE OF ROTATION OF THE
SENTATIVE WHO IS TRAINED STARTER WHEN STARTING OR
TO ENTER THE ENCLOSURE MOTORING THE GAS TUR-
UNDER SUCH CONDITIONS. BINE.
• THE FIRE EXTINGUISHING a. When entering enclosure during gas

SYSTEM SHALL BE MADE generator operation, wear proper ear
INACTIVE ACCORDING TO protection.
DURES. b. Start and operate the gas generator per
• SECONDARY AIR TO THE Table 3.
OFF. HIGH SECONDARY AIR- c. Shut down the gas generator per
FLOW MAY PREVENT OPEN- Table 6.
ING OR CLOSING THE
ENCLOSURE DOOR. d. Emergency shut down the gas, genera-
tor per Table 7.

Y-29
GEK 97310
VOLUME I
ADDENDUM Y
e. Refer to paragraph 5-3.30 and 5-3.31, 8-5 SPECIAL GAS GENERATOR
pressure characteristics. (See tables V-21C,
V-21D, V-21G, and V-21H, and figures 5-32C, 8-5.1 General. Under normal operating con-
5-32D, 5-32G, 5-32H, 5-32K, 5-32M, 5-32P, ditions, the gas generator is constrained by the
and 5-32R.). operating limits published in the limits table.
f. Idle lube oil pressure is 29 psig shutdown or “trip” level should not be
(200 kPa) maximum after five minutes stabili- practiced.
zation for MIL-L-7808 and 50 psig (345 kPa)
for MIL-L-23699. In the event that any of the following situations
g. The corrected operating pressure of the
or limitation must be followed in order to
assure the gas generator continued normal
operation. These events are either not detected
gas generator speed and 150°F (66°C) at lube
or not prevented by the customary protective
pump discharge temperature. Oil pressure
devices of control systems.
measured at conditions other than standard
• Overtemperature During Starting
applicable table in Chapter 5.
8-4 EMERGENCY OPERATION. • Lube Oil Pressure
8-4.1 Emergency Shutdown. • High Speed Stalls

a. In an emergency, the gas generator may • Starter Duty Cycle
ing the fuel valve. However, this should only • Re-Start Following High Power Trip
will decrease life of gas generator. • Gas Generator Windmilling
per Table 7. 8-5.2 Overtemperature. During starting and
acceleration to idle, the cooling airflow to the
8-4.2 Post Shutdown Fire. components of the gas generator hot section
are not sufficient to protect the metals at T5.4
a. During a normal shutdown, the exhaust
alarm and trip levels specified in the limits
gas temperature should decrease. If, during
table. A lower T5.4 limit is therefore estab-
ture increases instead of decreases, it indicates lished, with higher levels acceptable provided
that combustion is still taking place because of they exist for limited times as depicted on the
a leaking fuel valve. (A slight temperature curve in figure 1 titled “Transient Temperature
increase after rotation stops is normal.) Make Limits”. This must be monitored by the opera-
certain fuel is shut off, and motor the gas gen- tor. The overtemperature inspection called for
erator. This will blow out the fire. As soon as by entry into area B requires hot section disas-
temperature decreases to normal, discontinue sembly and inspection in a qualified facility.
motoring.
Y-30
GEK 97310
VOLUME I
ADDENDUM Y
8-5.3 Lube Oil Supply Pressure. The lube oil c. There is no duty cycle limit on the
supply pressure limits given in the limit table hydraulic starter as long as the oil temperature
are “distress”’ limits. Protective devices can- is maintained below 140°F (60°C).
not reliably monitor supply pressure because
the proper pressure is dependent on gas gener- 8-5.6 Re-Start Following High Power Trip.
ator speed, oil type and oil temperature. An In the event that re-start of the gas generator is
operator must therefore derive a corrected oil required within 1 minute to 2 hours following
pressure as directed in the appropriate pressure a trip or rapid shutdown from high power, after
correction table in Chapter 5 to determine if coastdown of HPC rotor, a 5 minute motoring
the lube system is performing within the high- at 2000 - 2500 rpm should precede the fire up.
low limits stated. The objective is to cool the high pressure tur-
bine rotor so that blade tips maintain clearance
8-5.4 High Speed Stall. Stalls incurred at gas with the more rapidly cooling case.
generator rotational speeds above 7500 rpm NOTE
can result in high pressure compressor blade
fracture. The gas generator can be operated Motoring at 2000-2500 rpm is recom-
after an inspection of the compressor stages 3 mended only for those gas generators
through 6 verifies that blade tip clanging has equipped with continuous lube starters.
not occurred. If tip clanging has occurred, fur- 8-5.7 Windmilling.
required, which necessitates blade removal a. Gas Generator. If the inlet system is
from the spool. such that air will be forced through the gas
generator when it is shut down, the gas genera-
8-5.5 Starter Duty Cycle - Air, Natural Gas, tor may rotate. The duration of gas generator
or Hydraulic. windmilling is limited by the lubricity of its
rotor bearings. The following defines these
a. Starting - Air or Natural Gas limits:
45 seconds on,
2 minutes off for any number of cycles (1) The gas generator may windmill
or 2 minutes on, 5 minutes off, for two weeks at speeds below 100 RPM, pro-
2 minutes on, vided each period is preceded by normal gas
21 minutes off for any number of generator operation.
cycles. (2) The gas generator may windmill
for up to five minutes at speeds between
b. Motoring - Air or Natural Gas 100 RPM and 1000 RPM provided each period
5 minutes on, is preceded by normal gas generator operation.
2 minutes off,
5 minutes on, 18 minutes off for any (3) Unlimited windmilling of the gas
number of cycles or 10 minutes on, generator is allowed at gas generator speeds
20 minutes off for any number of above 1000 RPM, provided the scavenge oil
cycles. (For 10 minutes of motoring, temperature is maintained below 340°F
maximum starter air inlet temperature (171°C). At these speeds the lube supply and
is 200°F.) scavenge systems are in normal operation.
Adequate cooling of the oil must be provided
at the higher free rotational speeds.

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CAUTION
THE ROTOR WILL FREE ITSELF AFTER A COOLING PERIOD OF 3 TO 4 HOURS.
1. Conditions permitting, decelerate gas gener- T5.4 drops below Manually shut off
ator to idle and close fuel valves 400°F (204°C) and fuel supply
NGG and NPT
decelerate
2. Observe T5.4 for 3 minutes after shutdowns 700°F (371°C) max Motor gas generator.
Continue motoring
until temperature
decreases
power setting greater than 1150°F (621°C)
has occurred, and a “hot restart” is required,
proceed as follows:
system can be cleared and the gas gener-
ator can be restarted within 1 minute
b. If a “hot restart” is performed between 1
minute and 2 hours following the emer-
gency shutdown, motor the gas genera-
tor at 2000-2500 rpm NGG for 5
then be accomplished

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ADDENDUM
7LM2500-GD-MG

GEK 97310
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ADDENDUM Z
TABLE OF CONTENTS
1-0 INTRODUCTION ......................................................................................... Z-3

2-0 REFERENCE DATA ..................................................................................... Z-3
3-0 INSTALLATION DRAWINGS .................................................................... Z-3
4-0 EQUIPMENT DESCRIPTION .................................................................... Z-3
5-0 INSTRUMENTATION AND SUPPLY REQUIREMENTS ...................... Z-3
6-0 SERVICE REQUIREMENTS ...................................................................... Z-6
6-1.1 Natural Gas. ..................................................................................................... Z-6
7-0 OPTIONAL HARDWARE KITS, 7LM2500-GD-MG ............................... Z-6
8-0 GAS GENERATOR OPERATION .............................................................. Z-6
8-1.1 Performance Ratings and Operating Limits..................................................... Z-7
8-1.2 Performance Ratings........................................................................................ Z-7
8-1.3 Operating Limits .............................................................................................. Z-8
8-2 INITIAL OPERATION................................................................................. Z-8
8-2.1 General............................................................................................................. Z-8
8-2.2 Special Instrumentation ................................................................................... Z-8
8-2.3 Preparation ....................................................................................................... Z-23
8-2.4 Gas Generator and Associated Equipment Check List .................................... Z-23
8-2.5 Governor and Manual Control Check.............................................................. Z-23
8-2.6 Start-up and Checkout...................................................................................... Z-24
8-2.7 Ignition Check.................................................................................................. Z-26
8-2.8 Motoring .......................................................................................................... Z-26
8-2.9 False Start......................................................................................................... Z-26
8-2.10 Governor Check ............................................................................................... Z-27
8-2.11 Wet Prestart ...................................................................................................... Z-27
8-2.12 Manual Start and Operation ............................................................................. Z-27
8-2.13 Operation to Maximum Power ........................................................................ Z-27
8-2.14 Automatic Operation........................................................................................ Z-27
8-3 NORMAL OPERATION .............................................................................. Z-32
8-3.1 General............................................................................................................. Z-32
8-3.2 Interlocks ......................................................................................................... Z-32
8-3.3 Operation ......................................................................................................... Z-32
8-4 EMERGENCY OPERATION ...................................................................... Z-33
8-4.1 Emergency Shutdown ...................................................................................... Z-33
8-4.2 Post Shutdown Fire .......................................................................................... Z-33
8-5 SPECIAL GAS GENERATOR CONSTRAINS ......................................... Z-37
8-5.1 General............................................................................................................. Z-37
8-5.2 Overtemperature .............................................................................................. Z-37
8-5.3 Lube Oil Supply Pressure ................................................................................ Z-37

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TABLE OF CONTENTS (cont.)
8-5.4 High Speed Stall .............................................................................................. Z-37

8-5.5 Starter Duty Cycle - Air or Natural Gas .......................................................... Z-37
8-5.6 Re-Start Following High Power Trip............................................................... Z-38
8-5.7 Windmilling ..................................................................................................... Z-38
Figure Title Page
1 Transient Temperature Limits .......................................................................... Z-9

2 Lube Pump Discharge Pressure vs. Gas Generator Speed
using Lube Oil, MIL-L-23699 ....................................................................... Z-10
3 Lube Pump Discharge Pressure vs. Gas Generator Speed using
Lube Oil, MIL-L-7808................................................................................... Z-11
4 Deleted
5 Deleted
6 7LM2500-GD Acceleration and Deceleration Fuel Flow Requirements ........ Z-13
LIST OF TABLES
Table Title Page
1 INSTRUMENTATION CONNECTIONS - 7LM2500-GD-MG..................... Z-4

2 SUPPLY SERVICE CONNECTIONS - 7LM2500-GD-MG .......................... Z-5
3 GAS GENERATOR OPERATING LIMITS ................................................... Z-20
4 PRESTART CHECKS ..................................................................................... Z-25
5 START-UP AND OPERATION ...................................................................... Z-28
6 GAS GENERATOR SHUTDOWN................................................................. Z-31
7 EMERGENCY SHUTDOWN......................................................................... Z-34
8 OIL PRESSURE CORRECTIONS FOR TEMPERATURE (MIL-L-7808)... Z-35
9 OIL PRESSURE CORRECTIONS FOR TEMPERATURE (MIL-L-23699). Z-36

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7LM2500-GD-MG model gas generator basic High Pressure Turbine Nozzle, 68 (31)
configuration and control system differences. Stg 1
In addition, the coverage of reference data, High Pressure Turbine Nozzle, 127 (58)
instrumentation and supply connections, spe- Stg 2
cial servicing requirements, optional hardware Turbine Mid Frame 530 (240)
kits and the complete gas generator operating
instructions for the 7LM2500-GD-MG model Variable Stator Actuating 19 (9)
are included. Mech
2-0 REFERENCE DATA.
DRAWING LIST
EQUIPMENT Drawing No.
Gas Generator Assembly Gas Generator Installation L31705

(General Electric Co., Cincinnati, Ohio) Drawing
Model No. 7LM2500-GD-MG Fuel System Flow Diagram L24327
Dwg. No. L21380G07 Lubrication System Flow L24007
Diagram
PERFORMANCE RATING
Refer to paragraph 8-1.1. Ignition Units L21454
Gas Generator Assembly L21380G07
GAS GENERATOR WEIGHTS Drawing
The average weights of the major gas genera- 3-0 INSTALLATION DRAWINGS.
tor components are: A complete set of installation drawings have
been provided.
Gas Generator 4212 (1911) 4-0 EQUIPMENT DESCRIPTION.
The 7LM2500-GD-MG is a natural gas fueled,
Inlet Gearbox 38 (17) marinized gas generator.
Compressor Front Frame 517 (235) 5-0 INSTRUMENTATION AND SUP-
PLY REQUIREMENTS.
See tables 1 and 2.
Combustor 120 (54)

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Table 1. INSTRUMENTATION CONNECTIONS - 7LM2500-GD-MG
E2 Power turbine inlet temperature MS3106R-14S-9S

E3 A-sump RTD/TC MS3106R12S-3S/W
E4 B-sump RTD/TC MS3106R12S-3S/W
E5 C-sump RTD/TC MS3106R12S-3S/W
E6 Accessory gearbox RTD/TC MS3106R12S-3S/W
E10 Starter speed switch (optional) MS3106R-10SL-4S
E11 Lube supply RTD/TC MS3106R12S-3S/W
L7 Lube scavenge pressure tap AN818-4C or MS9197-04
NOTE
For all other instrumentation connections, see the Installation Drawings, provided
with gas generator.

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ADDENDUM Z
Table 2. SUPPLY SERVICE CONNECTIONS - 7LM2500-GD-MG

CAUTION
L1 Oil Supply 1-1/4 inch line to Lube Pump on Gas
Generator AN818-24C or MS9197-24
Filters AN818-16C or MS9197-16
AN818-20C or MS9197-20
Generator AN818-16C or MS9197-16
spheric vent or to exhaust duct (flame arrestor)
A16 Aspirator Air Supply GE tube flange PN 9643M28P32 + V band
clamp PN 9014M45P32
or MS9197-12
S1A Waterwash manifold (Alternate)
NOTE
For all other instrumentation connections, see the Installation Drawings, provided
with gas generator.

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ADDENDUM Z
6-0 SERVICE REQUIREMENTS. 7-0 OPTIONAL HARDWARE KITS,
7LM2500-GD-MG.
6-1.1 Natural Gas.
a. The required supply pressure to the detailed list of optional kits available for this
fuel manifold on the gas generator is 305 psig particular gas generator model.
(2103 kPa) maximum.
8-0 GAS GENERATOR OPERATION.
b. The temperature of the gas supply at
the fuel manifold connection on the gas gener- a. These instructions contain the detailed
ator must be in the range of 20°F (-7°C) above gas generator operating procedures and limits
the saturated vapor temperature of the gas at recommended by the General Electric Com-
the supply pressure as a minimum and 350°F pany for the 7LM2500-GD-MG Gas
(177°C) as a maximum. Based on consider- Generator.
it is recommended that the maximum gas sup-
ply temperature be limited to 150°F (66°C). If
the supply temperature of the gas is not repeat-
able on a day-to-day basis it may be necessary
to change the starting fuel adjustment to adjust
the supply pressure to the gas generator to
maintain a constant Btu-per-cubic-foot supply.
Once started, the engine will accept variations
in supply temperature of ±20°F (±11°C). The
maximum fuel flow required, assuming a
lower heating value of 19,000 Btu/lb, is
11,000 pph for the 7LM2500-GD-MG model
gas generator.

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ADDENDUM Z
b. The instructions are intended to 8-1.1 Performance Ratings and Operating
provide operating personnel with the Limits.
information required to operate the gas
generator. They pertain to routine and emer- NOTE
gency conditions and procedures. When a fault Ratings published in this manual apply
exists, refer to Volume I, Chapter 4, to the gas generator. The driven unit
TROUBLESHOOTING. ratings/limits may be lower in some
cases and shall take precedence over
c. It is possible that these instructions the gas generator manual limits.
may not provided for every possible variation
in equipment or contingency to be met in con- 8-1.2 Performance Ratings.
nection with the operation of the gas generator.
Refer requests for additional information to the a. The rated performance of the
General Electric Company, Marine and Indus- 7LM2500-GD-MG gas generator in the new
trial Engine Division, Cincinnati, Ohio 45215. and clean condition is as follows:
WARNING Isentropic Gas Horsepower

IF A QUESTIONABLE CONDITION - Continuous 20000
EXISTS DO NOT OPERATE THE - Maximum 25000
Heat Rate, BTU/IGHP-Hr
BEEN MADE. DO NOT REPEAT - Average, Continuous 6530
HOT STARTS, COMPRESSOR - Average, Maximum 6226
STALLS, OR OTHER RECOGNIZED Based on the following
PROBLEMS WITHOUT PRIOR conditions:
FAILURE TO DO SO CAN RESULT Inlet Air Temperature 59°
IN UNDUE STRESS BEING Altitude Sea Level
IMPOSED ON GAS GENERATOR Inlet Losses 0”H2O
ATE OR SUBSEQUENT DESTRUC- Exhaust Losses 0”H2O
TIVE FAILURE OF THE GAS Relative Humidity 0%
GENERATOR AND INJURY TO Compressor Bleed 0
PERSONNEL.
Accessory Power Extraction 0
Hot Effective Exhaust Area 208.5 sq in
Exhaust Gas Temperature
T5.4 Avg @ Continuous 1145°F
Rating
T5.4 Avg @ Maximum 1240°F
Rating

Z-7
GEK 97310
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ADDENDUM Z
b. Starting fuel flow for the g. The fuel rates shown on the curve will
7LM2500-GD-MG model gas generator is give starting times to 5000 rpm idle of 60 to 90
normally set by the minimum stop on the gas seconds and accelerations from idle to maxi-
fuel metering valve. The proper fuel flow set- mum power of 15 seconds.
ting for the minimum stop, on a heat consump- h. Normal decelerations from maximum
tion basis, is 10.45 x 106 ± 0.46 x 106 BTU/hr. power to idle should be made in approximately
for ambient temperature of -65°F (-54°C) to 2 to 3 minutes - this will enhance the time
+ 130°F (54°C), and is based upon commenc- between hot section repairs and the life of the
ing fuel and ignition at 1200 ± 100 rpm. Where gas generator.
a minimum stop is not utilized, acceptable
light offs can be obtained in the sub-idle 8-1.3 Operating Limits. Refer to table 3.
region, however, during such starts, ignition NOTE
should be initiated at that fuel flow corre-
sponding to the minimum stop with its associ- If any operating limit is exceeded, ver-
ated tolerance. If starts in the sub-idle region ify instrumentation accuracy before
are required, refer to Gas Generator Installa- troubleshooting or inspecting gas
tion Design Manual MID-IDM-2500-5. generator.
c. Typical transient fuel flow require- 8-2 INITIAL OPERATION.
ments are shown in Acceleration Fuel Sched- 8-2.1 General. Initial operational period is
ule, figure 6.
NOTE gas generator replacement or major mainte-
The acceleration fuel schedule show in nance on the system.
figure 6 is provided as an example tran- 8-2.2 Special Instrumentation.
sient fuel flow curve only. Refer to
Installation Design Manual a. Required for operation.
MID-IDM-2500-5 for the Gas generator speed sensor 0-11,000 rpm
LM2500-GD-MG gas generator model Lube oil scavenge tempera- 0-400°F
transient fuel flow requirements. ture sensors (A-, B-, C- (-18 to 204°C)
d. Acceleration fuel rates greater than sumps and accessory
those in the IDM may result in over-tempera- gearbox)
ture and possible stall of the gas generator. Lube oil supply temperature 0-400°F
Acceleration fuel rates lower than those shown sensor (-18 to 204°C)
can result in “hung” starts in the below idle Vibration indicators gas 0-4 in/sec or
speed range. generator 0-10 mil DA
e. Above the idle speed point, low accel- Lube oil supply pressure 0-100 psig
eration fuel rates will not harm the gas genera- (0-690 kPa)
tor and will only result in slower acceleration Power turbine inlet gas 0-2000°F
times. temperature (T5.4) (-18 to 1093°C)
f. For normal accelerations from idle to Compressor discharge 0-300 psig
power settings the changes should be made pressure (0-2070 kPa)
section repairs and the life of the gas genera-
(0-1380 kPa)
tor; a time of 2 to 3 minutes is reasonable.

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Figure 2. Lube Pump Discharge Pressure vs. Gas Generator Speed

using Lube Oil, MIL-L-23699

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Figure 3. Lube Pump Discharge Pressure vs. Gas Generator Speed using Lube Oil, MIL-L-7808

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Figure 4 and 5. Deleted

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Figure 6. 7LM2500-GD Acceleration and Deceleration Fuel Flow Requirements (Sheet 1 of 7)

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Normal
Alarm/ Operating
NOTE
• Correct lube pressures in accordance with table 8 or 9.
Lubrication Gas Generator Alarm 8 psig ± 1 psig 20-60 psig Bypass until
above 8000 rpm
(41 kPa ± 6. 9 kPa) (138-414 kPa) 4500 rpm
Gas Generator Alarm 110 psig ± 10 psig 10-100 psig Scavenge
Scavenge (759 kPa ± 69 kPa) (69-690 kPa) Discharge Pressure
Gas Generator Alarm 180°-220°F 140°-160°F Normal Operating
Lube Supply (82°-104°C) (60°-71°C) Range reflects tem-
during operation
above idle speed
Gas Generator Trip 330°-350°F 160°-275°F Normal Operating
Lube Scav- (166°-177°C) (71°-135°C) Range reflects tem-
enge Tempera- perature expected
tures - four Alarm 290° - 310°F during operation
Fuel Fuel Manifold 305 psig Supply Pressure as
System Pressure (2103 kPa) reflected at the fuel
(Natural manifold inlet on
Gas) the gas generator

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ADDENDUM Z
Normal
Alarm/ Operating
Fuel Supply Alarm 150°-170°F -65°-150°F Starting Fuel Flow
Temperature (66°-77°C) (-54°-66°C) Adjustments may be
required to compen-
ature variation;
above idle, tempera-
ture variation of
±20°F (±11°C) shall
be maintained
on gas generator
starter torque
requirements
Fuel and
Ignition
Fuel and igni- start after purge
tion (if purge cycle
cycle is used)
simultaneously with
start initiation
Failure to Trip 380°-420°F T5.4 Activate 10 sec-
Light-Off (193°-216°C) onds time delay
simultaneously with
application of fuel
and ignition
simultaneously with
start initiation. De-
energize ignition,
fuel system and
starter air supply

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ADDENDUM Z
Normal
Alarm/ Operating
to 4500 rpm (if onds time delay
purge cycle is upon completion of
used) purge. De-energize
fuel and ignition
systems and starter
air supply
Exhaust Failure to Trip 380°-420°F 0-1600°F Trip if temperature
Gas Light-Off (193°-216°C) (-18°-871°C) does not reach
within 10 seconds
tion are applied
Overtemperature
• Condition - 20.0 KIGHP @ 208.5 sq. in. AE8
Alarm 1175°F (635°C) 1145°F (618°C)
Trip 1185°F (641°C)
Vibration Gas Generator Trip 7 mils DA 0-3 mils DA Avoid continuous
operation over
4 mils
Alarm 4 mils DA
Flame flame fuel shutoff valve
upon loss of flame

Z-22
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ADDENDUM Z
b. Required for Monitoring and g. All instrumentation connec-
Troubleshooting: tions made and secure _______
Fuel Manifold pressure sensor 0-400 psig
(0-2758 kPa)
i. Gas generator assembly free of
j. Gas generator inlet air area
(0-2758 kPa)
Fuel supply temperature -65-250°F screen secure _______
(-54 to 121°C)
k. Gas generator compressor rear
Gas generator inlet air -65-150°F frame leakage ports, struts 7
temperature (-54 to 66°C) and 10, are open (not capped) _______
Power turbine inlet gas 0-75 psia l. Continuous lube supply starter
pressure (0-517.5 kPa) is initially serviced _______
Remote reading variable vane -5° to +45° m. Lube oil storage tank serviced
indicator to full level _______
Starter air supply pressure 0-50 psig n. Lube oil supply valves open _______
8-2.3 Preparation. The gas generator and
associated systems must be inspected and p. T5.4 thermocouple system
checked out for proper installation and opera- functioning properly _______
8-2.4 Gas Generator and Associated Equip- r. Compressor inlet total pres-
ment Check List. Complete the following sure probe aligned properly
checklist. and free of damage _______
a. Gas Generator Assembly S/N _______ s. Variable stator system secure _______
b. Mounting base secured to t. Required check and inspec-
foundation _______ tions specified in Packager’s
manual for gas generator con-
trol have been performed _______
d. Gas generator support mounts 8-2.5 Governor and Manual Control Check.
and links in place and secure _______ Refer to Packager’s manual.
and secure _______

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WARNING
SHUT DOWN.
UNDER SUCH CONDITIONS. b. Perform prestart checks per table 4.
SYSTEM SHALL BE MADE c. Perform ignition checkout per
THE CUSTOMER’S
PROCEDURES. d. Perform motoring procedure per
paragraph 8-2.8.
ENCLOSURE SHALL BE SHUT e. Perform false start per paragraph 8-2.9.
ENCLOSURE DOOR.
• THE ENCLOSURE DOOR g. Perform a wet prestart per
AN OBSERVER SHALL BE STA- h. Perform a manual start and operate per
ENTRY PROCEDURES SHALL i. Operate to maximum power per
BE FOLLOWED. paragraph 8-2.13.

paragraph 8-2.14.

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ADDENDUM Z
Item Requirements

Fuel valves Closed
Ignition Off
Oil tank level Full
Lube oil temperature Above +20°F (+1°C) for MIL-L-23699
pressure at manifold inlet 0
flow 0

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ADDENDUM Z
WARNING
• ASSURE POWER TO IGNITION a. Make ignition and natural-gas supply
fuel, motor gas generator for one minute;
allow gas generator to coast down. c. Hold MOTORING pushbutton closed
lead away from the exciter. while gas generator is coasting down, loosen
d. Turn off electrical power to the ignition 8-2.9 False Start. Perform false start as
system. Reconnect input lead to exciter and follows:
e. Repeat steps b, c and d, disconnecting manual gas valve closed, make automatic start
the No. 2 exciter. of gas generator per packager’s manual.


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8-2.10 Governor Check. Check governor sys- b. Operate gas generator up to rated
tem per packager’s manual. power, if possible, but do not exceed exhaust
gas temperature (T5.4) limit or corrected speed
limit (10,050 RPM). Hold at this power setting
follows:
a. With ignition lead disconnected, but system is unstable, adjust per packager’s
with manual gas valve open and governing manual.
generator per packager’s manual. c. Log all instrument readings once they
stabilize. Refer to table 5, step 9.
light-off speed (1100 to 1300 rpm). Fuel valve d. Reduce gas generator speed to idle.
should open and fuel manifold pressure should After stabilizing for three minutes, record all
be approximately 3 psig (21 kPa). Adjust fuel instrument readings. Refer to table 6, step 2.
because of lack of flame. e. Check fail-safe section of control sys-
c. Allow gas generator to coast to stop; tem per packager’s manual.
gas from gas generator. Continue to motor for f. After gas generator has been stabilized
60 seconds to purge fuel from the gas at idle for five minutes, make normal shut-
generator. down. Refer to table 6, steps 3 and 4.
8-2.12 Manual Start and Operation. Perform 8-2.14 Automatic Operation. Check auto-
manual start per packager’s manual with fuel matic operation per packager’s manual.
Refer to table 5. a. Accelerate to idle.
CAUTION
(refer to packager’s manual) to increase gas shut down gas generator.
within limits, adjust it per work h. Correct any leaks observed.
package 118 00. If vibrations are not within
limits, consult the local General Electric i. Remove all temporary instrumentation.
Company representative.
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ADDENDUM Z

1. Assure that prestart checks Installations using constant power
are completed per Table 4 control mode should consult the
contract documents or the General
Electric Company for determining
alarm and trip settings, which are
unique to each application
CAUTION
IF T5.4 RAPIDLY APPROACHES OR EXCEEDS SPECIFIED LIMITS (CONTRACT
DOCUMENTS) ABORT START.
NOTE
NOTE
3. At 1100 to 1300 RPM NGG
a. Ignition on
b. Fuel valve open Fuel manifold pres-
sure approximately
3 psig (21 kPa). See
paragraph 8-1.1
c. Note time to lightoff 10 seconds maximum Abort start-automatic shutdown.
(T5.4 above 400°F/ Investigate/correct cause.
204°C)
4. Note time to 4500 ± 200 90 seconds maximum Troubleshoot system and take cor-
RPM from starter initiation rective action if RPM stops
increasing or it takes longer than
90 seconds to reach 4300 RPM

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ADDENDUM Z
5. At 4300 to 4700 RPM NGG
a. Starter shutoff valve Valve closed Manually close starter air supply
should close
automatically
c. Check lube discharge Indication Recheck at idle
pressure
6. Note time to 5000 RPM 60 to 90 seconds
NGG typical
7. At idle check the
following:
a. Oil pressure 7-9 psig (48-62 kPa) Alarm at 8 ± 1 psig
min. See figure 2 or 3 (55 ± 6.9 kPa)
Trip at 6 ± 1 psig (41 ± 6.9 kPa)
b. NGG 5000 RPM ± Adjust
250 RPM
c. T5.4 1000°F (538°C) max Emergency shutdown - table 7
d. Gas generator vibration 0 to 3 mils DA Alarm set at 4 mils. Automatic
normal shutdown if above 7 mils.
action
e. Compressor inlet Approximately equal Troubleshoot sensing and indicat-
temperature (T2) to outside air ing system. Correct as required
temperature
leaks
sient operation

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ADDENDUM Z

b. NGG 10,050 PRM maxi- *
mum corrected
NOTE
c. Oil Pressure See figure 2 or 3 plus Emergency or automatic shutdown
tables 8 and 9 if 5 psig (34 kPa) out of limits
d. Scavenge oil 160°F to 275°F Alarm at 290-310°F (143°-
temperature (71°C to 135°C) 154°C); automatic shutdown if
above 340°F (171°C)
e. Gas generator vibration 3 mils maximum DA *
4 mils (Alarm) DA Troubleshoot
7 mils (Trip) DA Emergency or automatic shutdown
f. Fuel manifold pressure 305 psig (2103 kPa) **
max
g. Fuel inlet temperature -65° to 150°F **
(-54° to +66°C)
manual
manual
to outside air
temperature
k. VSV schedule See applicable figure Correct as required per
in WP 118 00 WP 118 00
its, shutdown.

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ADDENDUM Z
Step Corrective Action for Abnormal

No. Procedure Normal Results Results
1. Set gas generator at idle Gas generator Emergency shutdown
power decelerates
following:
a. Lube discharge pressure 7-9 psig (48-62 kPa) Alarm at 8 ± 1 psig (55 ± 6.9 kPa)
Trip at 6 ± 1 psig (41 ± 6.9 kPa)
b. Lube supply temperature See table 8 or 9
d. T5.4 Approximately 1000°F Troubleshoot and take corrective
(538°C) action
e. Gas generator vibration 3 mils maximum (DA) Alarm set at 4 mils. Automatic
action
f. Fuel inlet temperature -65° to 150°F
(-54° to 66°C)
g. Scavenge oil filter ∆P Refer to packager’s
manual
h. Lube oil supply filter ∆P Refer to packager’s
manual
i. Lube scavenge tempera- 160°-275°F Alarm at 300° ± 10°F
tures (A, B, C, and AGB) (71° -135°C) Trip at 340° ± 10°F
3. After stabilizing at idle for 5 T5.4 drops below 400°F Manually shut off fuel supply
minutes, close fuel valves (204°C) NGG deceler-
ates and stops
4. Observe T5.4 for 3 minutes 700°F (371°C) Motor gas generator. Continue
after shutdown maximum motoring until temperature
decreases

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VOLUME I
ADDENDUM Z
j. Check gas generator and mounting • SECONDARY AIR TO THE
system for loose parts; tighten as necessary. ENCLOSURE SHALL BE SHUT
ING OR CLOSING THE
operation for normal operation, refer to pack- SHALL BE KEPT OPEN. IF THE
8-3.2 Interlocks. Refer to packager’s manual TIONED AT THE ENCLOSURE
generator operation. ENTRY PROCEDURES SHALL
BE FOLLOWED.
LATED GLOVES AS
NECESSARY.
OPERATING.
SHUT DOWN.
ENCLOSURE OR IN THE
ENTRY SHOULD BE
MOTORING THE GAS
TURBINE.
b. Start and operate the gas generator per
• THE FIRE EXTINGUISHING table 5. Do not exceed operating limits of
SYSTEM SHALL BE MADE table 3.
THE CUSTOMER’S c. Shut down the gas generator per
PROCEDURES. table 6.

Z-32
GEK 97310
VOLUME I
ADDENDUM Z
d. Emergency shut down the gas genera- 8-4.2 Post Shutdown Fire.
tor per table 7.
a. During a normal shutdown, the exhaust
e. Refer to tables 8 and 9 for oil pressure gas temperature should decrease. If during
correction factors. time gas generator is coasting to stop, tempera-
f. Idle lube oil pressure is 29 psig that combustion is still taking place because of
(200 kPa) maximum after five minutes stabili- a leaking fuel valve. (A slight temperature
zation for MIL-L-7808 and 50 psig (345 kPa) increase after rotation stops is normal.) Make
for MIL-L-23699. certain fuel is shut off, and motor the gas gen-
g. The operating pressure of the lube oil temperature decreases to normal, discontinue
shall be 40 to 50 psig (276 to 345 kPa) at stan- motoring.
dard conditions of 9000 rpm gas generator
speed and 150°F (66°C) at lube pump dis-
charge temperature. Oil pressure measured at
conditions other than standard shall be cor-
rected to standard conditions using tables 8
and 9.


per table 7.

Z-33
GEK 97310
VOLUME I
ADDENDUM Z

CAUTION
THE ROTOR WILL FREE ITSELF AFTER A COOLING PERIOD OF 3 TO 4
HOURS. CHECK FOR FREEDOM OF ROTATION BY TURNING ROTOR BY
HAND.
1. Conditions permitting, decelerate gas gen- T5.4 drops below Manually shut off
erator to idle and close fuel valves 400°F (204°C) and fuel supply
NGG and NPT
2. Observe T5. 4 for 3 minutes after shutdown 700°F (371°C) max Motor gas generator.
Continue motoring
until temperature
decreases
power setting (T5.4 greater than 1150°F/
621°C) has occurred, and a “hot restart” is
a. If fault detection and sequencing system
can be cleared and the gas generator can
be restarted within 1 minute following
coastdown of the HPC rotor, acceptable
restarts can be made using the normal
starting procedure.
generator at 2000-2500 rpm NGG for 5
the HPC rotor, restarts can be made

Z-34
GEK 97310
VOLUME I
ADDENDUM Z
Table 8. OIL PRESSURE CORRECTIONS FOR TEMPERATURE (MIL-L-7808)
Oil Temp. Pressure Oil Temp. Pressure Oil Temp. Pressure Oil Temp. Pressure
°F °C Additive °F °C Additive °F °C Additive °F °C Additive
100 (37.8) -5.5 140 (60) + .6 180 (82) +6.4 220 (104) +12.4
102 (39.9) -5.2 142 (61.2) + .8 182 (83.1) +6.7 222 (105.9) +12.7
104 (40) -4.8 144 (62.4) +1.1 184 (84.5) +7.0 224 (106.7) +13.0
106 (40.1) -4.5 146 (63.6) +1.7 186 (85.5) +7.3 226 (107.9) +13.3
108 (42.2) -4.2 148 (64.6) +1.7 188 (86.9) +7.6 228 (109.1) +13.6
110 (43) -3.8 150 (66) +2.0 190 (88) +7.9 230 (110) +13.9
112 (44.3) -3.5 152 (66.9) +2.2 192 (89) +8.2
114 (45.6) -3.2 154 (67.7) +2.5 194 (90) +8.5
116 (46.6) -2.9 156 (68.9) +2.8 196 (91) +8.8
118 (48) -2.6 158 (70.1) +3.1 198 (92) +9.1
120 (49) -2.3 160 (71) +3.4 200 (93) +9.4

122 (50) -2.0 162 (72.1) +3.7 202 (94.5) +9.7
124 (51.1) -1.7 164 (73.2) +4.0 204 (95.6) +10.0
126 (52.1) -1.4 166 (74.5) +4.3 206 (96.7) +10.3
128 (53) -1.1 168 (76.1) +4.5 208 (97.8) +10.6
130 (54) - .8 170 (77) +4.9 210 (99) +10.9

132 (55.1) - .5 172 (78) +5.2 212 (100) +11.2
134 (56.5) - .2 174 (78.9) +5.5 214 (101.1) +11.5
136 (57.8) - .0 176 (80.1) +5.8 216 (102.3) +11.8
138 (58.9) + .3 178 (81.2) +6.1 218 (103.1) +12.1
Read Lube Pump Discharge Pressure and Lube Pump Inlet Temperature. Algebraically add the pressure additive, as
indicated by observed temperature, to observed pressure.
Example: Observed Lube Pump Discharge Pressure 40 psig (276 kpa)
Lube Pump Inlet Temperature 164°F (73.2°C)
Pressure Additive +4 psig (27.6 kpa)
Corrected Pressure 40 + 4 = 44 psig (276.0 + 27.6 = 303.6 kpa)

Z-35
GEK 97310
VOLUME I
ADDENDUM Z
Table 9. OIL PRESSURE CORRECTIONS FOR TEMPERATURE (MIL-L-23699)
NOTE
The following values are for corrections to 9000 rpm NGG and 150°F lube inlet tempera-
ture. Read oil pressure and temperature then algebraically add the pressure additive (as
indicated for that particular rpm and lube temperature) to the observed lube pressure. Cor-
rected lube pressure limit is 40 to 50 psig.
GAS GENERATOR SPEED RPM
OIL
TEMP
F° (C°) 8000 8100 8200 8300 8400 8500 8600 8700 8800 8900 9000 9100 9200 9300 9400 9500
100(37.8) -8.7 -9.9 -11.1 -12.3 -13.5 -14.8 -16.0 -17.2 -18.5 -19.8 -21.1 -22.4 -23.7 -25.0 -26.3 -27.6
110(43.3) -3.5 -4.7 -5.9 -7.1 -8.3 -9.5 -10.7 -11.9 -13.1 -14.3 -15.5 -16.7 -17.8 -19.0 -20.2 -21.4
120(48.9) - .7 -1.7 -2.7 -3.8 -4.8 -5.8 -6.8 -7.9 -9.0 -10.1 -11.2 -12.3 -13.4 -14.5 -15.6 -16.7
130(54.4) +3.4 +2.4 +1.4 + .4 - .6 -1.6 -2.6 -3.6 -4.6 -5.6 -6.6 -7.6 -8.6 -9.6 -10.6 -11.6
140(60.0) +5.7 +4.8 +4.0 +3.1 +2.3 +1.4 + .5 -.4 -1.3 -2.1 -3.1 -4.0 -5.0 -5.9 -6.8 -7.8
150(65.6) +8.4 +7.6 +6.8 +6.0 +5.2 +4.4 +3.6 +2.7 +1.8 + .9 0 -.9 -1.8 -2.7 -3.7 -4.6
160(71.1) +10.7 +10.0 +9.2 +8.3 +7.5 +6.7 +5.8 +5.0 +4.1 +3.3 +2.4 +1.5 + .6 - .4 -1.3 -2.2
170(76.7) +12.4 +11.6 +10.8 +10.0 +9.2 +8.4 +7.6 +6.8 +6.0 +5.2 +4.4 +3.3 +2.3 +1.3 + .3 - .7
180(82.2) +13.6 +12.8 +12.0 +11.2 +10.4 +9.6 +8.8 +8.0 +7.3 +6.5 +5.7 +4.7 +3.6 +2.6 +1.5 + .5
190(87.8) +14.5 +13.7 +12.9 +12.1 +11.3 +10.5 +9.7 +8.9 +8.1 +7.2 +6.4 +5.5 +4.5 +3.6 +2.6 +1.7
200(93.3) +15.1 +14.4 +13.6 +12.8 +12.0 +11.2 +10.4 +9.5 +8.7 +7.8 +7.0 +6.1 +5.2 +4.4 +3.5 +2.6
NOTE: OIL MIL-L-23699
EXAMPLE: OBSERVED NGG 8900 RPM
OBSERVED OIL PRESSURE 58 PSIG (400 kPa)
OIL TEMPERATURE 120°F(49°C)
PRESSURE ADDITIVE -10.1 PSIG (69.6 kPa)
CORRECTED PRESSURE 58-10.1 = 47.9 PSIG(330.4 kPa)

Z-36
GEK 97310
VOLUME I
ADDENDUM Z
8-5 SPECIAL GAS GENERATOR CON- 8-5.3 Lube Oil Supply Pressure. The lube
STRAINS. oil supply pressure limits given in the limit
8-5.1 General. Under normal operating con- cannot reliably monitor supply pressure
ditions, the gas generator is constrained by the because the proper pressure is dependent on
operating limits published in the limits table. engine speed, oil type, and oil temperature. An
Continuous operation between the alarm and operator must therefore derive a corrected oil
shutdown or “trip” level should not be pressure as directed on the appropriate pres-
practiced. sure correction table to determine if the lube
system is performing within the high-low lim-
In the event that any of the following situations its stated on each table.
assure the gas generator continued normal generator rotational speeds above 7500 rpm
operation. These events are either not detected can result in high pressure compressor blade
or not prevented by the customary protective fracture. The gas generator can be operated
devices of control systems. after an inspection of the compressor stages 3
• Lube Oil Pressure ther inspection and stress relief of the blades is
• High Speed Stalls required, which necessitates blade removal
• Starter Duty Cycle from the spool.
• Gas Generator Windmilling 8-5.5 Starter Duty Cycle - Air or Natural
Gas.
acceleration to idle, the cooling air flow to the a. Starting -
components of the engine hot section are not
sufficient to protect the metals at T5.4 alarm 45 seconds on, 2 minutes off for
and trip levels specified in the limits table. A any number of cycles or
lower T5.4 limit is therefore established, with 2 minutes on, 5 minutes off,
higher levels acceptable provided they exist 2 minutes on, 21 minutes off for
for limited times as depicted on the curve in any number of cycles.
figure 1 titled “Transient Temperature Limits”.
This must be monitored by the operator. The b. Motoring -
into area B requires hot section disassembly 5 minutes on, 2 minutes off,
and inspection in a qualified facility. 5 minutes on, 18 minutes off for
any number of cycles or
10 minutes on, 20 minutes off
for any number of cycles. (For
10 minutes of motoring, maxi-
mum starter air inlet tempera-
ture is 200°F.)

Z-37
GEK 97310
VOLUME I
ADDENDUM Z
c. There is no duty cycle limit on the (1) The gas generator may windmill
hydraulic starter as long as the oil temperature for two weeks at speeds below 100 RPM, pro-
is maintained below 140°F. vided each period is preceded by normal gas
generator operation.
In the event that re-start of the gas generator is (2) The gas generator may windmill
required; within 1 minute to 2 hours following for up to five minutes at speeds between
a trip or rapid shutdown from high power, after 100 RPM and 1000 RPM, provided each
coastdown of HPC rotor, a 5 minute cranking period is preceded by normal gas generator
at 2400 rpm should precede the fire up. The operation.
objective is to cool the high pressure turbine
rotor, so that blade tips maintain clearance (3) Unlimited windmilling of the gas
with the more rapidly cooling case. generator is allowed at gas generator speeds
above 1000 RPM, provided the scavenge oil
8-5.7 Windmilling. temperature is maintained below 340°F
(171° C). At these speeds the lube supply and
a. Gas Generator. If the inlet system is scavenge systems are in normal operation.
such that air will be forced through the gas Adequate cooling of the oil must be provided
generator when it is shut down, the gas genera- at the higher free rotational speeds.
tor shaft may rotate. The duration of gas gener-
ator windmilling is limited by the lubricity of
its rotor bearings. The following defines these
limits:

Z-38
GEK 97310
VOLUME I
ADDENDUM AA
ADDENDUM
7LM2500-GE-MGX

GEK 97310
VOLUME I
ADDENDUM AA
TABLE OF CONTENTS
1-0 INTRODUCTION ....................................................................................... AA-3

2-0 REFERENCE DATA................................................................................... AA-3
3-0 INSTALLATION DRAWINGS .................................................................. AA-4
4-0 EQUIPMENT DESCRIPTION.................................................................. AA-4
5-0 NOX SUPPRESSION (Steam Injection System) ...................................... AA-4
6-0 INSTRUMENTATION AND SUPPLY REQUIREMENTS.................... AA-4
7-0 SERVICE REQUIREMENTS.................................................................... AA-4
7-1.1 Natural Gas.................................................................................................... AA-4
7-1.2 Steam Servicing Requirements (NOX Suppression)..................................... AA-5
8-0 OPTIONAL HARDWARE KITS - 7LM2500-GE-MGX......................... AA-7
9-0 GAS GENERATOR OPERATION............................................................ AA-7
9-1 PERFORMANCE RATINGS AND OPERATING LIMITS................... AA-7
9-1.1 Performance Ratings ..................................................................................... AA-8
9-1.2 Steam Scheduling Requirements During Operation (NOX Suppression)..... AA-9
9-1.3 Operating Limits............................................................................................ AA-9
9-2 INITIAL OPERATION .............................................................................. AA-21
9-2.1 General .......................................................................................................... AA-21
9-2.2 Special Instrumentation Required for Operation........................................... AA-21
9-2.3 Special Instrumentation Required for Monitoring and Troubleshooting ...... AA-21
9-2.4 Preparation..................................................................................................... AA-22
9-2.5 Gas Generator and Associated Equipment Check List.................................. AA-22
9-2.6 Governor and Manual Control Check ........................................................... AA-23
9-2.7 Start-Up and Checkout .................................................................................. AA-23
9-2.8 Ignition Check ............................................................................................... AA-25
9-2.9 Motoring ........................................................................................................ AA-25
9-2.10 False Start ...................................................................................................... AA-25
9-2.11 Governor Check............................................................................................. AA-26
9-2.12 Wet Prestart.................................................................................................... AA-26
9-2.13 Manual Start and Operation........................................................................... AA-26
9-2.14 Operation to Maximum Power ...................................................................... AA-30
9-2.15 Automatic Operation ..................................................................................... AA-30
9-3 NORMAL OPERATION ............................................................................ AA-30
9-3.1 General .......................................................................................................... AA-30
9-3.2 Interlocks ....................................................................................................... AA-30
9-3.3 Operation ....................................................................................................... AA-32
9-4 EMERGENCY OPERATION.................................................................... AA-33
9-4.1 Emergency Shutdown.................................................................................... AA-33
9-4.2 Post Shutdown Fire........................................................................................ AA-39
9-5 SPECIAL GAS TURBINE CONSTRAINTS ........................................... AA-39
9-5.1 General .......................................................................................................... AA-39
9-5.2 Overtemperature ............................................................................................ AA-39

AA-1
GEK 97310
VOLUME I
ADDENDUM AA
9-5.3 Lube Oil Supply Pressure.............................................................................. AA-39

9-5.4 High Speed Stall ............................................................................................ AA-39
9-5.5 Starter Duty Cycle - Air or Natural Gas and Hydraulic Starter (optional).... AA-40
9-5.6 Re-Start Following High Power Trip ............................................................ AA-40
9-5.7 Windmilling................................................................................................... AA-40
Figure Title Page
1 Transient Temperature Limits (Typical) ........................................................ AA-10
2 Lube Pump Discharge Pressure vs. Gas Generator Speed using Lube Oil,
MIL-L-23699................................................................................................. AA-11
3 Lube Pump Discharge Pressure vs. Gas Generator Speed using
Lube Oil, MIL-L-7808 .................................................................................. AA-11
4 Deleted
5 Natural Gas Fuel System with Steam Injection Schematic ........................... AA-13
6 Steam to Fuel Weight Ratio vs Fuel Flow ..................................................... AA-14
7 Steam/Fuel Premix Manifold Pressure vs. Fuel Flow Requirement
at Various Steam/Fuel Ratios ................................................................ AA-15
8 Steam/Gas Mixture Temperature vs Steam/Fuel Ratio ................................. AA-16
LIST OF TABLES
Table Title Page
1 INSTRUMENTATION CONNECTIONS - 7LM2500-GE-MGX................ AA-5

2 SUPPLY CONNECTIONS - 7LM2500-GE MGX ....................................... AA-6
3 OPERATING LIMITS AND RANGES........................................................ AA-17
4 PRESTART CHECKS................................................................................... AA-24
5 START-UP AND OPERATION .................................................................... AA-26
6 GAS GENERATOR SHUTDOWN .............................................................. AA-31
7 EMERGENCY SHUTDOWN ...................................................................... AA-33
8 LUBE OIL PRESSURE CORRECTIONS FOR INDUSTRIAL LM2500
GAS GENERATORS L34379 VSV CONTROL-3R DAMPER BEARING
(MIL-L-23699 OIL) ...................................................................................... AA-35
GAS GENERATORS L34379 VSV CONTROL-3R DAMPER BEARING
(MIL-L-7808 OIL) ........................................................................................ AA-36
GAS GENERATORS L34379 VSV CONTROL (MIL-L-23699 OIL) ........ AA-37
GAS GENERATORS L34379 VSV CONTROL (MIL-L-7808 OIL) .......... AA-38

AA-2
GEK 97310
VOLUME I
ADDENDUM AA
1-0 INTRODUCTION. GAS GENERATOR WEIGHTS
7LM2500-GE-MGX model gas generator The average weights of the major gas genera-
basic configuration and control system differ- tor components are:
ences. In addition, the coverage of reference
data, instrumentation and supply connections, Component Wt-Lbs (Kg)
special servicing requirements, optional hard- Gas Generator 4212 (1911)
ware kits and the complete gas generator oper- Inlet Gearbox 38 (17)
ating instructions for the 7LM2500-GE-MGX
model are included.
2-0 REFERENCE DATA. Compressor Rotor 552 (250)
EQUIPMENT Compressor Stator, Rear 93 (42)
Gas Generator Assembly Compressor Rear Frame 421 (191)
(General Electric Co., Cincinnati, Ohio) Combustor 120 (54)
Model No. 7LM2500-GE-MGX High Pressure Turbine Rotor 419 (190)
Drawing No. L25250G39 High Pressure Turbine Nozzle,
Stg 1 68 (31)
PERFORMANCE RATING
Stg 2 127 (58)
Turbine Mid Frame 530 (240)
Mechanism 19 (9)
DRAWING LIST
Gas Generator Installation

Drawing L31705
Diagram L24007
Drawing L25250G39

AA-3
GEK 97310
VOLUME I
ADDENDUM AA
3-0 INSTALLATION DRAWINGS. 6-0 INSTRUMENTATION AND
A complete set of installation drawings have SUPPLY REQUIREMENTS.
been provided. See Table 1 and 2.
4-0 EQUIPMENT DESCRIPTION. 7-0 SERVICE REQUIREMENTS.

The 7LM2500-GE-MGX is a natural gas fired
gas generator with NOX suppression 7-1.1 Natural Gas.
capability.
5-0 NOX SUPPRESSION (STEAM natural gas fuel manifold on the gas generator
INJECTION SYSTEM). is 355 + 5 psig (2448 + 35 kPa) maximum.
a. As an option, the 7LM2500-GE-MGX b. The temperature of the gas supply at

gas generator can be equipped for suppression the fuel manifold connection on the gas gener-
of oxides of nitrogen (NOX) in the gas genera- ator must be in the range of 20°F (-6.7°C)
tor exhaust gases. This is accomplished by above the saturated vapor temperature as a
introduction of steam into the natural gas minimum, and 350°F (177°C) as a maximum.
delivery system upstream of the fuel manifold If the temperature of the gas is not repeatable
and the use of larger flow area fuel nozzles. on a day-to-day basis, it may be necessary to
The steam and natural gas are mixed prior to change the starting fuel adjustment to adjust
introduction into the fuel manifold by means the supply pressure to the gas generator to
of a "tee" connection exiting into a static mixer maintain a constant BTU-per-cubic-foot sup-
to ensure complete mixing of the steam and ply. The maximum fuel flow required, assum-
gas. The mixer itself may have appropriate ing a lower heating value of 19,000 BTU/lb is
connections which will delete the need for a 13,500 pph (6124 kg/h) for the
separate tee (see figure 5). The LM2500 NOX 7LM2500-GE-MGX model gas generator.
suppression system has been designed to meet
the requirements of the U.S.E.P.A. standard for
NOX emissions for stationary gas turbines and
includes a conservative margin for meeting the
tive, local codes where applicable.

AA-4
GEK 97310
VOLUME I
ADDENDUM AA
Table 1. INSTRUMENTATION CONNECTIONS - 7LM2500-GE-MGX
E-1 Vibration pickup, Gas Generator Diagnostic System Corp.
Part No. 303-03
(optional)
(optional)
NOTE
For all other instrumentation connections, refer to applicable Installation Drawings.
7-1.2 Steam Servicing Requirements (NOX must be controlled in a manner to prevent any
Suppression). sudden pressure spikes which could momen-
tarily displace the fuel. Other criteria, such as
a. The steam delivery pressure at the calculated gas generator steam flow required
manifold connection shall be 400 psig to meet the requirement of the applicable EPA
(2758 kPa) nominal. The temperature of the standard or other local codes, corresponding
steam supplied to the manifold shall be 600°F fuel flow and the gas generator internal cycle
(316°C) nominal, and shall be free of pressure pressure level may be obtained from the tabu-
pulsations in the 0 to 300 Hz range. The steam lar performance data sheets.
AA-5
GEK 97310
VOLUME I
ADDENDUM AA
Table 2. SUPPLY CONNECTIONS - 7LM2500-GE MGX

CAUTION
ALL LINES MUST BE FLEXIBLE ENOUGH TO ALLOW 3/4 INCH (19MM)
THERMAL GROWTH WITHOUT PLACING STRAIN ON LINES OR ON GAS
GENERATOR.
F1 Natural gas supply 2 inch line from Fuel Control Unit to
Gas Generator Fuel Manifold
L1 Oil Supply 1-1/2 inch line to Lube Pump on Gas
Generator AN818-24C or
MS20819-24C
L2 Lube pump discharge 1 inch line from Lube Pump to Oil
Supply Filters AN818-16C or
MS20819-16C
L4 Lube supply inlet port 1 inch line from Oil Supply Filters to
Gas Generator AN818-16C or
MS20819-16C
L3 Scavenge oil discharge 1-1/4 inch line from Gas Generator
Scavenge Pump to oil Scavenge Filter
and Cooler AN818-20C or
MS20819-20C
A2 Bleed Air 16th stage compressor bleed air lines if
used (1.92 inch ID)
A12 Air/Oil Separator 3 inch line from air/oil separator to
atmospheric vent or to exhaust duct
(flame arrestor)
S1 Waterwash manifold 3/4 inch line - hot water line to water-
wash manifold on Gas Generator Inlet
Duct AN818-12C or MS9197-12
NOTE
For all other supply connections needed, see paragraph 3-0.

AA-6
GEK 97310
VOLUME I
ADDENDUM AA
7LM2500-GE-MGX.
a. Refer to Volume II, WP 001 00 for a EXISTS, DO NOT OPERATE THE
detailed list of optional kits available for this GAS GENERATOR UNTIL A THOR-
particular gas generator model. OUGH INVESTIGATION HAS
9-0 GAS GENERATOR OPERATION. HOT STARTS, COMPRESSORS
gas generator operating procedures and limits THOROUGH INVESTIGATION.
pany for the 7LM2500-GE-MGX Gas IN UNDUE STRESS BEING
Generator. IMPOSED ON GAS GENERATOR
b. The instructions are intended to pro- ATE OR SUBSEQUENT DESTRUC-
vide operating personnel with the information TIVE FAILURE OF THE GAS
required to operate the gas generator. They GENERATOR AND INJURY TO
pertain to routine and emergency conditions PERSONNEL.
and procedures. When a fault exists, refer to
Volume I, Chapter IV, 9-1 PERFORMANCE RATINGS AND
TROUBLESHOOTING. OPERATING LIMITS.

NOTE
equipment or contingency to be met in connec- to the gas generator. The driven unit
tion with the operation of the gas generator. ratings/limits may be lower in some
Refer requests for additional information to the cases and shall take precedence over
General Electric Company; Marine and Indus- the gas generator manual limits.
trial Engines and Service Division; Cincinnati,
Ohio 45215-6301.

AA-7
GEK 97310
VOLUME I
ADDENDUM AA
9-1.1 Performance Ratings. Power Turbine Speed 3600 3600
RPM RPM
a. The rated performance of the
7LM2500-GE-MGX gas turbine in the new Heat Rate, Max 6885 6822
and clean condition as compared to gas gener- BTU/ BTU/
ator performance with steam injection, is as hp-hr hp-hr
follows: Power Turbine Inlet 1458°F 1437°F
Gas Temperature (792°C) (781°C)
Normal With NOX
(Dry) Steam Suppression Steam Injection 0 Lbs/ 3538
Hr Lbs/Hr
NOTE
NOTE (1605
kg/hr)
The use of steam injection to control
NOX emissions results in a change in Fuel Flow 10690 10592
gas generator performance. Unless spe- Lbs/Hr Lbs/Hr
cifically agreed to in the applicable (4849 (4805
contract documents, all performance kg/hr) kg/hr)
guarantees are based upon “dry” opera-
NOX Emissions (ppm 184 *112
tion with no steam injection. at 15% O2)
Brake Horsepower 29,500 29,500 * Limit is per US-EPA and is based upon
29,500 BHP at 4-1 ISO or standard day
Inlet Air Temperature 59°F 59°F conditions for an electric utility application.
(15°C) (15°C)
Exhaust Back Pressure 0” H2O 0” H2O
Compressor Bleed 0 Lbs/ 0 Lbs/
Sec Sec
Accessory Horsepower 0 0
Extraction

AA-8
GEK 97310
VOLUME I
ADDENDUM AA
b. Starting fuel flow for the g. Normal decelerations from maximum
7LM2500-GE-MGX model gas generator is power to idle should be made in approximately
normally set by the minimum stop on the gas 2 to 3 minutes; this will enhance the time
fuel metering valve. The proper fuel flow set- between hot section repairs and the life of the
ting for the minimum stop, on a heat consump- gas generator.
tion basis, is 10.45 x 106 + 0.46 x 106 BTU/
hour for ambient temperatures of -65°F (- 9-1.2 Steam Scheduling Requirements
54°C) to +130°F (54°C), and is based on com- During Operation (NOX Suppression).
mencing ignition and fuel at 1200 + 100 rpm. See Figures 6, 7, and 8.
Where a minimum stop is not utilized, accept-
able light-offs can be obtained in the sub-idle a. Steam flow must be scheduled as a
region, however during such starts, ignition function of fuel flow and must be shut off dur-
should be initiated at that fuel flow corre- ing starting and acceleration to idle. Steam
sponding to the minimum stop with its associ- flow should be initiated at a fuel flow of
ated tolerance. If starts in the sub-idle region 3000 pph +450 pph on acceleration when oper-
are required, refer to Gas Generator Installa- ating on natural gas. Subsequently, the steam
tion Design Manual MID-IDM-2500-5. should be shut off at these points on a deceler-
ation. During initiation of steam flow, the gas
c. Acceleration fuel rates greater than generator should be operating at a stabilized
those shown will result in overtemperature and steady-state condition. Refer to figures 6, 7,
possible stall of the gas generator. Accelera- and 8 for steam/fuel ratios, manifold pressure/
tion fuel rates lower than those shown can flow requirements and temperature/ratio
result in "hung" starts in the below idle speed requirements. During gas generator accelera-
range. tions, adjust steam flow after gas generator is
on point. Conversely, during decelerations,
d. Above the idle speed point, low accel- steam flow should be adjusted downward
eration fuel rates will not harm the gas genera- before gas generator decels. To avoid flame-
tor and will only result in slower acceleration out during rapid decelerations, it is recom-
times. mended that transient steam/fuel ratios in
excess of 2.2 (lbs/lb) be avoided.
e. For normal accelerations from idle to
NOTE
NOTE
f. The fuel rate shown on the curve will ify instrumentation accuracy before
give starting times to 5000 rpm (idle) of 60 to troubleshooting or inspecting gas
90 seconds and accelerations from idle to max- generator.
imum power of 15 seconds.

AA-9
GEK 97310
VOLUME I
ADDENDUM AA
Figure 1. Transient Temperature Limits (Typical)

AA-10
GEK 97310
VOLUME I
ADDENDUM AA
Figure 2. Lube Pump Discharge Pressure vs. Gas Generator Speed using Lube Oil,
MIL-L-23699
Figure 3. Lube Pump Discharge Pressure vs. Gas Generator Speed using Lube Oil, MIL-L-7808

AA-11
GEK 97310
VOLUME I
ADDENDUM AA
Figure 4. Deleted

AA-12
GEK 97310
VOLUME I
ADDENDUM AA
Figure 5. Natural Gas Fuel System with Steam Injection Schematic

AA-13
GEK 97310
VOLUME I
ADDENDUM AA
Figure 6. Steam to Fuel Weight Ratio vs Fuel Flow

AA-14
GEK 97310
VOLUME I
ADDENDUM AA
Figure 7. Steam/Fuel Premix Manifold Pressure vs. Fuel Flow Requirement

at Various Steam/Fuel Ratios
AA-15
GEK 97310
VOLUME I
ADDENDUM AA
Figure 8. Steam/Gas Mixture Temperature vs Steam/Fuel Ratio

AA-16
GEK 97310
VOLUME I
ADDENDUM AA
Table 3. OPERATING LIMITS AND RANGES
Normal
Alarm/ Operating
NOTE
• Continous operation should not take place with any parameter indicating between the
• Correct lube pressures in accordance with Tables 8, 9, 10, or 11.
Lubrica- Gas Generator Alarm 8 psig + 1 psig 20-60 psig Bypass until
tion Sys- Lube Supply (55 kPa + 6.9 kPa) (138-414 kPa) 4500 rpm
tem - Pressure below 8000 rpm,
Settings 15 psig + 1 psig
and (103 kPa +
Operat- 6.9 kPa) above
ing 8000 rpm
Ranges
Gas Generator Trip 6 psig + 1 psig 20-60 psig Bypass until
Lube Supply (41 kPa + 6.9 kPa) (138-414 kPa) 4500 rpm
Pressure
Gas Generator Alarm 110 psig + 10 psig 10-100 psig Scavenge Dis-
Scavenge Dis- (759 kPa + 69 kPa) (69-690 kPa) charge Pressure
180 psig
(1241 kPa)
Gas Generator Alarm 200° + 20°F 140° - 160°F Normal Operat-
Lube Supply (93° + 11.1°C) (60° - 71°C) ing Range reflects
expected during
operation above
idle speed
Gas Generator Trip 340° + 10°F 160° - 275°F Normal Operat-
Lube Scavenge (171° + 5.6°C) (71° - 135°C) ing Range reflects
Temperatures - temperature
Alarm 300° + 10°F expected during
(149° + 5.6°C) operation above
idle speed

AA-17
GEK 97310
VOLUME I
ADDENDUM AA
Table 3. OPERATING LIMITS AND RANGES - Continued
Normal
Alarm/ Operating
Fuel Fuel/Steam 355 psig Normal Supply
System Supply (2413 kPa) Pressure as
(Natural Pressure reflected at the
Gas) fuel manifold
inlet.
Fuel Steam Alarm 400°F (See paragraph
Supply (204°C) 9-1.2
Temperature
Trip 450°F
(232°C)
Starting Starter Supply 40 psig Starting Pres-
System Pressure (276 kPa) Requirements
based on engine
starter torque
requirements.
Application of 1200 + 100 rpm
Ignition and
Fuel
Application of 1700 + 100 rpm 1700 + 100 rpm
Ignition and for start after
Fuel (If purge purge cycle.
cycle is used)
Starting Time Trip 1200 + 100 rpm Activate 20 sec-
simulataneously
with start
initiation
Failure to Trip 400°F + 20°F Activate 10 sec-
Light-Off (T5.4) ond time delay
(204°C + 11.1°C) simultaneously
with application
of fuel and
ignition

AA-18
GEK 97310
VOLUME I
ADDENDUM AA
Normal
Alarm/ Operating
simultaneously
with start initia-
tion. De-energize
ignition, fuel sys-
tem and starter air
supply
to 4500 rpm (If ond time delay
used) of purge. De-
energize fuel and
ignition systems
and starter air
supply
Exhaust Failure to Light Trip 400°F + 20°F 0 - 900°F Trip if tempera-
Gas Tem- Off (204°C + 11.1°C) (-17.8 - 482°C) ture does not
perature reach 400°F
(204°C) within 10
seconds after igni-
tion and fuel are
applied
Field Limits (AE8 = 208.5 in2)
Gas Fuel Con-
trol 1510°F 0 - 1510°F
Limit (821°C) (17.8 - 821°C)
Alarm 1515°
(824°C)
Trip 1575°F
(857°C)

AA-19
GEK 97310
VOLUME I
ADDENDUM AA
Normal
Alarm/ Operating
Vibration Gas Generator
a) Acceler- Alarm * Less than Continuous
ometer Trip ** Alarm limit operation
above alarm
limit is to be
avoided
b) Transducer Alarm 4 mils + 0-3 mils DA Continous opera-
1 mil DA tion above 4 mils
is to be avoided
Trip 7 mils +
1 mil DA
* Alarm - 1.50 inches/sec between 84 and 125 Hz or 1.75 inches/sec above 125 Hz.
** Trip - 2.50 inches/sec between 84 and 125 Hz or 3.00 inches/sec above 125 Hz.
Speed Gas Generator Trip 10200 + 50 rpm 0-10100 rpm
(50 Hz and 60 Hz applications)
Flame Flame fuel shut-off valve
upon loss of flame
Thrust Recoup See Remarks Recoup See Chapter IV
Balance Pressure Pressure: for acceptable
Pressure 0-150 psig envelope (cor-
P54: rected recoup
0-60 psig pressure vs cor-
rected exhaust gas
total pressure,
P54)

AA-20
GEK 97310
VOLUME I
ADDENDUM AA
9-2 INITIAL OPERATION. Power turbine inlet gas . . . . . 0-75 psia
that period of operation immediately following Compressor discharge . . . . . . 0-300 psig
gas generator replacement or major mainte- pressure (0-2070 kPa)
nance on the system. Fuel supply pressure . . . . . . . 0-400 psig
(0-2758 kPa)
Operation. Steam supply pressure . . . . . . 0-500 psig
(0-3447 kPa)
Gas Generator . . . . . . . . . . . 0-11,000 rpm
speed sensor Fuel supply temperature. . . . . 0-400°F
Lube oil scavenge . . . . . . . . 0-400°F (-18 to
temperature sensors (A, B, (-18 to 204°C)
C-sumps and 204°C) Steam supply temperature . . . 0-700°F
accessory gearbox)
(0-371°C)
Lube oil supply tempera- . . . 0-400°F
ture sensor (-18 to Gas turbine inlet air . . . . . . . . 0-150°F
204°C) temperature (-18 to 66°C)
Vibration indicators, . . . . . . . 0-4 in/sec or
Lube oil scavenge pressure. . . 0-200 psig
Gas generator 0-10 mil DA (0-1379 kPa)
Power turbine inlet gas . . . . 0-2000°F Remote reading variable . . . . -5° to +45°
temperature (T5.4) (-18 to vane indicator
1093°C)
Starter air supply . . . . . . . . . . 0-50 psig
Lube oil supply pressure. . . . 0-100 psig pressure (optional) (0-345 kPa)
(0-690 kPa)
Recoup Pressure . . . . . . . . . . 0-150 psig

(0-1034 kPa)

Fuel/Steam manifold . . . . . . 0-400 psi

Fuel/Steam manifold . . . . . . 0-500°F

temperature sensor (-18-260°C)
Compressor inlet total . . . . . 10-16 psia


AA-21
GEK 97310
VOLUME I
ADDENDUM AA
9-2.4 Preparation. The gas generator and l. Gas generator compressor _________
associated systems must be inspected and rear frame leakage ports,
checked out for proper installation and opera- struts 7 and 10, are open
tion before normal operation can commence. (not capped).
9-2.5 Gas Generator and Associated Equip- m. Continous lube supply _________
ment Check List. Complete the following starter is initially serviced
checklist. per Packager’s manual.
n. Lube oil storage tank ser- _________
a. Gas Generator Assembly _________ viced to full level
S/N
o. Lube oil supply valves _________
b. Mounting base secured to _________ open
foundation
p. All filters are serviced per _________
c. Intake air and exhaust gas _________ Packager’s manual
q. Fire alarm/extinguish sys- _________
d. Bonding straps in place _________ tem “ON” and operative
and secure
r. T5.4 thermocouple system _________
e. Gas generator and exhaust _________
duct support mounts and
links in place and secure s. Ignition system operative _________
f. All service connections _________ t. Compressor inlet total _________
made and secure pressure probe aligned
properly and free of
g. All lines have been _________
damage
flushed per Packager’s
manual u. Variable stator vane _________
system secure
g. All instrumentation con- _________
nections made and secure v. Required checks and _________
i. All accessories are secure _________
Packager’s manual for gas
per Packager’s manual
generator control have
j. Gas generator assembly _________ been performed
free of loose objects and
all lines/electrical leads
connected
k. Gas generator inlet air _________
area free of foreign
objects. Inlet screen
secure.

AA-22
GEK 97310
VOLUME I
ADDENDUM AA
Check. Refer to Packager's manual. COOL DOWN. AVOID CON-
9-2.7 Start-Up and Checkout. WEAR THERMALLY INSU-
WARNING SARY.
MET: OPERATING.

ENTRY SHOULD BE
OPERATION, CONTACT GE generator operation, wear proper ear protec-
FIELD SERVICE FOR A REPRE- tion.
SENTATIVE WHO IS TRAINED b. Perform prestart checks per Table 4.
UNDER SUCH CONDITIONS. c. Perform ignition checkout per para-
graph 9-2.8.
SYSTEM SHALL BE MADE d. Perform motoring procedure per para-
INACTIVE ACCORDING TO graph 9-2.9
THE CUSTOMER’S PROCE- e. Perform false start per paragraph
DURES. 9-2.10.
• SECONDARY AIR TO THE f. Perform governor check per paragraph
ENCLOSURE SHALL BE SHUT 9-2.11.
FLOW MAY PREVENT OPEN- g. Perform a wet prestart per paragraph
ING OR CLOSING THE 9-2.12.
SHALL BE KEPT OPEN. IF THE i. Operate to maximum power per para-
GAS TURBINE IS OPERATING, graph 9-2.14.
TIONED AT THE ENCLOSURE j. Check automatic operation per para-
DOOR AND CONFINED SPACE graph 9-2.15.
BE FOLLOWED.

AA-23
GEK 97310
VOLUME I
ADDENDUM AA
Item Requirements
Fuel valves Closed
Ignition Off
Oil tank level Full
Fuel supply
pressure 350 + 5 psig (2413 + 35 kPa)
temperature See paragraph 7-1.1
flow See paragraph 9-1.1, step b
Steam supply
pressure 400 psig (1278 kPa) Nominal
temperature 600°F (315°C) Nominal
flow See paragraph 9-1.2, step a

AA-24
GEK 97310
VOLUME I
ADDENDUM AA
have been completed and lines flushed, the gas
WARNING
z ASSURE POWER TO IGNITION a. Make ignition, natural-gas and steam
SYSTEMS IS OFF WHEN DIS- supply systems inoperative as follows:
LEAD. TAG SWITCH "OUT OF tion unit.
SERVICE" TO PRECLUDE
INADVERTENT ACTIVATION. (2) Close natural gas and steam man-
ual shutoff valves to fuel control unit.
z ASSURE FUEL AND STEAM
VALVES ARE CLOSED b. Depress MOTORING pushbutton. Gas
THROUGHOUT THIS PROCE- generator will start to rotate. If it does not,
DURE. refer to Packager's manual for supply pressure
to starter.
fuel, motor gas generator for one minute; c. Hold MOTORING pushbutton closed
allow gas generator to coast down. until gas generator speed stabilizes, and check
b. Disconnect number one ignition exciter pressure, release MOTORING pushbutton;
input lead at exciter. Temporarily secure input while gas generator is coasting down, loosen
lead away from the exciter. oil fittings at lube pump to bleed air from sys-
c. Turn on electrical power to the ignition minimum of 2200 rpm.
igniter fires.
9-2.10 False Start. Perform false start as fol-
d. Turn off electrical power to the ignition lows:
system. Reconnect input lead to No. 1 ignition
exciter and safety-wire connector. a. With ignition leads disconnected and
e. Repeat steps b, c and d, disconnecting of gas generator per Packager's manual.
the No. 2 exciter.
f. If an audible report is not heard on mal start cycle and then abort because of lack
No. 1 and/or No. 2 igniters, check the system of flame.
to isolate the problem, and take appropriate
corrective action.

AA-25
GEK 97310
VOLUME I
ADDENDUM AA
9-2.11 Governor Check. Check governor sys- supply if required. Start will then abort
tem per Packager's manual. because of lack of flame.
9-2.12 Wet Prestart. Perform wet prestart as c. Allow gas generator to coast to stop;
follows: then motor it to purge any remaining natural
a. With ignition lead disconnected, but 60 seconds to purge fuel from the gas genera-
with manual gas valve open and governing tor.
generator per Packager's manual. 9-2.13 Manual Start and Operation. Perform
manual start per Packager's manual with fuel
b. Gas generator should accelerate to valve open and with ignition lead connected.
light-off speed (1100 to 1300 rpm). Fuel valve Refer to Table 5.

1. Assure that prestart checks are Investigate cause of con-

completed per Table 4 dition. If T5.4 start limit
is exceeded perform
overtemperature
inspection.
CAUTION
IF T5.4 RAPIDLY APPROACHES OR 1300°F (704°C), ABORT START.
NOTE
A start may be aborted at any time by closing fuel valve, allowing gas turbin to motor
NOTE
If purge cycle is required, NGG in step 3 may be revised. See Table 3.
3. At 1100 to 1300 RPM NGG
a. Ignition on

AA-26
GEK 97310
VOLUME I
ADDENDUM AA

b. Fuel valve open Fuel manifold pres-

sure approximately
3 psig (21 kPa). See
paragraph 9-2.12,
step b.
c. Note time to lightoff (T5.4 10 seconds maximum Abort start-automatic
above 400°F [204°C]) shutdown. Investigate/
correct cause.
4. Note time to 4500 + 200 RPM 90 seconds maximum Troubleshoot system and
take corrective action if
RPM stops increasing or
it takes longer than
90 seconds to reach
4300 RPM
5. At 4300 to 4700 RPM NGG
a. Starter shutoff valve should Valve closed Manually close starter

close automatically air supply

a. Oil pressure 20-60 psig Alarm at 8 + 1 psig
(134-414 kPa) (55 + 6.9 kPa). Trip at
See figures 2 and 3 6+ 1 psig (41 + 6.9 kPa)
b. NGG 5000 RPM ± Adjust
250 RPM
c. T5.4 1000°F (538°C) max Emergency shutdown -
Table 7
d. Vibration-Gas Generator

AA-27
GEK 97310
VOLUME I
ADDENDUM AA

a) Accelerometer Alarm *** Automatic normal shut-

Trip **** down if above trip level.
corrective action.
b) Transducer 0-3 mils DA Alarm set at 4 mils.
corrective action.
e. Compressor inlet temperature Approximately equal Troubleshoot sensing
(T2) to outside air tempera- and indicating system.
ture Correct as required
f. Check for fuel and oil leaks No leaks allowed Correct as required
7A. Operating with NOx Suppression Refer to Packager’s
Manual
8. Set desired power setting. Less than alarm limit Correct as required.
Observe T5.4 during transient Refer to figure 1
operation
following:
b. NGG (corrected) 0-10,100 rpm *
NOTE
c. Oil Pressure See figure 2 or 3 plus Emergency or automatic
Tables 8 thru 11 shutdown if 5 psig
(35 kPa) out of limits.
d. Scavenge oil temperature 160°F to 275°F Alarm set at 300°F
(71°C to 135°C) (149°C). Automatic
shutdown if above
340°F (171°C)

AA-28
GEK 97310
VOLUME I
ADDENDUM AA

e. Vibration-Gas Generator
a) Accelerometer Alarm *** Automatic normal shut-
Trip **** down if above trip level.
corrective action.
corrective action.
f. Fuel manifold pressure 355 psig (2448 kPa) **
max
g. Fuel inlet temperature (See paragraph 7-1.1) **
manual
manual
to outside air
temperature
k. Variable stator vane angle See applicable figure Correct as required per
in WP 118 00 WP 118 00
l. Steam supply pressure 400 psig (2758 kPa) Adjust supply
nominal
m. Steam supply temperature 600°F (316°C) Adjust supply
nominal
limits, shutdown.
*** Alarm - 1.50 inches/sec between 84 and 125 Hz or 1.75 inches/sec above 125 Hz.
**** Trip - 2.50 inches/sec between 84 and 125 Hz or 3.00 inches/sec above 125 Hz.

AA-29
GEK 97310
VOLUME I
ADDENDUM AA
9-2.14 Operation to Maximum Power. 9-2.15 Automatic Operation. Check
automatic operation per Packager's manual.
CAUTION
(refer to Packager's manual) to increase gas
vibration. If variable stator system is not shut down gas generator.
within limits, adjust it per work packages
118 00. If vibrations are not within limits, con- g. Check lube oil and fuel filters and
sult the local General Electric Company repre- strainers; clean or replace as necessary.
sentative.
b. Operate gas Generator up to rated
power, if possible, but do not exceed exhaust i. Remove all temporary instrumentation.
gas temperature (T5.4) limit. Hold at this
power setting until all temperatures stabilize. j. Check gas generator and mounting sys-
If governing system is unstable, adjust per tem for loose parts; tighten as necessary.
Packager's manual.
stabilize. Refer to Table 5, step 9. 9-3.1 General. Normal operation is the rou-
tine operation of an installed gas generator.
d. Reduce gas generator speed to idle. For directions in the use of manual or auto-
After stabilizing for three minutes, record all matic operation for normal operation, refer to
instrument readings. Refer to Table 6, Step 2. Packager's manual.
e. Check fail-safe section of control sys- 9-3.2 Interlocks. Refer to Packager's man-
tem per Packager's manual. ual for description of interlocks which affect
gas generator operation.
f. After gas generator has been stabilized

AA-30
GEK 97310
VOLUME I
ADDENDUM AA
.

1. Set gas generator at idle power Gas generator deceler- Emergency shutdown
ates to idle
2. After stabilizing for 3 minutes,
read and record the following:
a. Oil pressure 20-60 psig Alarm at 8 + 1 psig
(138-414 kPa) (55 + 6.9 kPa)
Trip at 6 + 1 psig
(41 + 6.9 kPa)
b. NGG 5000 rpm + 50 Adjust
c. T5.4 1000°F Max Troubleshoot and take
(538°C) corrective action.
d. Vibration-Gas Generator
a) Accelerometer Alarm * Automatic normal shut-
Trip ** down if above trip level.
corrective action.
corrective action.
e. Fuel inlet temperature (See paragraph 7-1.1)
f. Scavenge oil filter ∆P Refer to packager’s
manual
g. Lube oil supply filter ∆P Refer to packager’s
manual
3. After stabilizing at idle for 5 min- T5.4 drops below Manually shut off fuel
utes, close fuel valve 400°F (204°C) NGG supply
4. Observe T5.4 for 3 minutes after 700°F (371°C) Motor gas generator.
* Alarm - 1.50 inches/sec between 84 and 125 Hz or 1.75 inches/sec above 125 Hz.
** Trip - 2.50 inches/sec between 84 and 125 Hz or 3.00 inches/sec above 125 Hz.

AA-31
GEK 97310
VOLUME I
ADDENDUM AA
WARNING
SARY.
MET: OPERATING.

ENTRY SHOULD BE
OPERATION, CONTACT GE generator operation, wear proper ear
FIELD SERVICE FOR A REPRE- protection.
TO ENTER THE ENCLOSURE b. Start and operate the gas generator per
UNDER SUCH CONDITIONS. Table 5. Do not exceed operating limits of
Table 3.
Table 6.
DURES.
d. If required, emergency shutdown the
• SECONDARY AIR TO THE gas generator per paragraph 9-4.1 and Table 7.
OFF. HIGH SECONDARY AIR- e. Refer to paragraph 5-3.30 and 5-3.31,
FLOW MAY PREVENT OPEN- for lube correction factors and lube supply
ING OR CLOSING THE pressure characteristics. (See tables V-21C,
ENCLOSURE DOOR. V-21D, V-21G, and V-21H, and figures 5-32C,
5-32D, 5-32G, 5-32H, 5-32K, 5-32M, 5-32P,
• THE ENCLOSURE DOOR and 5-32R.)
GAS TURBINE IS OPERATING, NOTE
NOTE
TIONED AT THE ENCLOSURE Addendum AA affects PNL34379P01
DOOR AND CONFINED SPACE only.
BE FOLLOWED. f. The operating lube oil pressure limits
are dependent upon the control system config-
• ALLOW THE GAS TURBINE TO uration and the lube oil type used. Refer to
COOL DOWN. AVOID CON- Tables 8 through 11.
AA-32
GEK 97310
VOLUME I
ADDENDUM AA
9-4 EMERGENCY OPERATION. b. Emergency shutdown shall be made
per Table 7.

ing the fuel and steam valves. However, this .
should only be done in an emergency, since

rapid shutdown will decrease life of gas
generator.
CAUTION
THE ROTOR WILL FREE ITSELF AFTER A COOLING PERIOD OF 3 TO 4
HOURS. CHECK FOR FREEDOM OF ROTATION BY TURNING ROTOR BY
HAND.
1. Conditions permitting, decelerate T5.4 drops below Manually shut off fuel
gas generator to idle and close fuel 400°F (204°C); NGG supply
and steam valves decelerate

AA-33
GEK 97310
VOLUME I
ADDENDUM AA
CAUTION
IF THE STEAM AND FUEL VALVES HAVE BEEN SHUT OFF SIMULTA-
NEOUSLY DUE TO AN EMERGENCY CONDITION, SEQUENCING THE NOR-
MALLY CLOSED DRAIN VALVE TO OPEN DURING SPEED ROLLBACK
(PREFERABLY IN THE SUB-IDLE REGION) MUST BE DONE SUCH THAT A
NATURAL PURGING OF THE MANIFOLD IS ACCOMPLISHED.
3. If an emergency shutdown from a
high power setting (T5.4) greater
than 1150°F (621°C) has occurred,
and a "hot restart" is required, pro-
ceed as follows:

sequencing system can be
cleared and the gas generator
can be restarted within 1 minute
following coastdown of the
HPC rotor, acceptable restarts
can be made using the normal
starting procedure.
b. If a “hot restart” is to be per-
formed between 1 minute and 2
hours following the emergency
shutdown, motor the gas gener-
ator at 2000-2500 rpm NGG for
5 minutes. At the end of the
5 minute motoring/purge cycle
perform normal restart and
accelerate to idle. Acceleration
to the desired power setting can
c. After 2 hours following coast-
down of the HPC rotor, restart
starting procedure.

AA-34
GEK 97310
VOLUME I
ADDENDUM AA
Table 8. LUBE OIL PRESSURE CORRECTIONS FOR INDUSTRIAL LM2500
GAS GENERATORS L34379 VSV CONTROL-3R DAMPER BEARING (MIL-L-23699 OIL)
NOTE
The following values are for corrections to 9000 rpm NGG and 150°F (66°C) lube inlet
temperature. Read oil pressure and temperature then algebraically add the pressure addi-
sure. Corrected lube pressure limit is 56 to 68 psig (386-468.90 kPa).
Oil
Supply
Temp.
(°F) 8000 8100 8200 8300 8400 8500 8600 8700 8800 8900 9000
100 -10.52 -12.01 -13.52 -15.04 -16.58 -18.12 -19.68 -21.25 -22.84 -24.43 -26.04
110 -5.20 -6.60 -8.03 -9.49 -10.98 -12.48 -14.00 -15.53 -17.07 -18.59 -20.10
120 -0.99 -2.30 -3.62 -4.96 -6.29 -7.64 -9.01 -10.38 -11.77 -13.18 -14.56
130 +3.19 +2.02 +0.83 -0.37 -1.57 -2.79 -4.01 -5.24 -6.48 -7.72 -8.98
140 +7.26 +6.16 +5.05 +3.93 +2.80 +1.67 +0.52 -0.63 -1.80 -2.97 -4.15
150 +10.75 +9.71 +8.66 +7.61 +6.54 +5.47 +4.39 +3.31 +2.22 +1.11 0
160 +13.80 +12.83 +11.84 +10.79 +9.73 +8.65 +7.57 +6.48 +5.38 +4.27 +3.15
170 +15.99 +15.00 +14.01 +13.01 +12.00 +10.99 +9.97 +8.94 +7.87 +6.77 +5.66
180 +17.80 +16.77 +15.73 +14.67 +13.62 +12.55 +11.47 +10.38 +9.28 +8.17 +7.05
190 +18.85 +17.84 +16.83 +15.82 +14.79 +13.74 +12.69 +11.62 +10.55 +9.47 +8.37
200 +19.85 +18.87 +17.88 +16.88 +15.88 +14.86 +13.83 +12.79 +11.74 +10.68 +9.61
210 +20.79 +19.83 +18.87 +17.89 +16.91 +15.91 +14.91 +13.89 +12.87 +11.83 +10.79
220 +21.68 +20.75 +19.80 +18.85 +17.89 +16.91 +15.93 +14.94 +13.93 +12.92 +11.90
Oil
Supply
Temp.
(°F) 9100 9200 9300 9400 9500 9600 9700 9800 9900 10000
100 -27.67 -29.30 -30.95 -32.61 -34.28 -35.96 -37.66 -39.37 -41.10 -42.85
110 -21.62 -23.15 -24.70 -26.25 -27.80 -29.38 -30.97 -32.57 -34.18 -35.80
120 -15.95 -17.35 -18.73 -20.11 -21.51 -22.93 -24.35 -25.78 -27.22 -28.67
130 -10.25 -11.52 -12.80 -14.10 -15.40 -16.72 -18.03 -19.36 -20.70 -22.05
140 -5.34 -6.54 -7.75 -8.97 -10.19 -11.43 -12.67 -13.92 -15.18 -16.45
150 -1.11 -2.23 -3.36 -4.50 -5.64 -6.87 -8.11 -9.36 -10.62 -11.88
160 +2.02 +0.88 -0.27 -1.41 -2.56 -3.72 -4.89 -6.06 -7.25 -8.44
170 +4.50 +3.33 +2.14 +0.93 -0.28 -1.49 -2.72 -3.96 -5.21 -6.47
180 +5.92 +4.77 +3.63 +2.46 +1.29 +0.10 -1.10 -2.31 -3.53 -4.76
190 +7.27 +6.15 +5.03 +3.89 +2.74 +1.58 +0.42 -0.76 -1.95 -3.15
200 +8.54 +7.45 +6.34 +5.23 +4.11 +2.98 +1.84 +0.69 -0.47 -1.64
210 +9.73 +8.67 +7.59 +6.51 +5.41 +4.30 +3.19 +2.06 +0.93 -0.21
220 +10.86 +9.80 +8.73 +7.64 +6.54 +5.43 +4.31 +3.17 +2.03 +0.88
NOTE
Oil MIL-L-23699

AA-35
GEK 97310
VOLUME I
ADDENDUM AA
GAS GENERATORS L34379 VSV CONTROL-3R DAMPER BEARING (MIL-L-7808 OIL)
NOTE
sure. Corrected lube pressure limit is 47.5 to 58.5 psig (327.50-403.40 kPa).
Oil
Supply
Temp.
(°F) 8000 8100 8200 8300 8400 8500 8600 8700 8800 8900 9000
100 -4.08 -5.20 -6.34 -7.49 -8.65 -9.82 -10.99 -12.18 -13.37 -14.57 -15.78
110 +0.05 -1.01 -2.07 -3.14 -4.22 -5.31 -6.41 -7.52 -8.63 -9.76 -10.89
120 +3.54 +2.54 +1.54 +0.54 -0.48 -1.50 -2.53 -3.57 -4.61 -5.66 -6.72
130 +6.58 +5.59 +4.60 +3.59 +2.57 +1.55 +0.51 -0.53 -1.58 -2.64 -3.71
140 +8.65 +7.71 +6.77 +5.82 +4.87 +3.90 +2.88 +1.85 +0.80 -0.30 -1.40
150 +10.25 +9.27 +8.27 +7.27 +6.26 +5.25 +4.22 +3.18 +2.13 +1.07 0
160 +11.32 +10.36 +9.40 +8.42 +7.44 +6.45 +5.44 +4.43 +3.40 +2.37 +1.33
170 +12.33 +11.39 +10.45 +9.50 +8.54 +7.57 +6.59 +5.60 +4.60 +3.59 +2.58
180 +13.27 +12.37 +11.45 +10.52 +9.59 +8.64 +7.68 +6.72 +5.74 +4.75 +3.76
190 +14.19 +13.30 +12.40 +11.49 +10.58 +9.65 +8.72 +7.78 +6.80 +5.83 +4.83
200 +15.04 +14.15 +13.25 +12.34 +11.42 +10.49 +9.55 +8.60 +7.64 +6.67 +5.69
210 +15.71 +14.84 +13.95 +13.65 +12.14 +11.21 +10.27 +9.33 +8.37 +7.41 +6.43
220 +16.31 +15.44 +14.56 +13.67 +12.77 +11.86 +10.94 +10.00 +9.06 +8.11 +7.15
Oil
Supply
Temp.
(°F) 9100 9200 9300 9400 9500 9600 9700 9800 9900 10000
100 -16.99 -18.22 -19.45 -20.70 -21.95 -23.21 -24.49 -25.76 -27.05 -28.35
110 -12.03 -13.18 -14.34 -15.51 -16.68 -17.86 -19.05 -20.25 -21.46 -22.67
120 -7.78 -8.89 -9.93 -11.07 -12.24 -13.41 -14.60 -15.79 -17.00 -18.21
130 -4.79 -5.86 -6.94 -8.04 -9.13 -10.24 -11.35 -12.48 -13.66 -14.85
140 -2.52 -3.65 -4.78 -5.94 -7.09 -8.25 -9.41 -10.60 -11.79 -13.00
150 -1.09 -2.17 -3.28 -4.40 -5.52 -6.65 -7.79 -8.94 -10.11 -11.28
160 +0.27 -0.79 -1.87 -2.95 -4.05 -5.15 -6.27 -7.39 -8.53 -9.67
170 +1.55 +0.51 -0.54 -1.60 -2.67 -3.74 -4.83 -5.93 -7.03 -8.15
180 +2.76 +1.74 +0.72 -0.32 -1.36 -2.41 -3.49 -4.57 -5.67 -6.79
190 +3.82 +2.80 +1.78 +0.74 -0.31 -1.37 -2.44 -3.52 -4.61 -5.71
200 +4.69 +3.68 +2.65 +1.62 +0.58 -0.48 -1.54 -2.62 -3.70 -4.80
210 +5.44 +4.44 +3.44 +2.42 +1.39 +0.35 -0.69 -1.75 -2.82 -3.90
220 +6.18 +5.20 +4.21 +3.20 +2.19 +1.17 +0.14 -0.90 -1.95 -3.02
NOTE
Oil MIL-L-7808

AA-36
GEK 97310
VOLUME I
ADDENDUM AA
GAS GENERATORS L34379 VSV CONTROL (MIL-L-23699 OIL)
NOTE
sure. Corrected lube pressure limit is 60 to 74 psig (413.70-510.25 kPa).
Oil
Supply
Temp.
(°F) 8000 8100 8200 8300 8400 8500 8600 8700 8800 8900 9000
100 -12.24 -13.89 -15.53 -17.18 -18.85 -20.54 -22.23 -23.95 -25.67 -27.41 -29.16
110 -6.58 -8.14 -9.72 -11.32 -12.92 -14.48 -16.05 -17.63 -19.23 -20.83 -22.46
120 -1.58 -2.99 -4.42 -5.86 -7.30 -8.73 -10.17 -11.62 -13.07 -14.50 -15.96
130 +3.30 +2.03 +0.76 -0.52 -1.81 -3.10 -4.42 -5.74 -7.07 -8.41 -9.76
140 +7.75 +6.56 +5.37 +4.17 +2.95 +1.73 +0.50 -0.74 -1.99 -3.25 -4.52
150 +11.53 +10.42 +9.30 +8.16 +7.02 +5.87 +4.71 +3.54 +2.37 +1.19 0
160 +14.72 +13.59 +12.46 +11.31 +10.17 +9.00 +7.82 +6.64 +5.45 +4.25 +3.06
170 +16.97 +15.91 +14.84 +13.72 +12.57 +11.42 +10.25 +9.02 +7.77 +6.51 +5.24
180 +18.47 +17.34 +16.20 +15.05 +13.88 +12.70 +11.50 +10.30 +9.08 +7.85 +6.61
190 +19.51 +18.40 +17.28 +16.14 +15.00 +13.85 -12.68 +11.50 +10.31 +9.11 +7.89
200 +20.48 +19.40 +18.30 +17.19 +16.07 +14.94 +13.80 +12.64 +11.48 +10.30 +9.11
210 +21.41 +20.34 -19.27 +18.18 +17.09 +15.98 +14.86 +13.73 +12.59 +11.43 +10.27
220 +22.30 +21.25 -20.20 +19.13 +18.06 +16.97 +15.87 +14.74 +13.60 +12.44 +11.26
Oil
Supply
Temp.
(°F) 9100 9200 9300 9400 9500 9600 9700 9800 9900 10000
100 -30.93 -32.71 -34.50 -36.31 -38.16 -40.04 -41.94 -43.86 -45.79 -47.73
110 -24.09 -25.73 -27.39 -29.06 -30.72 -32.40 -34.09 -35.81 -37.54 -39.30
120 -17.41 -18.88 -20.36 -21.85 -23.35 -24.86 -26.28 -27.92 -29.46 -31.01
130 -11.12 -12.50 -13.88 -15.27 -16.67 -18.08 -19.50 -20.93 -22.37 -23.82
140 -5.80 -7.09 -8.39 -9.69 -11.01 -12.33 -13.67 -15.01 -16.36 -17.73
150 -1.24 -2.53 -3.83 -5.14 -6.47 -7.80 -9.14 -10.49 -11.86 -13.23
160 +1.85 +0.63 -0.59 -1.82 -3.12 -4.43 -5.76 -7.10 -8.48 -9.91
170 +3.96 +2.67 +1.36 +0.04 -1.29 -2.63 -3.99 -5.36 -6.74 -8.14
180 +5.36 +4.09 +2.80 +1.51 +0.21 -1.10 -2.43 -3.77 -5.12 -6.48
190 +6.66 -5.42 +4.17 +2.91 +1.63 +0.35 -0.95 -2.26 -3.58 -4.92
200 +7.90 +6.69 +5.47 +4.23 +2.98 +1.72 +0.45 -0.83 -2.13 -3.43
210 +9.09 +7.90 +6.70 +5.49 +4.26 +3.00 +1.74 +0.45 -0.86 -2.17
220 +10.07 +8.87 +7.66 +6.44 +5.20 +3.95 +2.69 +1.41 +0.12 -1.17
NOTE
Oil MIL-L-23699

AA-37
GEK 97310
VOLUME I
ADDENDUM AA
GAS GENERATORS L34379 VSV CONTROL (MIL-L-7808 OIL)
NOTE
sure. Corrected lube pressure limit is 52 to 64 psig (358.55-441.25 kPa).
Oil
Supply
Temp.
(°F) 8000 8100 8200 8300 8400 8500 8600 8700 8800 8900 9000
100 -3.53 -4.74 -5.97 -7.20 -8.44 -9.68 -10.94 -12.22 -13.50 -14.79 -16.09
110 +0.98 -0.16 -1.30 -2.45 -3.62 -4.79 -5.97 -7.16 -8.36 -9.57 -10.78
120 +4.76 +3.70 +2.62 +1.54 +0.45 -0.65 -1.75 -2.87 -3.99 -5.12 -6.33
130 +7.80 +6.73 +5.65 +4.56 +3.46 +2.34 +1.22 +0.11 -1.02 -2.15 -3.30
140 +10.07 +9.01 +7.94 +6.86 +5.75 +4.59 +3.42 +2.24 +1.05 -0.15 -1.37
150 +11.35 +10.27 +9.18 +8.07 +6.96 +5.83 +4.69 +3.53 +2.37 +1.20 0
160 +12.39 +11.33 +10.26 +9.18 +8.09 +6.99 +5.87 +4.75 +3.61 +2.46 +1.30
170 +13.38 +12.34 +11.30 +10.24 +9.17 +8.09 +7.00 +5.90 +4.79 +3.66 +2.53
180 +14.32 +13.30 +12.28 +11.25 +10.20 +9.15 +8.08 +7.00 +5.91 +4.82 +3.70
190 +15.23 +14.23 +13.23 +12.21 +11.17 +10.11 +9.03 +7.94 +6.85 +5.74 +4.62
200 +15.96 +14.96 +13.95 +12.93 +11.89 +10.85 +9.79 +8.72 +7.64 +6.55 +5.44
210 +16.61 +15.63 +14.63 +13.62 +12.60 +11.57 +10.53 +9.48 +8.42 +7.34 +6.25
220 +17.24 +16.28 +15.30 +14.30 +13.30 +12.29 +11.26 +10.23 +9.18 +8.12 +7.05
Oil
Supply
Temp.
(°F) 9100 9200 9300 9400 9500 9600 9700 9800 9900 10000
100 -17.40 -18.72 -20.05 -21.38 -22.73 -24.08 -25.45 -26.83 -28.22 -29.61
110 -12.01 -13.24 -14.49 -15.74 -17.00 -18.27 -19.55 -20.84 -22.13 -23.44
120 -7.56 -8.80 -10.05 -11.30 -12.57 -13.84 -15.13 -16.42 -17.73 -19.04
130 -4.44 -5.61 -6.83 -8.07 -9.32 -10.58 -11.90 -13.24 -14.59 -15.96
140 -2.59 -3.83 -5.08 -6.35 -7.62 -8.91 -10.21 -11.52 -12.84 -14.18
150 -1.20 -2.41 -3.63 -4.86 -6.11 -7.37 -8.63 -9.92 -11.21 -12.51
160 +0.13 -1.06 -2.25 -3.46 -4.67 -5.90 -7.14 -8.40 -9.66 -10.93
170 +1.38 +0.23 -0.94 -2.12 -3.31 -4.51 -5.73 -6.95 -8.18 -9.43
180 -2.59 +1.43 +0.28 -0.91 -2.10 -3.32 -4.54 -5.77 -7.02 -8.28
190 +3.48 +2.34 +1.18 +0.01 -1.17 -2.36 -3.56 -4.78 -6.00 -7.24
200 +4.33 +3.20 +2.06 +0.91 -0.25 -1.42 -2.61 -3.80 -5.01 -6.23
210 +5.16 +4.05 +2.93 +1.79 +0.65 -0.50 -1.67 -2.85 -4.04 -5.23
220 +5.97 +4.88 +3.77 +2.66 +1.53 -0.40 -0.75 -1.91 -3.08 -4.26
NOTE
Oil MIL-L-7808

AA-38
GEK 97310
VOLUME I
ADDENDUM AA
9-4.2 Post Shutdown Fire. 9-5.2 Overtemperature. During starting and
acceleration to idle, cooling flows to compo-
a. During a normal shutdown, exhaust nents of the gas generator hot section are not
gas temperature should decrease. If, during sufficient to protect the metals at T5.4 alarm
time gas generator is coasting to stop, tempera- and trip levels specified in the limits table. A
ture increases instead of decreases, it indicates lower T5.4 limit is therefore established, with
that combustion is still taking place because of higher levels acceptable provided they exist
a leaking fuel valve. (A slight temperature for limited times as depicted on the curve titled
increase after rotation stops is normal.) Make "Transient Temperature Limits for Starts" (fig-
certain fuel is shut off, and motor the gas gen- ure 1). This must be monitored by the operator.
erator. This will blow out the fire. As soon as The overtemperature inspection called for by
temperature decreases to normal, discontinue entry into area B requires hot section disas-
motoring. sembly and inspection in a qualified facility.
9-5 SPECIAL GAS TURBINE 9-5.3 Lube Oil Supply Pressure. The lube
CONSTRAINTS. oil supply pressure limits given in the limit
table are "distress" limits. Protective devices
ditions, the gas generators are constrained by because the proper pressure is dependent on
the operating limits published in the limits gas generator speed, oil type, oil temperature,
table. Continuous operation between the alarm and number of oil jets. An operator must there-
and shutdown or "trip" level should not be fore derive a corrected oil pressure as directed
practiced. in the appropriate pressure correction tables to
In the event that any of the following situations within the high-low limits stated on each table.
assure the gas generators continued normal generator rotational speeds above 7500 rpm
operation. These events are either not detected can result in high pressure compressor blade
or not prevented by the customary protective fracture. The gas generator can be operated
devices of control systems. after an inspection of the compressor stages 3
from the spool.

AA-39
GEK 97310
VOLUME I
ADDENDUM AA
9-5.5 Starter Duty Cycle - Air or Natural 9-5.6 Re-Start Following High Power Trip.
Gas and Hydraulic Starter (optional). In the event that re-start of the gas generator is
required within two (2) hours following a trip
a. With starter inlet air pressure set at or rapid shutdown from high power, a five (5)
40 psig (276 kPa): minute motoring at 2050 + 50 rpm should pre-
cede the start-up. Refer to Table 7. The objec-
• 45 seconds on, 2 minutes off for any tive is to cool the high pressure turbine rotor,
numbers of cycles, so that blade tips maintain clearance with the
more rapidly cooling case.
or
9-5.7 Windmilling.
the gas generator is allowed at speeds above
b. With starter inlet air pressure set at 15 1000 rpm provided the lube oil temperature
psig (103 kPa) for motoring: limits are not exceeded. At these speeds, the
lube supply and scavenge systems are in nor-
• 5 minutes on, 2 minutes off with two mal operation.
or windmilling is allowed up to five (5) minutes,
• 10 minutes on, 20 minutes off for any normal gas generator operation.
number of cycles.

hydraulic starter, provided that the oil tempera-
ture to the starter is maintained under 140°F
(60°C).

AA-40
GEK 97310
VOLUME I
ADDENDUM AB
ADDENDUM
7LM2500-PH-NGA/MGA (STIG)

GEK 97310
VOLUME I
ADDENDUM AB
TABLE OF CONTENTS
1-0 INTRODUCTION....................................................................................... AB-3

2-0 REFERENCE DATA .................................................................................. AB-3
3-0 INSTALLATION DRAWINGS.................................................................. AB-4
4-0 EQUIPMENT DESCRIPTION ................................................................. AB-4
5-0 INSTRUMENTATION AND SUPPLY REQUIREMENTS ................... AB-4
6-0 SERVICE REQUIREMENTS ................................................................... AB-4
6-1.1 Natural Gas ................................................................................................... AB-4
6-1.2 Steam Injection System................................................................................. AB-5
6-1.3 Steam Flow, Pressure and Temperature Requirements ................................. AB-5
6-1.4 Steam Control and Scheduling Requirements............................................... AB-12
6-1.5 High Pressure Steam System ........................................................................ AB-12
6-1.6 Steam Scheduling.......................................................................................... AB-13
6-1.7 Steam Purity/Contamination Limits.............................................................. AB-14
7-0 OPTIONAL HARDWARE KITS - 7LM2500-PH-NGA ......................... AB-15
8-0 GAS TURBINE OPERATION .................................................................. AB-15
8-1.1 Performance Ratings and Operating Limits.................................................. AB-15
8-1.2 Performance Ratings ..................................................................................... AB-16
8-1.3 Operating Limits ........................................................................................... AB-17
8-2 INITIAL OPERATION .............................................................................. AB-17
8-2.1 General .......................................................................................................... AB-17
8-2.2 Special Instrumentation Required for Operation .......................................... AB-17
8-2.3 Special Instrumentation Required for Monitoring and Troubleshooting ...... AB-24
8-2.4 Preparation .................................................................................................... AB-24
8-2.5 Gas Turbine and Associated Equipment Checklist ....................................... AB-24
8-2.6 Governor and Manual Control Check........................................................... AB-25
8-2.7 Start-Up and Checkout.................................................................................. AB-25
8-2.8 Ignition Check............................................................................................... AB-26
8-2.9 Motoring........................................................................................................ AB-26
8-2.10 False Start...................................................................................................... AB-28
8-2.11 Governor Check ............................................................................................ AB-28
8-2.12 Wet Prestart ................................................................................................... AB-28
8-2.13 Manual Start and Operation .......................................................................... AB-28
8-2.14 Operation to Maximum Power...................................................................... AB-29
8-2.15 Automatic Operation..................................................................................... AB-29
8-3 NORMAL OPERATION............................................................................ AB-30
8-3.1 General .......................................................................................................... AB-30
8-3.2 Interlocks....................................................................................................... AB-30
8-3.3 Operation....................................................................................................... AB-34
8-4 EMERGENCY OPERATION ................................................................... AB-35
8-4.1 Emergency Shutdown ................................................................................... AB-35
8-4.2 Post Shutdown Fire ....................................................................................... AB-35

AB-1
GEK 97310
VOLUME I
ADDENDUM AB
8-5 SPECIAL GAS TURBINE CONSTRAINTS ........................................... AB-35

8-5.1 General .......................................................................................................... AB-35
8-5.2 Overtemperature............................................................................................ AB-36
8-5.3 Lube Oil Supply Pressure ............................................................................. AB-36
8-5.4 High Speed Stall............................................................................................ AB-36
8-5.5 Starter Duty Cycle - Air or Natural Gas........................................................ AB-36
8-5.6 Re-Start Following High Power Trip ............................................................ AB-36
8-5.7 No Power Turbine Rotation .......................................................................... AB-37
8-5.8 Windmilling .................................................................................................. AB-37
Figure Title Page
1 Transient Temperature Limits ....................................................................... AB-9

2 Deleted
3 Deleted
4 Deleted
5 Deleted
6 Steam Contamination - Maximum Solids ..................................................... AB-11
7 LM2500 STIG Steam Limits ........................................................................ AB-12
LIST OF TABLES
Table Title Page
1 INSTRUMENTATION CONNECTIONS - 7LM2500-PH-NGA/MGA...... AB-5

2 SUPPLY CONNECTIONS - 7LM2500-PH-NGA/MGA............................. AB-6
3 GAS TURBINE OPERATING LIMITS....................................................... AB-17
4 PRESTART CHECKS .................................................................................. AB-27
5 START-UP AND OPERATION.................................................................... AB-30
6 GAS TURBINE SHUTDOWN .................................................................... AB-33
7 EMERGENCY SHUTDOWN...................................................................... AB-37
8 DELETED
9 DELETED
10 DELETED
11 DELETED

AB-2
GEK 97310
VOLUME I
ADDENDUM AB
The information contained herein describes the Compressor Stator, Front 307 (139)
7LM2500-PH-NG/MGA STIG model gas tur- Compressor Stator, Rear 93 (42)
bine basic configuration and control system Compressor Rear Frame 421 (191)
differences. In addition, the coverage of refer- Combustor 120 (54)
ence data, instrumentation and supply connec-
tions, special servicing requirements, optional
hardware kits and the complete gas turbine High Pressure Turbine Nozzle, 68 (31)
operating instructions for the 7LM2500-PH- Stg 1
NGA/MGA model are included. High Pressure Turbine Nozzle, 127 (58)
Stg 2
2-0 REFERENCE DATA. Turbine Mid Frame 530 (240)
EQUIPMENT
(General Electric Co., Cincinnati, Ohio) High Speed Coupling Shaft 91 (41)
Model No. 7LM2500-PH-NGA/MGA Forward Adapter
Drawing No. L31430G21 Exhaust Duct Assembly 2741 (1243)
PERFORMANCE RATING
Refer to paragraph 8-1.1. Inner Deflector 255 (116)
Ring Seal 49 (22)
GAS TURBINE WEIGHTS Ring Support 74 (34)
turbine components are: Cover, Insulation 62 (28)
Variable Stator Actuating 19 (9)
Component Wt-Lbs/(Kg) Mech
Gas turbine - including inlet Outside Piping and Bracketing 278 (126)
diffuser, and coupling nut 7396 (3355) DRAWING LIST Drawing No.
High Pressure Steam Piping L31859
Schematic
Power Turbine 2777 (1260) Drawing
Inlet Gearbox 38 (17) Fuel System Flow Diagram L24327
Transfer Gearbox 245 (111) Lubrication System Flow L24328
Compressor Front Frame 517 (235) Diagram
Compressor Rotor 552 (250) Electrical Diagram L24329

AB-3
GEK 97310
VOLUME I
ADDENDUM AB
DRAWING LIST Drawing No. c. Steam injected into the fuel nozzle
steam manifold is directed into the combustion
Ignition Units L21454 Primary zone through a special steam and gas
Gas Turbine Assembly fuel nozzle with concentric tube construction.
Drawing L31430G21 The inner fuel nozzle passage supplies natural
Fuel and Steam Injection 682L400 gas, and the outer passage supplies steam to
Assembly the engine.
d. Each of the two CDP manifolds sup-
3-0 INSTALLATION DRAWINGS. plies steam to two compressor rear frame struts
which duct the steam into the inner hub of the
A complete set of installation drawings have compressor rear frame. From the inner hub of
been provided. the compressor rear frame, the steam flows
into the compressor discharge flowpath
4-0 EQUIPMENT DESCRIPTION. between the combustor inner liner and inner
combustion casing to mix with combustor liner
a. The 7LM2500-PH-NGA/MGA STIG cooling air, into the Stage 1 high pressure tur-
model is a non-marinized, natural gas fueled bine nozzle cooling air path, and into the high
gas turbine which is capable of accepting all of pressure turbine rotor and blade cooling air
the steam produced by a Heat Recovery Steam path.
Generator (HRSG) in the gas turbine exhaust
system, plus additional steam, within limita- e. The 7LM2500-PH-NGA/MGA engine
tions, from supplemental firing of the HRSG aero-thermal cycle has also been modified to
or from other sources. Benefits resulting from accommodate the addition of steam to the
injection of steam into the gas generator are engine airflow by increasing the high pressure
increased output horsepower, improved ther- turbine nozzle flow function and decreasing
mal efficiency, and suppression of the oxides the low pressure turbine nozzle flow function.
of nitrogen (NOx) in the engine exhaust gases.
f. Assembly and interface details of the
b. Steam is injected into the high pressure engine-mounted steam manifolds and
section of the engine by means of two separate steam/gas fuel nozzle system are defined on
engine-mounted manifold systems: a fuel noz- Drawing No. 682L400.
zle steam manifold and two compressor dis-
charge bleed air port manifolds. Steam flow in 5-0 INSTRUMENTATION AND
each of the two manifold systems is regulated SUPPLY REQUIREMENTS.
by separate metering valves, with the ratio of (See Tables 1 and 2.)
flow between the two systems based on opti-
mization of emissions suppression and avail- 6-0 SERVICE REQUIREMENTS.
able steam. A schematic diagram of the steam
systems is shown on Drawing No. L31859. 6-1.1 Natural Gas.

355 ± 5 psig (2448 ± 35 kPa) maximum.

AB-4
GEK 97310
VOLUME I
ADDENDUM AB
b. The temperature of the gas supply at 6-1.2 Steam Injection System.
must be in the range of 20°F (11°C) above the 6-1.3 Steam Flow, Pressure and Temperature
saturated vapor temperature as a minimum, Requirements.
and 350°F (177°C) as a maximum. Based on
consideration of control system components a. The high pressure steam injection sys-
however, it is recommended that the maximum tem includes two metering valves: one controls
gas supply temperature be limited to 150°F the flow to the fuel nozzles and the other con-
(66°C). If the supply temperature of the gas is trols the flow to the CDP manifolds. Flow
not repeatable on a day-to-day basis, it will be meters measure the flow through each meter-
necessary to change the control system starting ing valve.
fuel adjustment or to adjust the supply pressure
to the gas turbine to maintain a constant
BTU-per-cubic-foot supply. Once started the
gas turbine will accept variations in supply
temperature of ±20°F (±11°C). The maximum
fuel flow required, assuming a lower heating
value of 19,000 BTU/lb is 13,500 pph
(6123 kg/h) for the 7LM2500-PH-NGA/MGA
model gas turbine.
Table 1. INSTRUMENTATION CONNECTIONS - 7LM2500-PH-NGA/MGA

Item Nomenclature Mates With:
E-1 Vibration pickup, Gas Generator Diagnostic System Corp.
Part No. 303-03
E-18 D-sump scavenge oil temperature MS3106R12S-3S
E-13 Vibration pickup, power turbine Diagnostic System Corp.
Part No. 303-03

AB-5
GEK 97310
VOLUME I
ADDENDUM AB
Table 1. INSTRUMENTATION CONNECTIONS - 7LM2500-PH-NGA/MGA (Cont.)
Item Nomenclature Mates With:
(optional)
A23 CDP pressure port (optional) 0.500-20UNJF
NOTE
• For all other instrumentation connections, see Installation Drawings, provided with gas tur-
bine.
• Refer to Gas Turbine Packager's Manual for instrumentation required for monitoring steam
conditions.
Table 2. SUPPLY CONNECTIONS - 7LM2500-PH-NGA/MGA

CAUTION
Manifold
L1 Oil supply 1-1/2 inch line to Lube Pump on Gas Turbine
AN818-24C or MS20819-24C
AN818-16C or MS20819-16C.

AB-6
GEK 97310
VOLUME I
ADDENDUM AB
Table 2. SUPPLY CONNECTIONS - 7LM2500-PH-NGA/MGA (Cont.)
AN818-16C or MS20819-16C
L3 Scavenge oil discharge 1-1/4 inch line from Gas Turbine Scavenge Pump to oil
Scavenge Filter and Cooler AN818-20C or
MS20819-20C
to exhaust duct (flame arrestor)
Gas Turbine Inlet Duct AN818-16C or MS20819-16C
F3 Fuel manifold gas pressure tap MS20819-4
W16 CDP steam manifold supply 3-1/2 inch MS type flange from steam supply to
CDP steam manifold
W17 CDP steam manifold supply 3-1/2 inch MS type flange from steam supply to
CDP steam manifold
W18 Fuel nozzle steam supply 4 inch MS type flange from steam supply to fuel nozzle
steam manifold
W19 Fuel nozzle steam manifold drain MS20819-12/MS9197-12
W21 CDP steam manifold drain MS20819-8/MS9197-08
NOTE
• For all other supply connections needed, see Installation Drawings, provided with the gas
turbine.
• Refer also Gas Turbine Packager's Manual.

AB-7
GEK 97310
VOLUME I
ADDENDUM AB
b. The steam manifolds and gas/steam e. Whenever high pressure steam is
fuel nozzles are designed to flow steam by injected into the engine, a minimum flow
weight equivalent to approximately 10% of the should be provided to the fuel nozzle steam
high pressure compressor airflow (W25) or and CDP manifolds as defined in table 3 to
15 pounds per second (6.8 kg/sec) of steam at prevent condensation.
675°F (357.2°C), at a supply pressure to mani-
fold inlets of 325 psia (2241 kPa), at compres- f. A crossover line is included in the
sor discharge pressure (PS3) of 285 psia Packager's steam supply system to connect the
(1965 kPa) with steam flow split between fuel CDP steam manifold supply to the fuel nozzle
nozzles and CDP manifold. This steam split steam manifold supply. This crossover line
can be revised from the design point to meet provides purge and preheat air for the steam
application requirements for NOx reduction manifolds when no steam is being injected.
and steam availability. Maximum permissible The static pressure difference between the
steam pressure at the manifold inlet for either inner flowpath at the CDP steam discharge and
system is 700 psia (4826 kPa) and maximum the combustor dome at the fuel nozzle tip is
steam temperature is 960°F (516.6°C). sufficient to provide circulation of compressor
discharge air from the CDP steam manifold,
c. The minimum permissible steam tem- through the crossover and into the fuel nozzle
perature at the inlets to the manifolds is 50°F steam manifold to ensure that purge flow is
(28°C) above saturation. The maximum com- into the combustor and not from the combus-
bined combustor and CDP steam flow is tor. The crossover line contains a low pressure
approximately 69,000 lbs/hr (31298 kg/hr) @ drop check valve that prevents flow of steam
59°F (15°C) with each system operating with from the fuel nozzle steam supply to the CDP
its individual maximum steam flow. (See steam supply.
Table 3 and Figure 7 for more precise values).
d. The maximum permissible steam flow

into the fuel nozzle and CDP manifolds is a
function of compressor discharge pressure
(PS3) as given in figure 7. At very high steam
to fuel ratios, combustor efficiency may be
reduced and combustor flame out margin is
reduced.

AB-8
GEK 97310
VOLUME I
ADDENDUM AB

AB-9
GEK 97310
VOLUME I
ADDENDUM AB

AB-10
GEK 97310
VOLUME I
ADDENDUM AB
Figure 6. Steam Contamination - Maximum Solids

AB-11
GEK 97310
VOLUME I
ADDENDUM AB
Figure 7. LM2500 STIG Steam Limits
g. Levels of steam contamination must b. During normal transient accelerations

not exceed those defined in paragraph 6-1.7. or decelerations of the gas generator when the
decels or accels limits are not encountered, the
6-1.4 Steam Control and Scheduling steam flow is to be within the limits provided
Requirements. (Ref. Schematic GE L31859.) in figure 7. The stem flow rate shall never
increase more rapidly than 0. 07 lb/sec./sec.
6-1.5 High Pressure Steam System. (0.0318 kg/sec./sec.) (Table 3). Steam flow
shall be reduced during engine decel as rapidly
a. It is recommended that steam be sched- as necessary to follow engine PS3 changes
uled as a function of high pressure compressor such that the metered steam shall not exceed
discharge static pressure (PS3). Limits on high the scheduled steam limit by more than 5%.
pressure steam flow vs PS3 are shown in For engine shutdowns or step decrease power
figure 7. change transients the steam shall be shutdown
at the maximum rate of the steam metering
valves. For gradual reductions in power to lev-
els below schedule limits, the metering valves
shall be ramped closed at a rate that reduces
steam at 0.07 lb/sec/sec (0.03 kg/sec./sec.) or
less from the scheduled value to a value of
zero.

AB-12
GEK 97310
VOLUME I
ADDENDUM AB
c. Steam flow shall be initiated only after g. Both metering valves in the steam sys-
the engine is stabilized at power when the CDP tem must have a 100% travel shutdown time of
is within the limits given in figure 7. The less than 100 milliseconds (same as gas fuel
steam should be shut-off when engine horse- shutdown valve). The steam shut-off valves
power is below the CDF limits of figure 7. The shall close within 1.0 second.
General Electric Company should be consulted
when operation with steam is desired outside h. The gas turbine does not require any
the figure 7 limits. particular minimum steam flow through either
the fuel nozzle steam manifold or CDP mani-
d. Liquid water shall be prevented from folds, however consideration must be given to
entering the steam manifolds during engine the system external to the engine with respect
operation. Before initiating steam flow, steam to line lengths, volumes, pipe lagging, cooling
supply lines and components shall be purged air flow over the lines, etc., to prevent conden-
(preheated) until their metal temperatures are sate from developing due to an inadequate
at least 50°F (28°C) above the saturated steam superheat and/or insufficient flow through the
temperature. Precautions must be exercised to external pipes and components.
ensure that any steam condensation in the fuel
nozzle and CDP steam supply lines during 6-1.6 Steam Scheduling.
engine operation is continuously being
removed through the bleed drain systems. a. Steady state steam flow is scheduled as
a function of compressor discharge static pres-
e. The steam supply system shall be pro- sure (PS3). The steam flow operational limits
tected by check valves to prevent hot engine are provided in figure 7. The control system
gases from back flowing into the Purchaser shall limit the CDP to the maximum value
supplied steam system when steam is not being shown in figure 7 as a function of altitude
used for engine operation. (CDP x P2/14.7).
f. The steam system volume downstream b. On all emergency conditions requiring

of the metering valve affects transient opera- immediate redaction in power level, it will be
tion. It is recommended that the piping volume necessary to close both steam metering valves
from the metering valve to the steam manifold at least as rapidly as the fuel shutoff valves.
be no greater than 1272 cubic inches This rapid shutdown of the steam system
(0.021 M3) for each of the two systems, the avoids a high steam to fuel ratio in the com-
fuel nozzle supply and the CDP manifold bustor during rapid transients and, coupled
supply. with the specified downstream volumes, will
reduce the probability of combustor flameout.

AB-13
GEK 97310
VOLUME I
ADDENDUM AB
c. The steam control system shall remove S/F = Steam/Fuel Ratio (Wt.
all water and saturated steam and raise the pipe Basis)
or component metal temperature to at least
50°F (28°C) above steam saturation tempera- (3) By this equation, if there was zero
ture prior to initiation of steam injection into Na + K in the air and fuel, the maximum
the engine manifolds. When the preheating allowed in the steam in PPB would be 200
valves are open, the steam metering valves divided by S/F.
shall be closed. When the steam temperature at
the preheating valves is 50°F (28°C) or more b. Total Conductivity [Cation + Anion @
above saturation temperature, the control then 77°F (25°C)].
signals the preheating valves to close and pro-
vides a permissive signal for the steam meter- Normal: 0.5 - 1.5 Micro-OHM/CM
ing valves to open. The steam metering valves (95% of operating time)
must be opened in 30 seconds, if not, the pre- Abnormal: As high as 2.0 Micro-OHM/
heating cycle must be reinitiated. CM (5% of operating time)
6-1.7 Steam Purity/Contamination Limits. c. Total Solids.
a. Sodium + Potassium (Na + K): (1) The maximum total solids is

dependent upon the maximum steam to fuel
(1) The maximum amount of Na + K ratio at which the engine is to operate in the
allowed in the steam injected into M&I engine specific application. The value is determined
depends upon the total Na + K contamination from figure 6. Maximum size shall not exceed
from all sources; i.e., from the fuel, air, and 20 microns.
steam.
(2) With the exception of silica, there
(2) Therefore, the maximum Na + K is no differentiation between types of solids as
allowed in the steam is determined from the long as other limitations of this section are
equation: met. Silica in the steam is limited to 20 PPB.
(PPBFuel) + (PPBAir) A/F + (PPBSteam) S/F Interpretation of figure 6 should be made

= 200 PPB as follows:
Where: High Pressure Stem.

PPBFuel = Parts Per Billion Na + K in
(3) Calculate maximum steam to fuel
Fuel
ratio by dividing the total high pressure steam
PPBAir = Parts Per Billion Na + K in (fuel nozzles plus CDP) by fuel flow (WF36)
Air for site operating conditions. Where steam
PPBSteam = Parts Per Billion Na + K in flow may vary widely, the operating condition
Steam with the highest steam to fuel ratio should be
used.
A/F = Air/Fuel Ratio (Wt. Basis)

AB-14
GEK 97310
VOLUME I
ADDENDUM AB
(4) From the curve, determine the WARNING
"Total Solids Permissible" and apply this limit
to the high pressure steam supplied to the gas IF A QUESTIONABLE CONDITION
turbine. EXISTS DO NOT OPERATE THE
d. Steam Sampling. OUGH INVESTIGATION HAS
(1) Steam samples should be taken in HOT STARTS, STALLS, OR OTHER
accordance with ASTM 1066 Procedures. RECOGNIZED PROBLEM WITH-
OUT PRIOR THOROUGH INVESTI-
7-0 OPTIONAL HARDWARE KITS - GATION. FAILURE TO DO SO CAN
7LM2500-PH-NGA. RESULT IN UNDUE STRESS
BEING IMPOSED ON GAS TUR-
a. Refer to Volume II, WP 001 00 for a BINE COMPONENTS WITH IMME-
detailed list of optional kits available for this DIATE OR SUBSEQUENT
particular gas turbine model. DESTRUCTIVE FAILURE OF THE
GAS TURBINE AND INJURY TO
8-0 GAS TURBINE OPERATION. PERSONNEL.
a. These instructions contain the detailed 8-1.1 Performance Ratings and Operating
gas turbine operating procedures and limits Limits.
pany for the 7LM2500-PH-NGA Gas Turbine. NOTE
• Ratings published in this manual
b. The instructions are intended to pro- apply to the gas turbine. The driven
vide operating personnel with the information unit ratings/limits may be lower in
required to operate the gas turbine. They per- some cases and shall take prece-
tain to routine and emergency conditions and dence over the gas turbine manual
procedures. When a fault exists, refer to Vol- limits.
ume I. Chapter 4, TROUBLESHOOTING.
• Performance data with steam injection
c. It is possible that these instructions are available from the General Electric
may not provide for every possible variation in Company. Purchaser's request should
equipment or contingency to be met in connec- include site conditions, fuel heating
tion with the operation of the gas turbine. valve and chemical composition, steam
Refer requests for additional information to the quantities, steam temperature and steam
General Electric Company; Marine and Indus- supply pressure at the entrance to the
trial Engine Department; Cincinnati, Ohio steam manifolds.
45215.
d. Refer also to Gas Turbine Packager’s

Manual.

AB-15
GEK 97310
VOLUME I
ADDENDUM AB
8-1.2 Performance Ratings. b. Starting fuel flow for the
7LM2500-PH-NGA model gas turbine is nor-
a. The nominal average rated perfor- mally set by the minimum stop on the gas fuel
mance of the 7LM2500-PH-NGA gas turbine metering valve. The proper fuel flow setting
in the new and clean condition is as follows: for the minimum stop, on a heat consumption
basis, is 10.45 x 106 ± 0.46 x 106 BTU/HR
Power Turbine Speed commencing fuel and ignition at 1200 ± 100
3600 rpm 3000 rpm rpm. Where a minimum stop is not utilized,
acceptable light-offs can be obtained in the
• Shaft Horse- sub-idle region, however during such starts,
power - Base 36100 34250 ignition should be initiated at that fuel flow
• Heat Rate, BTU/ corresponding to the minimum stop with its
HP-Hr - Average associated tolerance. If starts in the sub-idle
(Base) 6287 6486 region are required, refer to Gas Turbine
Installation Design Manual MID-IDM-2500-9.
c. Refer to Installation Design Manual
Total Steam Flow 40000 lbs/hr (18155 kg/hr) MID-IDM-2500-9 for 7LM2500 gas turbine
Inlet Air transient fuel flow requirements.
Temperature 59°F (15°C) 59°F (15°C)
those shown will result in overtemperature and
Inlet Losses 4"H2O 4"H2O
possible stall of the gas turbine. Acceleration
Exhaust Losses 10"H2O 10"H2O fuel rates lower than those shown can result in
Relative Humidity 60% 60% "hung" starts in the below idle speed range.
Accessory Power e. Above the idle speed point, low accel-
Extraction 0 0 eration fuel rates will not harm the gas turbine
Power Turbine and will only result in slower acceleration
Inlet Gas times.
Temperature
T5.4 Average - 1475°F 1448°F f. For normal accelerations from idle to
At Base Rating (801.7°C) (786.7°C) power settings the changes should be made
section repairs and the life of the gas turbine.
g. Refer to paragraph 6-1.2 for descrip-

tion of the steam injection system.

AB-16
GEK 97310
VOLUME I
ADDENDUM AB
8-1.3 Operating Limits. Refer to Table 3. Gas Generator speed ............ 0-11,000 rpm
sensor
NOTE Lube oil scavenge ................ 0-400°F
If any operating limit is exceeded, temperature sensors (A, (-18 to 204°C)
verify instrumentation accuracy before B, C, D-sumps and trans-
troubleshooting or inspecting gas fer gearbox)
generator. Lube oil supply tempera- ..... 0-400°F
ture sensor (-18 to 204°C)
8-2 INITIAL OPERATION. Vibration indicators..............
Gas generator 0-4 in/sec or
8-2.1 General. Initial operational period is 0-10 mil DA
gas turbine installation, replacement, or major Power turbine ....................... 0-2 in/sec
maintenance on the system. 0-15 mil DA
Power turbine speed sensor.. 0-5000 RPM
8-2.2 Special Instrumentation Required for Power turbine inlet gas ........ 0-2000°F
Operation. temperature (T5.4) (-18 to 1093°C)
Lube oil supply pressure ...... 0-100 psig
(0-690 kPa)
Refer also to Gas Turbine Packager’s Manual
for instrumentation required for monitoring
steam supply system conditions.

Normal
Alarm/ Operating
NOTE
• Continuous operation should not take place with any parameter indicating
between the alarm and trip levels. If an alarm level is not shown, the trip level
is the operating limit.

Lubrication Gas turbine Alarm 8 psig ± 1 psig (55 20-60 psig Bypass until
System - lube pump kPa ± 6.9 kPa) (138-414 kPa) 4500 rpm
Settings and pressure below
Operating 8000 rpm 15 psig ±
Ranges 1 psig (103 kPa ±
6.9 kPa) above 8000
rpm

AB-17
GEK 97310
VOLUME I
ADDENDUM AB
Normal
Alarm/ Operating
Gas turbine Trip 6 psig ± 1 psig 20-60 psig Bypass until
lube supply (41 kPa ± 6.9 kPa) (138-414 kPa) 4500 rpm
pressure
charge pressure shall not exceed
180 psig
(1242 kPa)
Gas turbine Alarm 180° - 220°F 140° - 160°F Normal operat-
lube supply (82° - 104°C) 60° - 71°C ing range reflects
temperature temperature
expected during
operation above
idle speed
Gas turbine Trip 330° - 350°F 160° - 275°F Normal operat-
lube scavenge (166° - 177°C) (71° - 135°C) ing range reflects
temperatures - Alarm 290° - 310°F temperature
Five (143° - 154°C) expected during
operation above
idle speed
Fuel System Fuel manifold 0-355 psig Supply pressure
Natural Gas pressure (0-2448 kPa) as reflected at the
fuel manifold
inlet on the gas
turbine
Fuel supply Alarm 150°- 170°F -65° - 150°F Starting fuel
temperature (66° - 77°C) (-54° - 66°C) flow adjust-
ments are
required to com-
pensate for fuel
temperature vari-
ation.

AB-18
GEK 97310
VOLUME I
ADDENDUM AB
Normal
Alarm/ Operating
Starting Starter supply 40 psig Starting pressure
System pressure (276 kPa) requirement
based on gas tur-
bine starter
torque require-
ments
of fuel and
ignition
fuel and igni- for start after
tion (if purge purge cycle
cycle is used)
Starting time to Trip 1200 ± 100 rpm Activate
1200 rpm 20 seconds time
delay simulta-
neously with
start initiation
Failure to Trip 380°-420°F Activate
light-off (193°-216°C) 10 seconds time
T5.4 delay simulta-
neously with
application of
fuel and ignition
Starting time to Trip 4500 ± 200 rpm Activate
4500 rpm 90 seconds time
delay simulta-
neously with
start initiation.
De-energize
ignition, fuel
system and
starter air
supply

AB-19
GEK 97310
VOLUME I
ADDENDUM AB
Normal
Alarm/ Operating
Starting time Trip 4500 ± 100 rpm Activate
to 4500 rpm (if 60 seconds time
purge cycle is delay upon com-
used) pletion of purge.
De-energize fuel
and ignition sys-
tems and starter
air supply
Power Failure to Trip 380°F - 420°F 0° - 1600°F Trip if tempera-
Turbine Inlet light-off (193° - 216°C) (0° - 871°C) ture does not
temperature reach 400°F
(204°C) within
10 seconds after
fuel and ignition
are applied
Overtemperature:
Power Turbine Speed
3000 rpm 3600 rpm
(857°C) (857°C)
Alarm 1505°F 1515°F
(818°C) (824°C)
Vibration Gas generator Trip 7 mils DA 0-3 mils DA Avoid continu-
ous operation
above 4 mils
Alarm 4 mils DA
Power turbine Trip 10 mils DA 0-6 mils DA Avoid continu-
ous operation
above 7 mils
Alarm 7 mils DA
Speed Gas generator Trip 10,200 rpm 0-10,050 rpm
(for 60 HZ) (Max. physical speed)
0-9850 rpm
(Max. corrected speed)
(for 60 HZ) Power Turbine Trip 3,960 rpm 0-3,600 rpm

AB-20
GEK 97310
VOLUME I
ADDENDUM AB
Normal
Alarm/ Operating
Speed Gas generator Trip 10,200 rpm 0-10,050 rpm
(for 50 HZ) (Max. physical speed
0-9850 rpm
(Max. corrected speed)
(for 50 HZ) Power turbine Trip 3,300 rpm 0-3,000 rpm
NOTE
are considered.
Loss of Flame Combustor Close and lock-
valve upon loss
of flame
Thrust Bal- Recoup See remarks Recoup Refer to GEK
ance Pressure pressure: 97310, Volume I,
0-150 psig Para. 5-3.27, for
(0-1034 kPa) acceptable oper-
P5.4: ating envelope
(corrected
0-60 psig
recoup pressure
(0-413.7 kPa)
vs. corrected
exhaust gas total
pressure, P5.4
Gas Turbine/Steam Limits
Maximum Steam Pressure at Manifold Inlet 700 psig (4826 kPa)
Maximum Steam Supply Temperature 960°F (515.6°C)
Maximum Steam Supply Temperature 50°F (28°C) above saturation ref-
erenced to manifold inlet
pressure
Maximum Steam Flow:
- Total High Pressure Steam Flow See Figure 7.
at 59°F (15°C)
- Fuel Nozzle Steam See Figure 7.
Steam/Fuel Ratio (variable) Flow
- CDP Manifold Steam Flow See Figure 7.

AB-21
GEK 97310
VOLUME I
ADDENDUM AB
Normal
Alarm/ Operating
Minimum Steam Flow:
- The LM2500-PH-NGA gas turbine does not require any particular minimum steam
flow through either the fuel nozzle steam manifold or CDP manifolds, however consid-
erations must be given to the system external to the engine with respect to line lengths,
volumes, pipe lagging, cooling air flow over the lines, etc., to prevent condensate from
developing due to an inadequate superheat and/or insufficient flow through the external
pipers and components.
Steam Scheduling Relative to Fuel Flow
During Transients See Text
Steam Metering Valve Opening Rate, Maximum 0.07 lbs/sec/sec
(0.03 kg/sec/sec)
Steam Metering Valve Closing Time <100 ms
Steam Shutoff Valve Closing Time <1.0 sec
Steam Initiation PS3 > 125 psig (861.9 kPa)
Steam Shutoff PS3 < 120 psig (827.4 kPa)
Maximum Engine Compressor Discharge Pressure (FS3)- 282 psia*
During Stem Injection*
* NOTE
This pressure is for sea level operation and must be corrected for altitude for
each engine installation.
Maximum Engine Compressor Discharge 960°F (515.6°C)
Temperature

AB-22
GEK 97310
VOLUME I
ADDENDUM AB
Table 3. GAS TURBINE OPERATING LIMITS (Cont)
LM2500 OPERATIONAL LIMITS AND INTERLOCKS
STEAM
METERING,
(1) VALVES (2)
ITEM/EVENT ALARM CLOSED LIMIT
• Steam
- Steady State X - Steam flow less than site
Flow to Combustor requirement for NOx
X - Steam flow is > 2.70
times fuel flow
X - Exceeds figure 7 requirements
- Steam Temperature X <525°F (273.9°C)
at Engine Manifold X <500°F (260°C)
X >960°F (515.6°C)
- Pressure at Steam X >900 psia (6205 kPa)
Metering Valve Inlet >1000 psia (6895 kPa)
• PS3 X <120 psia (827.4 kPa)
• Fuel Valves Closed X
(1) ALARM REQUIRES POSITIVE CORRECTION ACTION
(2) SPECIFIED LIMITS ARE EXTREME VALUES OUTSIDE OF THE RANGE OF
NORMAL OPERATION.

AB-23
GEK 97310
VOLUME I
ADDENDUM AB
8-2.3 Special Instrumentation Required for f. All service connections made
Monitoring and Troubleshooting. and secure _______
Fuel manifold pressure .......... 0-400 psi
sensor (0-2758 kPa)
h. All instrumentation connec-
Compressor inlet total............ 10-16 psia
Power turbine inlet gas .......... 0-75 psia
j. Gas turbine assembly free of
Compressor discharge............ 0-300 psig
pressure 0-2068 kPa
Fuel supply pressure .............. 0-400 psig
(0-2758 kPa) k. Gas turbine inlet air area free
Fuel supply temperature ........ 0-250°F
secure. _______
(-18 to 121°C)
Gas turbine inlet air ............... -65 to 150°F
and 10, are open (not capped). _______
Lube oil scavenge pressure.... 0-200 psig
m. Continuous lube supply starter
(0-1377 kPa)
is initially serviced per Pack-
Remote reading variable........ -5 to +45° ager’s manual. _______
vane indicator
n. Lube oil storage tank serviced
Starter air supply pressure ..... 0-50 psig to full level _______
o. Lube oil supply valves open _______
8-2.4 Preparation. The gas turbine and asso- p. All filters are serviced per
ciated systems must be inspected and checked Packager’s manual _______
out for proper installation and operation before q. Fire alarm/extinguish system
normal operation can commence. “ON” and operative _______
8-2.5 Gas Turbine and Associated Equip- r. T5.4 thermocouple system
ment Checklist. Complete the following functioning properly _______
checklist. s. Ignition system operative _______
a. Gas Turbine Assembly S/N _______ t. Compressor inlet total pres-
foundation _______
u. Variable stator vane system
secure _______
d. Bonding straps in place and
tions specified in Packager's
secure _______
e. Gas turbine and exhaust duct have been performed _______
place and secure _______

AB-24
GEK 97310
VOLUME I
ADDENDUM AB
8-2.6 Governor and Manual Control Check. • SECONDARY AIR TO THE
Refer to Packager’s manual. ENCLOSURE SHALL BE SHUT
a. Steam supply system sequencing and FLOW MAY PREVENT OPEN-
control. Refer to gas turbine Packager’s ING OR CLOSING THE
manual. ENCLOSURE DOOR.
8-2.7 Start-Up and Checkout. • THE ENCLOSURE DOOR

WARNING
WHEN ENTERING THE GAS TUR- TIONED AT THE ENCLOSURE
BINE ENCLOSURE, THE FOLLOW- DOOR AND CONFINED SPACE
ING REQUIREMENTS SHALL BE ENTRY PROCEDURES SHALL
MET: BE FOLLOWED.
• THE GAS TURBINE SHALL BE • ALLOW THE GAS TURBINE TO

SHUT DOWN. COOL DOWN. AVOID CON-
• ENCLOSURE ENTRY DURING WEAR THERMALLY INSU-
ENGINE OPERATION IS PRO- LATED GLOVES AS
HIBITED IN GENERAL. IF NECESSARY.
ENTRY SHOULD BE
REQUIRED DURING ENGINE • EAR PROTECTION SHALL BE
OPERATION, CONTACT GE WORN IF GAS TURBINE IS
FIELD SERVICE FOR A REPRE- OPERATING.
TO ENTER THE ENCLOSURE • DO NOT REMAIN IN THE
UNDER SUCH CONDITIONS. ENCLOSURE OR IN THE
• THE FIRE EXTINGUISHING STARTER WHEN STARTING OR
SYSTEM SHALL BE MADE MOTORING THE GAS
INACTIVE ACCORDING TO TURBINE.
THE CUSTOMER’S
PROCEDURES. a. When entering enclosure during gas

paragraph 8-2.8.

paragraph 8-2.9.

AB-25
GEK 97310
VOLUME I
ADDENDUM AB
e. Perform false start per second) should be heard when the No. 2 spark
paragraph 8-2.10. igniter fires.
f. Perform governor check per d. Turn off electrical power to the ignition
paragraph 8-2.11. system. Reconnect input lead to No. 1 ignition
exciter and safety-wire connector.
paragraph 8-2.12. e. Repeat steps b, c, and d, disconnecting
the No. 2 exciter.
paragraph 8-2.13. f. If an audible report is not heard on
i. Operate to maximum power per tem to isolate the problem, and take corrective
paragraph 8-2.14. action.
j. Check automatic operation per 8-2.9 Motoring. After all preliminary checks
paragraph 8-2.15. have been completed and lines flushed, the gas
WARNING systems inoperative as follows:
• ASSURE POWER TO IGNITION (1) Disconnect power supply to igni-
SYSTEMS IS OFF WHEN DIS- tion unit.
ING IGNITION EXCITER INPUT (2) Close natural-gas manual shutoff
LEAD. TAG SWITCH “OUT OF valve to fuel control unit.
SERVICE” TO PRECLUDE
INADVERTENT ACTIVATION. b. Depress MOTORING pushbutton. Gas
turbine will start to rotate. If it does not, refer
• ASSURE FUEL VALVES ARE to Packagers manual for supply pressure to
CLOSED THROUGHOUT THIS starter.
PROCEDURE.
a. To clear combustor of any residual until gas generator speed stabilizes, and check
fuel, motor gas turbine for one minute; allow for oil pressure. If there is no indication of oil
gas turbine to coast down. pressure, release MOTORING pushbutton;
b. Disconnect number one ignition exciter fittings at lube pump to bleed air from system.
input lead at exciter. Temporarily secure input Starter should motor gas turbine to minimum
lead way from the exciter. of 2200 rpm.

AB-26
GEK 97310
VOLUME I
ADDENDUM AB
Item Requirements
Fuel valves Closed
Ignition Off
Ventilation inlet air (secondary cooling air) Off - air temp. below 70°F(21°C)
Oil tank level Full
• pressure at manifold inlet 50 psig maximum (345 kPa)
• temperature -65 to 150°F (-54° to 66°C)
• flow See paragraph 8-1.2, step b.

AB-27
GEK 97310
VOLUME I
ADDENDUM AB
follows:
of gas turbine per Packager's manual. POWER TURBINE ROTATION.
b. Gas turbine should go through normal a. The power turbine must rotate by the
start cycle and then abort because of lack of time the gas generator speed reaches 6000 rpm
flame. NGG. If power turbine speed indication is not
obtained and it is determined that a "thermal
8-2.11 Governor Check. Check governor sys- seizure” of the power turbine has occurred,
tem per Packager's manual. proceed as follows:
8-2.12 Wet Prestart. Perform wet prestart as NOTE

follows: • Power Turbine, except in a new
installation, will be rotating when
a. With ignition lead disconnected, but gas generator idle speed is attained.
system operating, make automatic start of gas • Thermal seizure of the power turbine
turbine per Packager's manual. rotor can occur when a hot gas turbine is
shut down and is most likely to occur
b. Gas generator should accelerate to within 30 to 40 minutes following gas
light-off speed (1100 to 1300 rpm). Fuel valve turbine operation. Thermal seizure is the
should open and fuel manifold pressure should condition where the power turbine rotor
be approximately 3 psig (21 kPa). Adjust fuel is prevented from rotating by hard con-
supply if required. Start will then abort tact between LPT blades and shrouds,
because of lack of flame. interstage seals and other internal inter-
c. Allow gas turbine to coast to stop; then unequal cooling rates of the various
motor it to purge any remaining natural gas power turbine components. The possi-
from gas turbine. Continue to motor for bility of thermal seizures can be reduced
60 seconds to purge fuel from the gas turbine. by operating the gas turbine at idle
8-2.13 Manual Start and Operation. Perform shutdown to achieve proper cooling of
manual start per Packager's manual with fuel the power turbine.
Refer to Table 5. (1) Shut down gas turbine.


AB-28
GEK 97310
VOLUME I
ADDENDUM AB
(3) Repeat steps (1) and (2) for two c. Log all instrument readings once they
additional start-up and shutdown cycles. stabilize. Refer to Table 5, step 9.
(4) If the power turbine does not d. Reduce gas turbine speed to idle. After
rotate after accomplishing substeps (1) through stabilizing for three minutes, record all instru-
(3), shut down the gas turbine. ment readings. Refer to Table 6, step 2.
tem per Packager's manual.
30 seconds. If the power turbine still does not f. After gas turbine has been stabilized at
rotate, shut down and investigate/correct the idle for five minutes, make normal shutdown.
cause. During the investigation for the cause of Refer to Table 6, steps 3 and 4.
blades in stages 4. 5. and 6 for shingling and 8-2.15 Automatic Operation. Check automatic
unlatching. If blades have become unlatched, operation per Packager’s manual.
encountered shingling may be bent thereby a. Accelerate to idle.
CAUTION c. Log all instrument readings.
MANUAL OPERATION MAY d. Decelerate to idle.

TIVE CIRCUITS. OPERATING LIM- e. Check for fuel or lube oil leaks.
a. Slowly increase manual control setting shut down gas turbine.
(refer to Packager's manual) to increase gas
generator speed. After each 500 rpm increase, g. Check lube oil and fuel filters and
log all instrument readings, paying particular strainers; clean or replace as necessary.
vibration. If variable stator system is not h. Correct any leaks observed.
within limits, adjust it per Work Package
118 00. If vibrations are not within limits, con- i. Remove all temporary instrumentation.
sult the local General Electric Company repre-
sentative. j. Check gas turbine and mounting sys-
b. Operate gas turbine up to rated power, tem for loose parts; tighten as necessary.
system is unstable. Adjust per Packager's
manual.

AB-29
GEK 97310
VOLUME I
ADDENDUM AB
8-3 NORMAL OPERATION. 8-3.2 Interlocks. Refer to Packager's manual
for description of interlocks which affect gas
8-3.1 General. Normal operation is the rou- turbine operation.
operation for normal operation, refer to Pack-
ager's manual.

CAUTION
EXCEEDED, PERFORM OVER-TEMPERATURE INSPECTION.
NOTE
A start may be aborted at any time by closing fuel valve, allowing gas turbine to motor for
60 seconds, then closing starter shutoff valve.
NOTE
3. At 1100 to 1300 rpm NGG
a. Ignition on
(21 kPa). See
paragraph 8-1.1
c. Note time to lightoff 10 seconds maximum Abort start-automatic shutdown.
(T5.4 above 400°F) Investigate and correct cause.
(204°C) 1200 rpm
4. Note time to 4500 ± 90 seconds maximum Troubleshoot system and take
200 rpm corrective action if rpm stops
increasing or it takes longer than 90
seconds to reach 4300 rpm

AB-30
GEK 97310
VOLUME I
ADDENDUM AB
5. At 4300 to 4700 rpm NGG
a. Starter shutoff valve Valve closed Manually close starter air supply
should close
automatically
Chapter 5 (55 ± 6.9 kPa).
Trip at 6 ± 1 psig
(41 ± 6.9 kPa)
b. NGG 5000 rpm ± 250 RPM Adjust
c. T5.4 1000°F (538°C) max Emergency shutdown - Table 7
d. NPT (unloaded) 1200 - 1900 rpm Troubleshoot and take corrective
action
e. Gas generator vibration 0 to 3 mils DA Alarm set at 4 mils. Automatic nor-
mal shutdown if above 7 mils.
action
f. Power turbine vibration 0 to 6 mils DA Alarm set at 7 mils. Automatic nor-
mal shutdown if above 10 mils.
action
g. Compressor inlet tem- Approximately equal to Troubleshoot sensing and indicat-
perature (T2) outside air temperature ing system. Correct as required
h. Check for fuel and oil No leaks allowed Correct as required
leaks
i. Maximum NGG with 6000 rpm NGG maxi- Shut down and investigate/correct
power turbine seizure mum for 30 seconds cause per paragraph 8-2.13
(thermal seizure)
sient operation

AB-31
GEK 97310
VOLUME I
ADDENDUM AB
b. NGG *
NOTE
The maximum allowable corrected speed is 9850 rpm.
c. NPT 0-3960 rpm *
d. Oil pressure See applicable table and Emergency or automatic shutdown
figure in Chapter 5 if 5 psig (34 kPa) out of limits
e. Scavenge oil 160°F to 275°F Alarm at 290-310°F (143-154°C);
temperature (71°C to 135°C) Automatic shutdown if above
340°F (171°C)
7 mils (Trip) Emergency or automatic shutdown
7 mils max (Alarm) *
10 mils max (Trip) Emergency or automatic shutdown
(-54° to +66°C)
j. Scavenge oil filter ∆P Refer to Packager’s
manual
k. Lube oil supply filter Refer to Packager’s
∆P manual
WP 118 00 WP 118 00
limits, shut down.

AB-32
GEK 97310
VOLUME I
ADDENDUM AB

1. Set gas turbine at idle power Gas generator deceler- Emergency shutdown
(unloaded) ates to idle
following:
a. Oil pressure See applicable Alarm at 8 ± 1 psig
figure in Chapter 5 (55 ± 6.9 kPa)
Trip at 6 ± 1 psig
(41 ± 6.9 kPa)
c. T5.4 Approximately Troubleshoot and take corrective
1000°F (538°C) action
e. Gas generator vibration 3 mils max. Alarm set at 4 mils. Automatic
action
f. Power turbine vibration 6 mils max. Alarm set at 7 mils. Automatic
corrective action
g. Fuel inlet temperature -65° to 150°F
(-54° to 66°C)
manual
manual
5 minutes, close fuel valve (204°C) NGG and NPT
decreases

AB-33
GEK 97310
VOLUME I
ADDENDUM AB
WARNING
SHUT DOWN.
FIELD SERVICE FOR A REPRE- a. When entering enclosure during gas
SENTATIVE WHO IS TRAINED turbine operation, wear proper ear protection.
THE CUSTOMER’S
PROCEDURES. d. Emergency shut down the gas turbine
per Table 7.
ENCLOSURE SHALL BE SHUT e. Refer to paragraph 5-3.30 and 5-3.31,
OFF. HIGH SECONDARY AIR- for lube correction factors and lube supply
FLOW MAY PREVENT OPEN- pressure characteristics. (See tables V-21A and
ING OR CLOSING THE V-21B and figures 5-32A, 5-32B, 5-32E, and
ENCLOSURE DOOR. 5-32F.)
• THE ENCLOSURE DOOR NOTE

Addendum AB affects PNL34379P01
only.
f. Idle lube oil pressure is 29 psig
(200 kPa) maximum after five minutes stabili-
zation.
BE FOLLOWED.

AB-34
GEK 97310
VOLUME I
ADDENDUM AB
g. The corrected operating pressure of the 8-5 SPECIAL GAS TURBINE
lube oil shall be per applicable table in CONSTRAINTS.
gas generator speed and 150°F (66°C) lube 8-5.1 General. Under normal operating con-
pump discharge temperature. Oil pressure ditions, the gas turbines are constrained by the
measured at conditions other than standard operating limits published in the limits table.
shall be corrected to standard conditions using Continuous operation between the alarm and
applicable table in Chapter 5. shutdown or "trip" level should not be prac-
ticed.
8-4.1 Emergency Shutdown. or events occur, the associated special action
a. In an emergency, the gas turbine may assure the gas turbines continued normal oper-
be shut down from any power setting by clos- ation. These events are either not detected or
ing the fuel value and steam metering valves not prevented by the customary protective
simultaneously. However. this should only be devices of control systems.
done in an emergency, since rapid shutdown
will decrease life of the gas turbine. • Overtemperature During Starting
b. Emergency shutdown shall be made • Lube Oil Pressure

per Table 7.
gas temperature should decrease. If, during • Re-Start Following High Power Trip
time gas turbine is coasting to stop, tempera-
ture increases instead of decreases, it indicates • No Power Turbine Rotation
a leaking fuel valve. A slight temperature • Gas Generator Windmilling
increase after rotation stops is normal. Make
bine. This will below out the fire. As soon as
motoring.

AB-35
GEK 97310
VOLUME I
ADDENDUM AB
8-5.2 Overtemperature. During starting and 8-5.5 Starter Duty Cycle - Air or Natural
acceleration to idle, cooling flows to compo- Gas.
ficient to protect the metals at T5.4 alarm and a. With starter inlet air pressure set at
trip levels specified in the limits table. A lower 40 psig (276 kPa).
levels acceptable provided they exist for lim- • 45 seconds on, 2 minutes off for any
ited times as depicted on the curve titled number of cycles.
"Transient Temperature Limits for Starts"
(figure 1). This must be monitored by the oper- or
by entry into area B requires hot section disas- • 2 minutes on, 5 minutes off with two
sembly and inspection in a qualified facility. such cycles in any 30 minute period.
8-5.3 Lube Oil Supply Pressure. The lube oil b. With starter inlet air pressure set at
supply pressure limits given in the limit table 15 psig (103 kPa).
are "distress" limits. Protective devices cannot
reliably monitor supply pressure because the • 5 minutes on, 2 minutes off with two
proper pressure is dependent on gas generator such cycles in any 30 minute period,
speed, oil type, oil temperature, and number of
oil jets. An operator must therefore derive a or
corrected oil pressure as directed in the appro-
priate pressure correction tables in Chapter 5 • 10 minutes on, 20 minutes off for any
to determine if the lube system is performing number of cycles.
8-5.4 High Speed Stall. Stalls incurred at gas hydraulic starter.
can result in high pressure compressor blade 8-5.6 Re-Start Following High Power Trip.
fracture. The gas turbine can be operated after In the event that re-start of the gar turbine is
an inspection of the compressor stages 3 required within two (2) hours following a trip
through 6 verifies that blade tip clanging has or rapid shutdown from high power, a five (5)
not occurred. If tip clanging has occurred, fur- minute cranking at 2000 to 2500 rpm should
ther inspection and stress relief of the blades is precede the fire up. The objective is to cool the
required, which necessitates blade removal high pressure turbine rotor, so that blade tips
from the spool. maintain clearance with the more rapidly cool-
ing case.

AB-36
GEK 97310
VOLUME I
ADDENDUM AB
8-5.7 No Power Turbine Rotation. A ther- d. Refire and accel to 6000 rpm. Do not
mally bound power turbine rotor could occur exceed 6000. Power turbine should break
under extreme conditions following a rapid away. If not, shut down and investigate for
shutdown from high power. Power turbine unlatched or shingled blades, or other cause.
acceleration to idle. If rotation does not occur, 8-5.8 Windmilling.
a. Unlimited windmilling or cranking of
a. Remain at idle for 30 seconds and shut the gas turbine is allowed at gas generator
down. speeds above 1000 rpm provided the lube oil
b. Refire and repeat Item a. speeds, the lube supply and scavenge systems

CAUTION
1. Conditions permitting deceler- T5.4 drops below 400°F Manually shut off fuel
ate gas turbine to idle and close (204°C) and NGG and NPT supply.
fuel valves decelerate
2. Observe T5.4 for 3 minutes after 700°F (371°C) max. Motor gas turbine. Con-
temperature decreases.
3. If an emergency shutdown from
a high power setting (T5.4)
greater than 1150°F (621°C) has
occurred, and a “hot restart” is

AB-37
GEK 97310
VOLUME I
ADDENDUM AB

sequencing system can be
cleared and the gas turbine
can be restarted within 1
minute following coastdown
of the HPC rotor, acceptable
restarts can be made using
the normal starting proce-
dure.
b. If a "hot restart" is to be per-
formed between 1 minute
and 2 hours following the
emergency shutdown, motor
the gas turbine at 2000 to
2500 rpm NGG for 5 minutes.
At the end of the
5 minute motoring cycle,
allow gas turbine to deceler-
ate to 1200 rpm. When
1200 rpm is obtained, restart
the gas turbine and acceler-
ate to idle. Acceleration to
the desired power setting can
coastdown of the HPC rotor,
restart can be made using the

AB-38
GEK 97310
VOLUME I
ADDENDUM AB
Tables 8 through 11. DELETED.

AB-39/(AB-40 Blank)
GEK 97310
VOLUME I
ADDENDUM AC
ADDENDUM AC
7LM2500-PL-MGA

GEK 97310
VOLUME I
ADDENDUM AC
TABLE OF CONTENTS
1-0 INTRODUCTION....................................................................................... AC-3

2-0 REFERENCE DATA .................................................................................. AC-3
3-0 INSTALLATION DRAWINGS.................................................................. AC-3
4-0 EQUIPMENT DESCRIPTION ................................................................. AC-4
5-0 INSTRUMENTATION AND SUPPLY REQUIREMENTS ................... AC-4
6-0 SERVICE REQUIREMENTS ................................................................... AC-4
6-1 NATURAL GAS .......................................................................................... AC-4
6-2 STEAM INJECTION SYSTEM................................................................ AC-8
6-2.1 Steam Flow, Pressure and Temperature Requirements ................................. AC-8
6-2.2 Steam Control and Scheduling Requirements............................................... AC-8
6-3 HIGH PRESSURE STEAM SYSTEM ..................................................... AC-8
6-4 STEAM SCHEDULING............................................................................. AC-16
6-5 STEAM PURITY/CONTAMINATION LIMITS .................................... AC-17
7-0 OPTIONAL HARDWARE KITS - 7LM2500-PL-MGA......................... AC-19
8-0 GAS TURBINE OPERATION .................................................................. AC-19
8-1 PERFORMANCE RATINGS AND OPERATING LIMITS .................. AC-20
8-1.1 Performance Ratings ..................................................................................... AC-20
8-1.2 Operating Limits ........................................................................................... AC-21
8-2 INITIAL OPERATION .............................................................................. AC-21
8-2.1 General .......................................................................................................... AC-21
8-2.2 Instrumentation Required for Operation ....................................................... AC-21
8-2.3 Additional Instrumentation Required for Monitoring and Troubleshooting. AC-22
8-2.4 Preparation .................................................................................................... AC-22
8-2.5 Gas Turbine and Associated Equipment Checklist ....................................... AC-22
8-2.6 Governor and Manual Control Check........................................................... AC-23
8-2.7 Start-up and Checkout................................................................................... AC-23
8-2.8 Ignition Check............................................................................................... AC-24
8-2.9 Motoring........................................................................................................ AC-25
8-2.10 False Start...................................................................................................... AC-25
8-2.11 Governor Check ............................................................................................ AC-25
8-2.12 Wet Prestart ................................................................................................... AC-25
8-2.13 Manual Start and Operation .......................................................................... AC-25
8-2.14 Operation to Maximum Power...................................................................... AC-32
8-2.15 Automatic Operation..................................................................................... AC-32
8-3 NORMAL OPERATION............................................................................ AC-34
8-3.1 General .......................................................................................................... AC-34
8-3.2 Interlocks....................................................................................................... AC-34
8-3.3 Operation....................................................................................................... AC-34
8-4 EMERGENCY OPERATION ................................................................... AC-35
8-4.1 Emergency Shutdown ................................................................................... AC-35
8-4.2 Post Shutdown Fire ....................................................................................... AC-35

AC-1
GEK 97310
VOLUME I
ADDENDUM AC
TABLE OF CONTENTS - (Cont.)
8-5 SPECIAL GAS TURBINE CONSTRAINTS ........................................... AC-37

8-5.1 General .......................................................................................................... AC-37
8-5.2 Overtemperature............................................................................................ AC-37
8-5.3 Lube Oil Supply Pressure ............................................................................. AC-37
8-5.4 High Speed Stall............................................................................................ AC-37
8-5.5 Starter Duty Cycle - Air or Natural Gas........................................................ AC-37
8-5.6 Re-Start Following High Power Trip ............................................................ AC-38
8-5.7 No Power Turbine Rotation .......................................................................... AC-38
8-5.8 Windmilling .................................................................................................. AC-38
Figure Title Page
1 LM2500-PL-MGA Steam Flow Limits ........................................................ AC-15

2 Steam Contamination - Maximum Solids ..................................................... AC-18
3 Transient Temperature Limits ....................................................................... AC-30
4 Deleted
LIST OF TABLES
Table Title Page
1 INSTRUMENTATION CONNECTIONS - 7LM2500-PL-MGA ................ AC-5

2 SUPPLY CONNECTIONS - 7LM2500-PL-MGA ....................................... AC-6
3 GAS TURBINE OPERATING LIMITS....................................................... AC-9
4 PRESTART CHECKS .................................................................................. AC-24
5 START-UP AND OPERATION.................................................................... AC-26
6 GAS TURBINE NORMAL SHUTDOWN .................................................. AC-33
7 EMERGENCY SHUTDOWN...................................................................... AC-35

AC-2
GEK 97310
VOLUME I
ADDENDUM AC
The information contained herein describes the Compressor Rear Frame 421 (191)
7LM2500-PL-MGA model gas turbine basic Combustor 120 (54)
configuration and control system differences. High Pressure Turbine Rotor 419 (190)
In addition, the coverage of reference data, High Pressure Turbine Nozzle,
instrumentation and supply connections, spe- Stage 1 68 (31)
Stage 2 127 (58)
instructions for the 7LM2500-PL-MGA model
are included. Turbine Mid Frame 530 (240)
2-0 REFERENCE DATA. Low Pressure Turbine Stator 601 (273)
Turbine Rear Frame 1071 (486)
EQUIPMENT
Gas Turbine Assembly Forward Adapter 91 (41)
(General Electric Co., Cincinnati, Ohio) Variable Stator Actuating
Model No. 7LM2500-PL-MGA Mech 19 (9)
Drawing No. L31430G39 Outside Piping and Bracketing 278 (126)
PERFORMANCE RATING DRAWING LIST Drawing No.
Refer to paragraph 8-1.1. High Pressure Steam Piping L43646

Schematic and
GAS TURBINE WEIGHTS L31859
The average weights of the major gas Drawing
turbine components are: Lubrication System Flow L24328
Diagram
diffuser, and coupling nut 7815 (3545) Gas Turbine Assembly L31430
Drawing
Fuel and Steam Injection
Assembly 682L400
Steam Augmented HP Recoup 682L457
Compressor Front Frame 517 (235) 3-0 INSTALLATION DRAWINGS.
Compressor Stator, Front 307 (139) A complete set of installation drawings has
been provided.

AC-3
GEK 97310
VOLUME I
ADDENDUM AC
4-0 EQUIPMENT DESCRIPTION. e. The 7LM2500-PL-MGA engine aero-
thermal cycle has also been modified to
a. The 7LM2500-PL-MGA model is a accommodate the addition of steam to the
marinized, natural gas fueled gas turbine engine airflow by decreasing the low pressure
which is capable of accepting steam produced turbine nozzle flow function from the standard
by a Heat Recovery Steam Generator (HRSG) configuration.
in the gas turbine exhaust system. Benefits
resulting from injection of steam into the gas f. Assembly and interface details of the
generator are increased output horsepower, engine-mounted steam manifolds and steam/
improved thermal efficiency, and suppression gas fuel nozzle system are defined on Drawing
of the oxides of nitrogen (NOx) in the engine No. 682L400.
exhaust gases.
b. Steam is injected into the high pressure SUPPLY REQUIREMENTS.
section of the engine by means of two separate See Tables 1 and 2.
engine-mounted manifold systems: a fuel noz-
zle steam manifold and two compressor dis- 6-0 SERVICE REQUIREMENTS.
charge steam manifolds. Steam flow in each of
6-1 NATURAL GAS.
the two manifold systems is regulated by sepa-
rate metering valves, with the ratio of flow a. The required supply pressure to the
between the two systems based on optimiza- natural gas fuel manifold on the gas turbine is
tion of emissions suppression and available determined by the required maximum power,
steam. A schematic diagram of the steam sys- fuel composition and supply temperature of
tems is shown on Drawing No. L43646 for the application.
premixed nozzle system and L31859 for noz-
zles with separate injection passages. b. The temperature of the gas supply at
c. Steam injected into the fuel nozzle must be in the range of 20°F (-7°C) above the
steam manifold is directed into the combustion saturated vapor temperature as a minimum,
primary zone through a special steam and gas and 350°F (177°C) as a maximum. Based on
fuel nozzle. The separate injection nozzles use consideration of control system components
concentric passages with separate orifices in however, it is recommended that the maximum
the tip, whereas the premix nozzles use a mix- gas supply temperature be limited to 150°F
ing chamber in the nozzle body. (66°C). If the supply temperature of the gas is
not repeatable on a day-to-day basis, it may be
d. Each of the two CDP manifolds sup-
necessary to change the control system starting
plies steam to two compressor rear frame struts
fuel adjustment or to adjust the supply pressure
which duct steam into the inner hub of the
to the gas turbine to maintain a constant Btu-
compressor rear frame. From the inner hub of
per-cubic-foot supply. Once started the gas tur-
the compressor rear frame, the steam flows
bine will accept variations in supply tempera-
into the compressor discharge flowpath
tures of ±20°F (±11°C). The maximum fuel
between the combustor inner liner and inner
flow required, assuming a lower heating value
combustion casing to mix with combustor lin-
of 19,000 Btu/lb, is 13,500 pph (6123 kg/hr)
ing cooling air, into the high pressure turbine
for the 7LM2500-PL-MGA model gas turbine.
stage 1 nozzle cooling air path, and into the
high pressure turbine rotor and blade cooling
air path.

AC-4
GEK 97310
VOLUME I
ADDENDUM AC
Table 1. INSTRUMENTATION CONNECTIONS - 7LM2500-PL-MGA
Instrumentation
Connection Nomenclature Mates With:
E1 Vibration pickup, gas generator MS3106R10SL-4S
E20A, E20B Power turbine inlet temperature MS3106-14S-2P
E20C, E20D
E3B A-sump scavenge oil temperature M83723/86G1005-6
E4B B-sump scavenge oil temperature M83723/86G1005-6
E5B C-sump scavenge oil temperature M83723/86G1005-6
E6B Accessory gearbox scavenge oil temperature M83723/86G1005-6
E11B Oil supply temperature M83723/86G1005-6
E18B D-sump scavenge oil temperature M83723/86G1005-6
E13 Vibration pickup, power turbine MS3106R10SL-4S
(optional)
A23 CDP pressure port 0.500-20UNJF
A31A HP Recoup MS20819-6C or MS9197-6C
F3A Natural gas fuel manifold pressure tap MS33656-4
L7 Lube scavenge pressure tap AN818-4C or MS20819-4C
E30 T3 Sensor (Dual T/C) (optional) MS3106-14S-2SX
E33 Remote reading variable stator vane protractor MS3106E16S-1S
(optional)

AC-5
GEK 97310
VOLUME I
ADDENDUM AC
Table 1. INSTRUMENTATION CONNECTIONS - 7LM2500-PL-MGA (Cont.)
Instrumentation
E35 T2/P2 Sensor (RTD) (optional) M83723/95G1005N or
M83723/86G1005N
E22/ E23 UV Flame Sensor MS3106-10SL-4S
NOTE
• For all other instrumentation connections, refer to installation drawings provided with gas
turbine.
• Refer to gas turbine Packager’s manual for instrumentation required for monitoring steam
conditions.
Table 2. SUPPLY CONNECTIONS - 7LM2500-PL-MGA

Mechanical
Interface
Connections Nomenclature Mates with:
CAUTION
ALL LINES MUST BE FLEXIBLE ENOUGH TO ALLOW 0.75 INCH (19 MM) THER-
F1A Natural gas supply 3.00 inch (76.2 mm) line from Fuel Control
Unit to Gas Turbine Fuel Manifold
L1 Oil supply 1.50 inch (38.1 mm) line to Lube Pump on
Gas Turbine AN818-24C or MS20819-24C
L2 Lube pump discharge 1.00 inch (25.4 mm) line from Lube Pump to
Oil Supply Filters AN818-16C or
MS20819-16C
L4 Lube supply inlet port 1.00 inch (25.4 mm) line from Oil Supply Fil-
ters to Gas Turbine AN818-16C or
MS20819-16C
L3 Scavenge oil discharge 1.25 inch (31.8 mm) line from Gas Turbine
Scavenge Pump to Oil Scavenge Filter and
Cooler AN818-20C or MS20819-20C
A4 Inlet duct seal flange (If required)
A6 Starter air or gas inlet port (optional)

AC-6
GEK 97310
VOLUME I
ADDENDUM AC
Table 2. SUPPLY CONNECTIONS - 7LM2500-PL-MGA (Cont.)
Mechanical
Interface
(optional)
A10 CDP seal leakage No. 1 (If required) 2.00 inch (50.8 mm) line
A12 Air/oil separator discharge 3.00 inch (76.2 mm) line from air/oil separa-
tor to atmospheric vent or to exhaust duct
(flame arrestor)
S1 Waterwash manifold 1.00 inch (25.4 mm) line - hot water line to
waterwash manifold on Gas Turbine Inlet
Duct AN818-16C or MS20819-16C
W16/ W16A CDP steam manifold supply 3.50 inch (88.9 mm) MS or ANSI type flange
from steam supply to CDP steam manifold
W18/ Fuel nozzle steam supply 4.00 inch (101.6 mm) MS or ANSI type
W18A flange from steam supply to fuel nozzle steam
manifold
W23 HP Recoup Steam Supply MS20819-12/MS9197-12
NOTE
• For all other supply connections, see Installation Drawings, provided with gas turbine.
• In addition, refer to Gas Turbine Packager’s Manual.

AC-7
GEK 97310
VOLUME I
ADDENDUM AC
6-2 STEAM INJECTION SYSTEM. e. Whenever high pressure steam is
injected into the engine, a minimum flow
6-2.1 Steam Flow, Pressure and Temperature should be provided to the fuel nozzle steam
Requirements. and CDP manifolds as described in Table 3 to
prevent condensation.
a. The high pressure steam injection sys-
tem includes two metering valves: one controls f. Depending on the specific type of gas/
the flow to the fuel nozzles and the other con- steam system selected, a crossover line may be
trols the flow to the CDP manifolds. Flow included in the Packager’s steam supply sys-
meters measure the flow through each meter- tem to connect the CDP steam manifold supply
ing valve. to the fuel nozzle steam manifold supply. The
crossover line provides purge and preheat air
b. The steam manifolds and gas/steam for the steam manifolds when no steam is
fuel nozzles are designed to flow steam by being injected. The static pressure difference
weight equivalent to approximately 5.5 per- between the inner flowpath at the CDP steam
cent of the high pressure compressor airflow discharge and the combustor dome at the fuel
(W25) or 8 pounds per second (3.6 kg/sec) of nozzle tip is sufficient to provide circulation of
steam at 675°F (357°C), at a supply pressure to compressor discharge air from the CDP steam
manifold inlets of 325 psia (2241 kPa), at com- manifold, through the crossover and into the
pressor discharge pressure (PS3) of 285 psia fuel nozzle steam manifold to ensure that
(1965 kPa) with steam flow split between fuel purge flow is into the combustor and not from
nozzles and CDP manifold. This steam split the combustor. The crossover line contains a
can be revised from the design point to meet low pressure drop check valve that prevents
application requirements for NOx reduction flow of steam from the fuel nozzle steam sup-
and steam availability. Maximum permissible ply to the CDP steam supply. Premix type fuel
steam pressure at the manifold inlet for either systems do not use this preheating method.
system is 700 psia (4826 kPa) and maximum
steam temperature is 960°F (517°C). g. Levels of steam contamination must
not exceed those defined in paragraph 6-7.
c. The minimum permissible steam tem-
perature at the inlets to the manifolds is 50°F 6-2.2 Steam Control and Scheduling
(28°C) above saturation. The maximum com- Requirements. (Ref. Schematic GE L31859).
bined combustor and CDP steam flow is
approximately 30,000 lbs/hr (3,608 kg/hr) @ 6-3 HIGH PRESSURE STEAM
59°F (15°C) with each system operating with SYSTEM.
its individual maximum steam flow. See
Table 3 and figure 1 for more precise values. a. It is recommended that steam be sched-
uled as a function of high pressure compressor
d. The individual maximum permissible discharge static pressure (PS3). Limits on high
steam flow into the fuel nozzle and CDP mani- pressure steam flow vs. PS3 are shown in
folds is a function of compressor discharge figure 1, with a maximum total flow of
pressure (PS3) as given in figure 1. At very 30,000 lb/hr.
high steam to fuel ratios, combustor efficiency
may be reduced and combustor flame out mar-
gin is reduced.
AC-8
GEK 97310
VOLUME I
ADDENDUM AC
Normal
Alarm/ Operating
NOTE
Lubrication Gas turbine lube Alarm 8 psig ± 1 psig 20-60 psig Bypass until
System - supply pressure (55 kPa ± 6.9 kPa) (138-413 kPa) 4500 rpm
Settings and below 8000 rpm;
above 8000 rpm
(41 kPa ± 6.9 kPa) (138-413 kPa) 4500 rpm
Gas turbine scav- Alarm 110 psig - 10 psig 10-100 psig Scavenge dis-
enge discharge (759 kPa ± 69 kPa) (69-690 kPa) charge pressure
pressure shall not exceed
180 psig
(1242 kPa)
Gas turbine lube Alarm 180-220°F 140-160°F Normal operat-
supply (82-104°C) (60-71°C) ing range reflects
temperature temperature
expected during
operation above
idle speed
Gas turbine lube Trip 330-350°F 160-275°F Normal operat-
scavenge temper- (166-177°C) (71-135°C) ing range reflects
atures - five temperature
Alarm 290-310°F expected during
(143-154°C) operation above
idle speed
Fuel Sys- Fuel manifold 0-355 psig Supply pressure
tem Natural pressure (0-2448 kPa) as reflected at the
Gas fuel manifold
inlet on the gas
turbine

AC-9
GEK 97310
VOLUME I
ADDENDUM AC
Normal
Alarm/ Operating
Fuel Sys- Fuel supply Alarm 150-170°F -65 to 150°F Starting fuel flow
tem Natural temperature (66-77°C) -54 to 66°C) adjustments are
Gas (Cont.) required to com-
pensate for fuel
temperature
variation
Starting Starter supply 35-40 psig Starting pressure
System pressure (241-276 kPa) requirement
(Pneumatic) based on engine
starter torque
requirements
fuel and ignition
fuel and ignition for start after
used)
simultaneously
with start
initiation
simultaneously
with ignition ini-
tiation. Deener-
gize ignition and
starter air supply
at 4500 rpm

AC-10
GEK 97310
VOLUME I
ADDENDUM AC
Normal
Alarm/ Operating
4500 rpm if purge ond time delay
cycle is used) upon completion
of purge. De-
energize ignition
systems and
starter air supply
at 4500 rpm
Power Failure to Trip 380-420°F 900-1200°F Trip if tempera-
Turbine light-off (193-216°C) (482-649°C) ture does not
Inlet at light-off reach 400°F
Temperature (204°C) within 10
seconds after fuel
and ignition are
applied
Overtemperature: Power Turbine Speed

natural gas 3600 rpm 3000 rpm
Trip 1575°F 1575°F
(857°C) (857°C)
Alarm 1555°F 1540°F
(Dry) (846°C) (838°C)
Vibration Gas Generator Trip 7 mils DA 0-3 mils DA Avoid continu-
ous operation
above 4 mils
Alarm 4 mils DA
Power Turbine Trip 10 mils DA 0-6 mils DA Avoid continu-
ous operation
above 7 mils
Alarm 7 mils DA

AC-11
GEK 97310
VOLUME I
ADDENDUM AC
Normal
Alarm/ Operating
Gas Trip 10,200 rpm 0-10,050 rpm
Generator (Max. physical
Speed speed)
0-10,100 rpm
(Max. cor-
rected speed)
Power For 60 Hz Trip 3960 rpm 0-3600 rpm
Turbine
For 50 Hz Trip 3300 rpm 0-3000 rpm
Speed
NOTE
Refer to packager’s manual for specific alarm and trip levels.
Loss of Fuel Combustor flame Trip Close and lockout
Flame fuel shut-off
valve upon loss of
flame (both
detectors)
Alarm Loss of flame on
one detector
Thrust Recoup pressure See remarks Recoup pres- Refer to GEK
Balance sure: 0-200 psig 97310, Volume I,
(0-1379 kPa) Paragraph 5-3.30,
for acceptable
Pressure P5.4: 0-60 psig operating enve-
(0-414 kPa) lope (corrected
recoup pressure
vs. corrected
exhaust gas total
pressure, P5.4)
Maximum Steam Supply Temperature 960°F (516°C)
Minimum Steam Supply Temperature 50°F (28°C) above saturation ref-
erenced to manifold inlet pressure

AC-12
GEK 97310
VOLUME I
ADDENDUM AC
Normal
Alarm/ Operating
Maximum Steam Flow:
- Total high pressure steam flow See figure 1
- Fuel nozzle steam - steam/fuel ratio (variable) flow See figure 1
- CDP manifold steam flow See figure 1
Minimum Steam Flow
The 7LM2500-PL-MGA gas turbine does not require any particular minimum steam flow
through either the fuel nozzle steam manifold or CDP manifolds, however considerations
must be given to the system external to the engine with respect to line lengths, volumes, pipe
lagging, cooling air flow over the lines, etc., to prevent condensate from developing due to an
inadequate superheat and/or insufficient flow through the external pipes and components.
Steam Scheduling Relative to Fuel Flow During
Transients See Text
Steam Metering Valve Opening Rate, Maximum 0.07 lb/sec/sec
(0.0318 kg/sec/sec)
Steam Initiation PS3 > 125 psia
(862 kPa)
Steam Shutoff PS3 < 120 psia
(827 kPa)
Maximum Engine Compressor Discharge Pressure (PS3)
During Steam Injection* 282 psia*
*NOTE: This pressure is for sea level operation and must be corrected for altitude for each
engine installation.

AC-13
GEK 97310
VOLUME I
ADDENDUM AC
LM2500 Operational Limits and Interlocks
STEAM
METERING
(1) VALVES (2)
• Steam
- Steady State
Flow to Combustor X - Steam flow less than site require-
ment for NOx
X - Steam flow is >2.70 times fuel flow
X X - Exceeds figure 1 requirements
- Steam Temperature at X <525°F (274°C)
Engine Manifold
X <500°F (260°C)
X >960°F (516°C)
Metering Valve Inlet
X >1000 psia (6895 kPa)
• PS3 X X <120 psia (827 kPa)
X X >282 psia (1944 kPa)
(1) ALARM REQUIRES POSITIVE CORRECTIVE ACTION.
(2) SPECIFIED LIMITS ARE EXTREME VALUES OUTSIDE OF THE RANGE OF NOR-
MAL OPERATION.

AC-14
GEK 97310
VOLUME I
ADDENDUM AC
Figure 1. LM2500-PL-MGA Steam Flow Limits

AC-15
GEK 97310
VOLUME I
ADDENDUM AC
b. During normal transient accelerations e. The steam supply system shall be pro-
or decelerations of the gas generator when the tected by check valves to prevent hot engine
decel or accel limits are not encountered, the gases from back flowing into the Purchaser
steam flow is to be within the limits provided supplied steam system when steam is not being
in figure 1. The steam flow rate shall never used for engine operation.
increase more rapidly than 0.07 lb/sec/sec
(0.0318 kg/sec/sec) (Table 3). Steam flow shall f. The steam system volume downstream
be reduced during engine decel as rapidly as of the metering valve affects transient opera-
necessary to follow engine PS3 changes such tion. It is recommended that the piping volume
that the metered steam shall not exceed the from the metering valve to the steam manifold
scheduled steam limit by more than 5 percent. be no greater than 1272 inch3 (0.021 m3) for
For engine shutdowns or step decrease power each of the two systems, the fuel nozzle supply
change transients the steam shall be shutdown and the CDP manifold supply.
valves. For gradual reductions in power to lev- g. Both metering valves in the steam sys-
els below schedule limits, the metering valves tem must have a 100 percent travel shutdown
shall be ramped closed at a rate that reduces time of less than 100 milliseconds (same as gas
steam at 0.07 lb/sec/sec (0.0318 kg/sec/sec) or fuel shutdown valve). The steam shutoff
less from the scheduled value to a value of valves shall close within 1.0 second.
zero.
h. The gas turbine does not require any
c. Steam flow shall be initiated only after particular minimum steam flow through either
the engine is stabilized at power when the CDP the fuel nozzle steam manifold or CDP mani-
is within the limits given in figure 1. The folds; however consideration must be given to
steam should be shut-off when engine horse- the system external to the engine with respect
power is below the CDP limits of figure 1. The to line lengths, volumes, pipe lagging, cooling
General Electric Company should be consulted air flow over the lines, etc., to prevent conden-
when operation with steam is desired outside sate from developing due to an inadequate
the figure 1 limits. superheat and/or insufficient flow through the
external pipes and components.
d. Liquid water shall be prevented from
entering the steam manifolds during engine 6-4 STEAM SCHEDULING.
operation. Before initiating steam flow, steam
supply lines and components shall be purged a. Steady state steam flow is scheduled as
(preheated) until their metal temperatures are a function of compressor discharge static pres-
at least 50°F (28°C) above the saturated steam sure (PS3). The steam flow operational limits
temperature. Precautions must be exercised to are provided in figure 1. The control system
ensure that any steam condensation in the fuel shall limit the CDP to the maximum value
nozzle and CDP steam supply lines during shown in figure 1 as a function of altitude
engine operation is continuously being (CDP x P2/14.7).
removed through the bleed drain systems.

AC-16
GEK 97310
VOLUME I
ADDENDUM AC
b. On all emergency conditions requiring (2) Therefore, the maximum Na + K
immediate reduction in power level, it will be allowed in the steam is determined from the
necessary to close both steam metering valves equation:
at least as rapidly as the fuel shutoff valves.
This rapid shutdown of the steam system (PPBFuel) + (PPBAir)A/F + (PPBSteam)S/F
avoids a high steam to fuel ratio in the com- = 200 PPB
bustor during rapid transients and, coupled
with the specified downstream volumes, will Where:
reduce the probability of combustor flameout. PPBFuel = Parts Per Billion Na + K in
Fuel
c. The steam control system shall remove
all water and saturated steam and raise the pipe PPBAir = Parts Per Billion Na + K in
or component metal temperature to at least Air
50°F (28°C) above steam saturation tempera- PPBSteam = Parts Per Billion Na + K in
ture prior to initiation of steam injection into Steam
the engine manifolds. When the preheating
valves are open, the steam metering valves A/F = Air/Fuel Ratio (Wt. Basis)
shall be closed. When steam temperature at the S/F = Steam/Fuel Ratio (Wt.
preheating valves is 50°F (28°C) or more Basis)
above saturation temperature. The control then
signals preheating values to close and provides (3) By this equation, if there was zero
a permissive signal for steam metering valves Na + K in the air and fuel, the maximum
to open. The steam metering valves must be allowed in the steam in PPB would be 200
opened in 30 seconds, if not, the preheating divided by S/F.
cycle must be reinitiated.
b. Total Conductivity [Cation + Anion @
6-5 STEAM PURITY/CONTAMINA- 77°F (25°C)].
TION LIMITS.
Normal: 0.5-1.5 micro-ohm/cm
a. Sodium + Potassium (Na + K): (95 percent of operating time)
Abnormal: As high as 2.0 micro-ohm/cm
(1) The maximum amount of Na + K (5 percent of operating time)
allowed in the steam injected into M&I engine
depends upon the total Na + K contamination c. Total Solids.
from all sources; i.e., from the fuel, air, and
steam. (1) The maximum total solids is
dependent upon the maximum steam to fuel
ratio at which the engine is to operate in the
specific application. The value is determined
from figure 2. Maximum contaminant size
shall not exceed 20 microns.

AC-17
GEK 97310
VOLUME I
ADDENDUM AC

AC-18
GEK 97310
VOLUME I
ADDENDUM AC
(2) With the exception of silica, there c. It is possible that these instructions
is no differentiation between types of solids as may not provide for every possible variation in
long as other limitations of this section are equipment and contingency to be met in con-
met. Silica in the steam is limited to 20 PPB. nection with the operation of the gas turbine.
Refer requests for additional information to:
(3) Calculate maximum steam to fuel
ratio by dividing the total high pressure steam General Electric Company
(fuel nozzles plus CDP) by fuel flow (WF36) Marine and Industrial Engine Division
for site operating conditions. Where steam Cincinnati, Ohio 45215.
flow may vary widely, the operating condition
with the highest steam to fuel ratio should be d. Refer also to Gas Turbine Packager’s
used. Manual.
(4) From the curve, determine the

WARNING
Total Solids Permissible and apply this limit to
the high pressure steam supplied to the gas IF A QUESTIONABLE CONDITION
turbine. EXISTS, DO NOT OPERATE THE
d. Steam Sampling. OUGH INVESTIGATION HAS
(1) Steam samples should be taken in HOT STARTS, COMPRESSOR
accordance with ASTM 1066 Procedures. STALLS OR OTHER RECOGNIZED
7-0 OPTIONAL HARDWARE KITS - THOROUGH INVESTIGATION.
7LM2500-PL-MGA. FAILURE TO DO SO CAN RESULT
a. Refer to your GE, M&I Customer Ser- IMPOSED ON GAS TURBINE COM-
vice Manager for a detailed list of optional kits PONENTS, WITH IMMEDIATE OR
currently available for this particular gas tur- SUBSEQUENT DESTRUCTIVE
bine model. FAILURE OF THE GAS TURBINE

pany for the 7LM2500-PL-MGA Gas Turbine.

ume I, Chapter 4, TROUBLESHOOTING.

AC-19
GEK 97310
VOLUME I
ADDENDUM AC
8-1 PERFORMANCE RATINGS AND 8-1.1 Performance Ratings.
OPERATING LIMITS.
a. The nominal average rated perfor-
NOTE mance of the 7LM2500-PL-MGA gas turbine
• Ratings published in this manual in the new and clean condition is as follows:
apply to the gas turbine. The driven
unit ratings/limits may be lower in Power Turbine
some cases and shall take prece- Speed 3600 rpm
dence over the gas turbine manual Shaft Horsepower - Base 30,400
limits. Heat Rate, BTU/HP-hr
- Average (Base) 6752
• Performance data with steam injection Based on the following conditions:
are available from the General Electric
Company. Purchaser’s request should Total Steam Flow 0 lbs/hr
include site conditions, fuel heating Inlet Air Temperature 59°F (15°C)
valve and chemical composition, steam Altitude Sea Level
quantities, steam temperature and steam Inlet Losses 0 in. H2O
supply pressure at the entrance to the Exhaust Losses 0 in. H2O
steam manifolds. Relative Humidity 60%
Compressor Bleed 0
Accessory Power 0
Extraction
Power Turbine Inlet Gas Tem-
perature, T5.4 Maximum
-At Base Rating (Dry)
@3600 rpm 1550°F (843°C)
@3000 rpm 1535°F (835°C)
b. Starting fuel flow for the 7LM2500-

PL-MGA model gas turbine is normally set by
the minimum stop on the gas fuel metering
valve. The proper fuel flow setting for the min-
imum stop, on a heat consumption basis, is
10.45 x 106 ± 0.46 x 106 BTU/hour commenc-
ing fuel and ignition at 1700 ± 100 rpm. Where
a minimum stop is not utilized, acceptable
lightoffs can be obtained in the sub-idle region,
however during such starts, ignition should be
MID-IDM-2500-9.

AC-20
GEK 97310
VOLUME I
ADDENDUM AC
c. Refer to Installation Design Manual 8-2.2 Instrumentation Required for
MID-IDM-2500-9 for 7LM2500 gas turbine Operation.
transient fuel flow requirements.
Gas generator speed sensor 0-11,000 rpm
those shown will result in over-temperature Lube oil scavenge tempera- 0-400°F
and possible stall of the gas turbine. Accelera- ture sensors (A, B, C, D- (-18 to 204°C)
tion fuel rates lower than those shown can sumps and accessory
result in hung starts in the below idle speed gearbox)
range. Lube oil supply temperature 0-400°F
e. Above the idle speed point, low accel- Vibration indicators 0-4 in/sec or
eration fuel rates will not harm the gas turbine gas generator 0-10 mil DA
power turbine 0-2 in/sec or
times.
0-15 mil DA
f. For normal accelerations from idle to Power turbine speed sensor 0-5000 rpm
power settings, the changes should be made Power turbine inlet gas 0-2000°F
more slowly to enhance the time between hot temperature (T5.4) (-18 to 1093°C)
section repairs and the life of the gas turbine. Lube oil supply pressure 0-100 psig
(0-690 kPa)
g. Refer to paragraph 6-2 for description
of the steam injection system. Power Turbine Inlet 0-100 psig
Pressure (P5.4) (0-690 kPa)
8-1.2 Operating Limits. Refer to Table 3. HP Recoup Pressure 0-200 psig
(HPRC) (0-1380 kPa)
NOTE Compressor Discharge 0-300 psig
If any operating limit is exceeded, ver- Pressure (PS3) (0-2070 kPa)
troubleshooting or inspecting gas Refer also to Gas Turbine Packager’s Manual
generator. for instrumentation required for monitoring

on the system.

AC-21
GEK 97310
VOLUME I
ADDENDUM AC
8-2.3 Additional Instrumentation Required g. All lines have been flushed per
for Monitoring and Troubleshooting. Packager’s manual _______
Fuel manifold pressure sensor 0-400 psig h. All instrumentation connec-
(0-2760 kPa) tions made and secure _______
Compressor inlet total pres- 10-16 psia i. All accessories are secure per
sure sensor (69-110 kPa) Packager’s manual _______
Fuel supply pressure 0-500 psig j. Gas turbine assembly free of
(0-3448 kPa) loose objects and all lines/
Fuel supply temperature 0-250°F electrical leads connected _______
(-18 to 121°C) k. Gas turbine inlet air area free
Gas turbine inlet air -65 to 150°F of foreign objects. Inlet screen
temperature (-54 to 66°C) secure _______
Lube oil scavenge pressure 0-200 psig l. Gas turbine compressor rear
(0-1379 kPa) frame leakage ports, struts 7
Remote reading variable -5 to 45 and 10, are open (not capped) _______
vane indicator degrees m. Continuous lube supply starter
Starter air supply pressure 0-50 psig is initially serviced per Pack-
(optional) (0-345 kPa) ager’s manual (if applicable) _______
Steam supply temperature 0-1000°F n. Lube oil storage tank serviced
(-18 to 538°C) to full level _______
o. Lube oil supply valves open _______
8-2.4 Preparation. The gas turbine and asso- p. All filters are serviced per
ciated systems must be inspected and checked Packager’s manual _______
q. Fire alarm /extinguish system
ON and operative _______
8-2.5 Gas Turbine and Associated Equip- r. T5.4 thermocouple system
ment Checklist. Complete the following functioning properly _______
checklist. s. Vibration system operative _______
a. Gas Turbine Assembly S/N _______ t. Ignition system operative _______
b. Mounting base secured to u. Compressor inlet total pressure
foundation _______ probe aligned properly and free
c. Intake air and exhaust gas of damage (if applicable) _______
ducts in place and secured _______ v. Steam manifolds aligned _______
d. Bonding straps in place and w. Steam HP recoup system
secure _______ installed _______
e. Gas turbine and exhaust duct x. Variable stator vane system
support mounts and links in secure _______
place and secure _______ y. Required checks and inspec-
f. All service connections made tions specified in Packager’s
and secure _______ manual for gas turbine control
have been performed _______

AC-22
GEK 97310
VOLUME I
ADDENDUM AC
8-2.6 Governor and Manual Control Check. AN OBSERVER SHALL BE STA-
Refer to Packager’s manual. TIONED AT THE ENCLOSURE
a. Steam supply system sequencing and ENTRY PROCEDURES SHALL
control. Refer to gas turbine Packager’s BE FOLLOWED.
manual.
8-2.7 Start-up and Checkout. COOL DOWN. AVOID CON-
MET:
OPERATING.
ENCLOSURE OR IN THE
OPERATION, CONTACT GE a. When entering enclosure during gas
FIELD SERVICE FOR A REPRE- turbine operation, wear proper ear protection.
paragraph 8-2.8.
paragraph 8-2.9.
DURES.
• SECONDARY AIR TO THE e. Perform false start per
ENCLOSURE DOOR.

AC-23
GEK 97310
VOLUME I
ADDENDUM AC
Item Requirement
Fuel valves Closed
Ignition Off
Ventilation Inlet Air (secondary cooling air) Off-air temp. below 70°F (21°C)
Oil tank level Full
Lube oil temperature Above 20°F (-7°C) for MIL-L-23699
Fuel supply - natural gas pressure at manifold inlet Ambient
h. Perform a manual start and operate per a. To purge the gas turbine system of any
paragraph 8-2.13. residual fuel, motor gas turbine at full motor-
ing speed for several minutes depending on
i. Operate to maximum power per actual inlet and exhaust volumes. Refer to
paragraph 8-2.14. packager’s manual for requirement. Allow gas
turbine to coast down.
paragraph 8-2.15. b. Disconnect number one ignition exciter
8-2.8 Ignition Check. lead away from the exciter.
WARNING c. Turn on electrical power to the ignition

igniter fires.
system. Reconnect input lead to ignition
VERTENT ACTIVATION.
exciter and safety wire connector.
the No. 2 exciter.
PROCEDURE.

AC-24
GEK 97310
VOLUME I
ADDENDUM AC
tem to isolate the problem, and take appropri- of flame (T5.4 < 400°).
8-2.11 Governor Check. Perform governor
8-2.9 Motoring. After all preliminary checks check per Packager’s manual.
generator can be motored as follows: 8-2.12 Wet Prestart. Perform wet prestart as
follows:
systems inoperative as follows: a. With ignition leads disconnected, but
(1) Disconnect power supply to system operating, make automatic start of the
ignition unit. gas turbine per Packager’s manual.
(2) Close natural-gas manual shutoff b. Gas generator should accelerate to

valves to fuel control unit. light-off speed (1600 to 1800 rpm). Fuel valve
b. Depress MOTORING pushbutton. Gas be approximately 3 psig (21 kPa). Adjust fuel
generator will start to rotate. If it does not, supply if required. Start will then abort
refer to Packager’s manual for supply pressure because of lack of flame (T5.4 < 400°).
to starter.
c. Allow gas turbine to coast to a stop;
c. Hold MOTORING pushbutton closed then motor it to purge any remaining natural
until gas generator speed stabilizes, and check gas from gas turbine. Continue to motor for at
for oil pressure. If there is no indication of oil least 60 seconds to purge fuel from gas turbine
pressure, release MOTORING pushbutton; and ducting.
oil fittings at lube pump to bleed air from sys- 8-2.13 Manual Start and Operation. Perform
tem. Starter should motor gas generator to manual start per Packager’s manual with fuel
minimum of 2200 RPM, with full supply valve open and with ignition lead connected.
pressure. Refer to Table 5.


follows:

of gas turbine per Packager’s manual.

AC-25
GEK 97310
VOLUME I
ADDENDUM AC
Step Corrective Action

No. Procedure Normal Result for Abnormal Results
1. Assure that prestart checks Investigate cause of condition. If
are completed per Table 4 T5.4 start limit is exceeded per-
form overtemperature inspection
CAUTION
ABORT START.
NOTE
A start may be aborted at any time by closing the fuel valve, allowing the gas generator to
NOTE
If purge cycle is required, step 3 should be preceded by high speed motoring cycle.
3. At 1600 to 1800 rpm NGG
a. Ignition on
8-1.12 step b
c. Note time to light-off 10 seconds maximum Abort start-automatic shutdown.
[T5.4 above 400°F Investigate and correct cause.
(204°C)] from fuel and
ignition on
4. Note time to 4500 ±200 rpm 90 seconds maximum Troubleshoot system and take
from initiation of corrective action if rpm stops
ignition increasing or if it takes longer than
90 seconds to reach 4300 rpm
5. At 4300 to 4700 rpm NGG
a. Starter shutoff valve Valve closed Manually close starter supply
should close
automatically

AC-26
GEK 97310
VOLUME I
ADDENDUM AC

a. Oil pressure See applicable figures in Alarm at 8 ±1 psig (55 ±6.9 kPa)
Chapter 5 Trip at 6 ±1 psig (41 ±6.9 kPa)
c. T5.4 1000°F (538°C) Emergency shutdown - Table 7
maximum
d. NPT (unloaded) 1200-1900 rpm Troubleshoot and take corrective
action
e. Gas generator vibration 0 to 3 mils DA Alarm set at 4 mils. Automatic
7 mils. Troubleshoot and take cor-
rective action
f. Power turbine vibration 0 to 6 mils DA Alarm set at 7 mils. Automatic
corrective action
g. Compressor inlet tem- Approximately equal to Troubleshoot sensing and indicat-
perature (T2) outside air temperature ing system. Correct as required
leaks
i. Maximum NGG with 6000 rpm NGG maxi- Shut down, investigate and cor-
power turbine seizure mum for 30 seconds rect cause per paragraph 8-2.13
(thermal seizure)
sient operation
a. T5.4 Less than alarm limit Ref. Note 1
b. NGG Ref. Note 1

AC-27
GEK 97310
VOLUME I
ADDENDUM AC

NOTE
The maximum allowable speed is 10,100 rpm.
c. NPT 0-3960 rpm Ref. Note 1
d. Oil pressure See applicable table and Emergency or automatic shut-
figure in Chapter 5 down if below 15 psig (103 kPa)
e. Scavenge oil tempera- 160-275°F Alarm at 290-310°F
tures (A, B, C, D sumps (71-135°C) (143-154°C); Automatic shut-
and accessory gearbox) down if above 340°F (171°C)
shutdown
g. Power turbine vibration 6 mils max Ref. Note 1.
7 mils max (Alarm) Troubleshoot
shutdown
h. Fuel manifold pressure 355 psig (2448 kPa) Ref. Note 2
maximum
i. Fuel inlet temperature -65 to 150°F Ref. Note 2
(-54 to 66°C)
j. Scavenge oil filter ∆P Refer to Packager’s Analyze any debris found. Check
manual screens and chip detector
k. Lube oil supply filter ∆P Refer to Packager’s
manual
WP 118 00 WP 118 00
n. HP recoup pressure Per figure 4 Correct as required per
paragraph 4-12.28
Note 1. Reduce power to stay within limits. If reducing power does not bring parameters within
limits, shut down. Troubleshoot any step changes in trends of operating parameters.
Note 2. If all other parameters are normal, correct discrepancy at next opportunity.

AC-28
GEK 97310
VOLUME I
ADDENDUM AC
CAUTION NOTE
DO NOT EXCEED 6000 RPM NGG • Power turbine except in a new or
AND 30 SECONDS OF GAS TUR- newly overhauled installation should
BINE OPERATION WITHOUT be rotating when gas generator idle
POWER TURBINE ROTATION. speed is attained.
a. The power turbine must rotate by the • Thermal seizure of the power turbine
time the gas generator speed reaches 6000 rpm rotor can occur when a hot gas turbine is
NGG. If power turbine speed indication is not shut down and is most likely to occur
obtained and it is determined that a thermal within 30 to 40 minutes following gas
seizure of the power turbine has occurred, pro- turbine operation. Thermal seizure is the
ceed as follows: condition where the power turbine rotor
is prevented from rotating by hard con-
interstage seals and other internal inter-
unequal cooling rates of the various
power turbine components. The possi-
bility of thermal seizures can be reduced
by operating the gas turbine at idle
shutdown to achieve proper cooling of
the power turbine.


AC-29
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ADDENDUM AC

AC-30
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ADDENDUM AC
Figure 4. Deleted

AC-31
GEK 97310
VOLUME I
ADDENDUM AC
(3) Repeat steps (1) and (2) for two c. Log all instrument readings once they
additional start-up and shutdown cycles. stabilize. Refer to Table 5, step 9.
(4) If the power turbine does not d. Reduce gas turbine speed to idle. After
rotate after accomplishing substeps (1) through stabilizing for three minutes, record all instru-
(3), shut down the gas turbine. ment readings. Refer to Table 6, step 2.
(5) Immediately after gas turbine e. Check fail-safe section of control sys-
rotation stops, re-start and accelerate to tem per Packager’s manual.
30 seconds. If the power turbine still does not f. After gas turbine has been stabilized at
rotate, shut down and investigate/correct the idle for five minutes, make normal shut-down.
cause. During the investigation for the cause of Refer to Table 6, steps 3 and 4.
blades in stages 4, 5, and 6 for shingling and 8-2.15 Automatic Operation. Check automatic
unlatching. If blades have become unlatched, operation per Packager’s manual.
encountered shingling may be bent, thereby a. Accelerate to idle or synchronous idle.
CAUTION
ELIMINATE CERTAIN PROTEC- e. Check for fuel or lube oil leaks.
ITS SHALL NOT BE EXCEEDED. f. After a total of five minutes at idle,
(refer to Packager’s manual) to increase gas g. Check lube oil filters, chip detectors,
generator speed. After each 500 rpm increase, and strainers; clean or replace as necessary.
attention to variable stator vane position and h. Correct any leaks observed.
within limits, adjust it per WP 118 00. If vibra- i. Remove all temporary instrumentation.
tions are not within limits, consult local Gen-
eral Electric Company representative. j. Check gas turbine and mounting sys-
b. Operate gas turbine up to rated power,
perature (T5.4) limit. Hold at this power set-
ting until all temperatures stabilize. If
ager’s manual.

AC-32
GEK 97310
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ADDENDUM AC
Table 6. GAS TURBINE NORMAL SHUTDOWN

following:
a. Oil pressure See applicable figure Alarm at 8 ±1 psig (55 ±6.9 kPa)
in Chapter 5 Trip at 6 ±1 psig (41 ±6.9 kPa)
c. T5.4 Approximately Troubleshoot system and take
1000°F (538°C) corrective action
e. Gas generator vibration 3 mils maximum Alarm above 4 mils. Automatic
shutdown if above 7 mils. Trou-
ble shoot and take corrective
action
f. Power turbine vibration 6 mils maximum Alarm above 7 mils. Automatic
shutdown if above 10 mils.
action
g. Fuel inlet temperature -65 to 150°F
(-54 to 66°C)
h. Scavenge oil filter ∆P Refer to Packager’s
manual
i. Lube oil supply filter ∆P Refer to Packager’s
manual
decreases

AC-33
GEK 97310
VOLUME I
ADDENDUM AC
ENCLOSURE DOOR.
tine operation of an installed gas turbine. For • THE ENCLOSURE DOOR
directions in the use of manual or automatic SHALL BE KEPT OPEN. IF THE
operation for normal operation, refer to Pack- GAS TURBINE IS OPERATING,
ager’s manual. AN OBSERVER SHALL BE STA-
8-3.2 Interlocks. Refer to Packager’s manual DOOR AND CONFINED SPACE
for description of interlocks which affect gas ENTRY PROCEDURES SHALL
turbine operation. BE FOLLOWED.

WARNING
OPERATING.
SHUT DOWN.
SENTATIVE WHO IS TRAINED a. When entering enclosure during gas
TO ENTER THE ENCLOSURE turbine operation, wear proper ear protection.
• THE FIRE EXTINGUISHING Table 5. Do not exceed operating limits of
SYSTEM SHALL BE MADE Table 3.
THE CUSTOMER’S PROCE- c. Shut down the gas turbine per Table 6.
DURES.
• SECONDARY AIR TO THE d. If required, emergency shutdown the
ENCLOSURE SHALL BE SHUT gas turbine per Table 7.
FLOW MAY PREVENT OPEN- e. Refer to applicable table in Chapter 5
for oil pressure correction factors.

AC-34
GEK 97310
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ADDENDUM AC
f. Idle lube oil pressure is 29 psig from any power setting by closing fuel valves
(200 kPa) maximum after five minutes and steam metering valves simultaneously.
stabilization.
b. Emergency shut-down shall be made
g. The corrected operating pressure of the per Table 7.
Chapter 5 at standard conditions of 9000 rpm 8-4.2 Post Shutdown Fire.
gas generator speed and 150°F (66°C) at lube
pump discharge temperature. Oil pressure a. During a normal shutdown, exhaust
measured at conditions other than standard gas temperature should decrease. If, during
shall be corrected to standard conditions using time gas turbine is coasting to stop, tempera-
applicable table in Chapter 5. ture increases instead of decreases, it indicates
8-4 EMERGENCY OPERATION. a leaking fuel valve. (A slight temperature
8-4.1 Emergency Shutdown. certain fuel is shut off, and motor the gas tur-
bine. This will blow out the fire. As soon as
a. In an emergency, when limits are temperature decreases to normal, discontinue
exceeded, the gas turbine may be shut down motoring.

No. Procedure Normal Result Abnormal Results
CAUTION
WILL FREE ITSELF AFTER A COOLING PERIOD OF 2 HOURS. CHECK FOR
1. Conditions permitting, deceler- T5.4 drops below 400°F Manually shut off fuel
ate gas turbine to idle and close (204°C) and NGG and NPT supply
fuel valves decelerate
2. Observe T5.4 for 3 minutes after 700°F (371°C) max Motor gas turbine. Con-

AC-35
GEK 97310
VOLUME I
ADDENDUM AC

No. Procedure Normal Result Abnormal Results
3. If an emergency shutdown from

a high power setting (T5.4)
greater than 1150°F (621°C) has
occurred, and a hot restart is
a. If a hot restart is to be per-
formed less than 2 hours fol-
shutdown, motor the gas tur-
bine at 2000-2500 rpm NGG
for 5 minutes. At the end of
the 5 minute motoring cycle,
allow gas turbine to deceler-
ate to 1700 rpm. When
1700 rpm is obtained, restart
the gas turbine and acceler-
ate to idle. Acceleration to
the desired power setting can
then be accomplished
b. After 2 hours following
coastdown of the HPC rotor,
restart can be made using the
normal starting procedure

AC-36
GEK 97310
VOLUME I
ADDENDUM AC
8-5 SPECIAL GAS TURBINE CON- 8-5.3 Lube Oil Supply Pressure. The lube oil
STRAINTS. supply pressure limits given in the limit table
are distress limits. Protective devices cannot
ditions, the gas turbines are constrained by the proper pressure is dependent on gas generator
operating limits published in the limits table. speed, oil type, oil temperature, and number of
shutdown or trip level should not be practiced. corrected oil pressure as directed on the appro-
priate pressure correction table to determine if
In the event that any of the following situations the lube system is performing within the high-
or events occur, the associated special action low limits stated on each table.
assure the gas turbines continued normal oper- 8-5.4 High Speed Stall. Stalls incurred at gas
ation. These events may not be detected or pre- generator rotational speeds above 7500 rpm
vented by the customary protective devices of can result in high pressure compressor blade
control systems. fracture. The gas turbine can be operated after
• Overtemperature During Starting through 6 verifies that blade tip clanging has
• Lube Oil Pressure ther inspection and stress relief of the blades is
• High Speed Stalls from the spool.
• Starter Duty Cycle (if applicable) 8-5.5 Starter Duty Cycle - Air or Natural
Gas.
• No Power Turbine Rotation 40 psig (276 kPa):
• Gas Generator Windmilling • 45 seconds on, 2 minutes off for any

number of cycles,
acceleration to idle, cooling flows to compo- or
ficient to protect the metals at T5.4 alarm and • 2 minutes on, 5 minutes off with two
trip levels specified in the limits table. A lower such cycles in any 30 minute period.
ited times as depicted on the Transient Tem-
perature Limits for Starts curve in figure 3.

AC-37
GEK 97310
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ADDENDUM AC
b. With starter inlet air pressure set at 8-5.7 No Power Turbine Rotation. A ther-
15 psig (103 kPa): mally bound power turbine rotor could occur
• 5 minutes on, 2 minutes off with two shutdown from high power. Power turbine
such cycles in any 30 minute period. rotation should initiate during gas turbine
or the following procedure should be used:
• 10 minutes on, 20 minutes off for any a. Remain at idle for 30 seconds and shut-
number of cycles. down.
c. There is no duty cycle limit on the b. Restart and repeat step a.

hydraulic starter.
c. Restart and repeat step a.
In the event that re-start of the gas turbine is d. Restart and accelerate to 6000 rpm. Do
required within 2 hours following a trip or not exceed 6000 rpm. Power turbine rotor
rapid shutdown from high power, a 5 minute should break away. If not, shut down and
motoring at 2000 to 2500 rpm must precede investigate for unlatched or shingled blades, or
the fire up. The objective is to cool the high other cause.
tain clearance with the more rapidly cooling 8-5.8 Windmilling.
case.
speeds above 1000 rpm provided the lube oil

windmilling is allowed up to 5 minutes, with
successive periods allowed if preceded by nor-
mal gas turbine operation.

AC-38
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ADDENDUM AD
ADDENDUM AD
7LM2500-PE-MGA

GEK 97310
VOLUME I
ADDENDUM AD
TABLE OF CONTENTS
1-0 INTRODUCTION ....................................................................................... AD-3

2-0 REFERENCE DATA ................................................................................... AD-3
3-0 INSTALLATION DRAWINGS .................................................................. AD-3
4-0 EQUIPMENT DESCRIPTION .................................................................. AD-4
5-0 INSTRUMENTATION AND SUPPLY REQUIREMENTS .................... AD-4
6-0 SERVICE REQUIREMENTS .................................................................... AD-4
6-1 NATURAL GAS........................................................................................... AD-4
6-2 STEAM INJECTION SYSTEM................................................................. AD-4
6-2.1 Steam Flow, Pressure and Temperature Requirements.................................. AD-4
6-2.2 Steam Control and Scheduling Requirements ............................................... AD-14
6-3 HIGH PRESSURE STEAM SYSTEM ...................................................... AD-14
6-4 STEAM SCHEDULING ............................................................................. AD-15
6-5 STEAM PURITY/CONTAMINATION LIMITS ..................................... AD-16
7-0 OPTIONAL HARDWARE KITS - 7LM2500-PE-MGA.......................... AD-16
8-0 GAS TURBINE OPERATION ................................................................... AD-16
8-1 PERFORMANCE RATINGS AND OPERATING LIMITS ................... AD-18
8-1.1 Performance Ratings...................................................................................... AD-18
8-1.2 Operating Limits ............................................................................................ AD-19
8-2 INITIAL OPERATION............................................................................... AD-19
8-2.1 General........................................................................................................... AD-19
8-2.2 Instrumentation Required for Operation........................................................ AD-19
8-2.3 Additional Instrumentation Required for Monitoring and Troubleshooting . AD-20
8-2.4 Preparation ..................................................................................................... AD-20
8-2.5 Gas Turbine and Associated Equipment Checklist........................................ AD-20
8-2.6 Governor and Manual Control Check............................................................ AD-21
8-2.7 Start-up and Checkout.................................................................................... AD-21
8-2.8 Ignition Check................................................................................................ AD-22
8-2.9 Motoring ........................................................................................................ AD-23
8-2.10 False Start....................................................................................................... AD-23
8-2.11 Governor Check ............................................................................................. AD-23
8-2.12 Wet Prestart .................................................................................................... AD-23
8-2.13 Manual Start and Operation ........................................................................... AD-23
8-2.14 Operation to Maximum Power ...................................................................... AD-28
8-2.15 Automatic Operation...................................................................................... AD-28
8-3 NORMAL OPERATION ............................................................................ AD-30
8-3.1 General........................................................................................................... AD-30
8-3.2 Interlocks ....................................................................................................... AD-30
8-3.3 Operation ....................................................................................................... AD-30
8-4 EMERGENCY OPERATION .................................................................... AD-31
8-4.1 Emergency Shutdown .................................................................................... AD-31
8-4.2 Post Shutdown Fire ........................................................................................ AD-31

AD-1
GEK 97310
VOLUME I
ADDENDUM AD
TABLE OF CONTENTS
8-5 SPECIAL GAS TURBINE CONSTRAINTS............................................ AD-34

8-5.1 General........................................................................................................... AD-34
8-5.2 Overtemperature ............................................................................................ AD-34
8-5.3 Lube Oil Supply Pressure .............................................................................. AD-34
8-5.4 High Speed Stall ............................................................................................ AD-34
8-5.5 Starter Duty Cycle - Air or Natural Gas ........................................................ AD-34
8-5.6 Re-Start Following High Power Trip............................................................. AD-35
8-5.7 No Power Turbine Rotation ........................................................................... AD-35
8-5.8 Windmilling ................................................................................................... AD-35
Figure Title Page
1 LM2500-PE-MGA Steam Flow Limits ......................................................... AD-8

2 Steam Contamination - Maximum Solids...................................................... AD-17
3 Transient Temperature Limits ........................................................................ AD-29
4 Deleted
LIST OF TABLES
Table Title Page
1 INSTRUMENTATION CONNECTIONS - 7LM2500-PE-MGA................. AD-5

2 SUPPLY CONNECTIONS - 7LM2500-PE-MGA........................................ AD-6
3 GAS TURBINE OPERATING LIMITS........................................................ AD-9
4 PRESTART CHECKS ................................................................................... AD-22
5 START-UP AND OPERATION .................................................................... AD-24
6 GAS TURBINE NORMAL SHUTDOWN ................................................... AD-31
7 EMERGENCY SHUTDOWN....................................................................... AD-33

AD-2
GEK 97310
VOLUME I
ADDENDUM AD
The information contained herein describes the High Pressure Turbine Rotor 419(190)
7LM2500-PE-MGA model gas turbine basic High Pressure Turbine Nozzle,
configuration and control system differences. Stage 1 68(31)
In addition, the coverage of reference data, High Pressure Turbine Nozzle,
instrumentation and supply connections, spe- Stage 2 127(58)
kits and the complete gas turbine operating Turbine Mid Frame 530(240)
instructions for the 7LM2500-PE-MGA model Low Pressure Turbine Rotor 1095(497)
are included. Low Pressure Turbine Stator 601(273)
2-0 REFERENCE DATA.
EQUIPMENT Forward Adapter 91(41)
Gas Turbine Assembly Variable Stator Actuating Mech 19(9)
(General Electric Co., Cincinnati, Ohio) Outside Piping and Bracketing 278(126)
Model No. 7LM2500-PE-MGA
Drawing No. L31430G24 & L31430G32 DRAWING LIST
PERFORMANCE RATING
Drawing No.
High Pressure Steam Piping L43646
GAS TURBINE WEIGHTS Schematic and
The average weights of the major gas L31859
turbine components are: Gas Turbine Installation L31705
Drawing
Component Wt-Lbs/(Kg) Lubrication System Flow L24328
Gas turbine - including inlet Diagram
duct, centerbody, exhaust Electrical Diagram L24329
diffuser, and coupling nut 7815(3545)
Gas Turbine Assembly L31430
Power Turbine 2830(1284) Drawing
Inlet Gearbox 38(17) Fuel and Steam Injection
Transfer Gearbox 245(111) Assembly 682L400
Compressor Front Frame 517(235) Steam Augmented HP Recoup 682L457
Compressor Stator, Rear 93(42) A complete set of installation drawings has
Compressor Rear Frame 421(191) been provided.
Combustor 120(54)

AD-3
GEK 97310
VOLUME I
ADDENDUM AD
4-0 EQUIPMENT DESCRIPTION. e. Assembly and interface details of the
engine-mounted steam manifolds and steam/
a. The 7LM2500-PE-MGA model is a gas fuel nozzle system are defined on Drawing
marinized, natural gas fueled gas turbine No. 682L400.
which is capable of accepting steam produced
by a Heat Recovery Steam Generator (HRSG) 5-0 INSTRUMENTATION AND SUP-
in the gas turbine exhaust system. Benefits PLY REQUIREMENTS. See Tables 1 and 2.
resulting from injection of steam into the gas
generator are increased output horsepower, 6-0 SERVICE REQUIREMENTS.
improved thermal efficiency, and suppression 6-1 NATURAL GAS.
of the oxides of nitrogen (NOx) in the engine
exhaust gases. a. The required supply pressure to the
b. Steam is injected into the high pressure determined by the required maximum power,
section of the engine by means of two separate fuel composition and supply temperature of
engine-mounted manifold systems: a fuel noz- the application.
zle steam manifold and two compressor dis-
charge steam manifolds. Steam flow in each b. The temperature of the gas supply at
of the two manifold systems is regulated by the fuel manifold connection on the gas turbine
separate metering valves, with the ratio of flow must be in the range of 20°F (-7°C) above the
between the two systems based on optimiza- saturated vapor temperature as a minimum,
tion of emissions suppression and available and 350°F (177°C) as a maximum. Based on
steam. A schematic diagram of the steam sys- consideration of control system components
tems is shown on Drawing No. L43646 for however, it is recommended that the maximum
premixed nozzle system and L31859 for noz- gas supply temperature be limited to 150°F
zles with separate injection passages. (66°C). If the supply temperature of the gas is
not repeatable on a day-to-day basis, it may be
c. Steam injected into the fuel nozzle necessary to change the control system starting
steam manifold is directed into the combustion fuel adjustment or to adjust the supply pressure
primary zone through a special steam and gas to the gas turbine to maintain a constant
fuel nozzle. The separate injection nozzles use Btu-per-cubic-foot supply. Once started the
concentric passages with separate orifices in gas turbine will accept variations in supply
the tip, whereas the premix nozzles use a mix- temperatures of ±20°F (±11°C). The maxi-
ing chamber in the nozzle body. mum fuel flow required, assuming a lower
d. Each of the two CDP manifolds sup- heating value of 19,000 Btu/lb, is 13,500 pph
plies steam to two compressor rear frame struts (6123 kg/hr) for the 7LM2500-PE-MGA
which duct steam into the inner hub of the model gas turbine.
compressor rear frame. From the inner hub of 6-2 STEAM INJECTION SYSTEM.
the compressor rear frame, the steam flows
into the compressor discharge flowpath 6-2.1 Steam Flow, Pressure and
between the combustor inner liner and inner Temperature Requirements.
combustion casing to mix with combustor lin-
ing cooling air, into the high pressure turbine a. The high pressure steam injection sys-
stage 1 nozzle cooling air path, and into the tem includes two metering valves: one controls
high pressure turbine rotor and blade cooling the flow to the fuel nozzles and the other con-
air path. trols the flow to the CDP manifolds. Flow
meters measure the flow through each meter-
ing valve.

AD-4
GEK 97310
VOLUME I
ADDENDUM AD
Table 1. INSTRUMENTATION CONNECTIONS - 7LM2500-PE-MGA
Instrumentation
El Vibration pickup, gas generator MS3106R10SL-4S
E20A, E20B Power turbine inlet temperature MS3106-14S-2P
E20C, E20D
E3B A-sump scavenge oil temperature M83723/86G1005-6
E4B B-sump scavenge oil temperature M83723/86G1005-6
E5B C-sump scavenge oil temperature M83723/86G1005-6
E6B Accessory gearbox scavenge oil temperature M83723/86G1005-6
E11B Oil supply temperature M83723/86G1005-6
E18B D-sump scavenge oil temperature M83723/86G1005-6
E13 Vibration pickup, power turbine MS3106R10SL-4S
A23 CDP pressure port 0.500-20UNJF
F3A Natural gas fuel manifold pressure tap MS33656-4
L7 Lube scavenge pressure tap AN818-4C or MS20819-4C
E30 T3 Sensor (Dual T/C) (optional) MS3106-14S-2SX
E33 Remote reading variable stator vane protractor MS3106E16S-1S
(optional)
E35 T2/P2 Sensor (RTD) (optional) M83723/95G1005N or
M83723/86G1005N
E22/E23 UV Flame Sensor MS3106-10SL-4S
NOTE
• For all other instrumentation connections, refer to installation
drawings provided with gas turbine.
• Refer to gas turbine Packager’s manual for instrumentation
required for monitoring steam conditions.

AD-5
GEK 97310
VOLUME I
ADDENDUM AD
Table 2. SUPPLY CONNECTIONS - 7LM2500-PE-MGA

Mechanical
Interface
CAUTION
ALL LINES MUST BE FLEXIBLE ENOUGH TO ALLOW 0.75 INCH (19 MM)
LINES OR ON GAS GENERATOR.
F1A Natural gas supply 3.00 inch (76.2 mm) line from Fuel Control Unit
to Gas Turbine Fuel Manifold
L1 Oil supply 1.50 inch (38.1 mm) line to Lube Pump on Gas
Turbine AN818-24C or MS20819-24C
L2 Lube pump discharge 1.00 inch (25.4 mm) line from Lube Pump to Oil
Supply Filters AN818-16C or MS20819-16C
L4 Lube supply inlet port 1.00 inch (25.4 mm) line from Oil Supply Filters
to Gas Turbine AN818-16C or MS20819-16C
L3 Scavenge oil discharge 1.25 inch (31.8 mm) line from Gas Turbine Scav-
enge Pump to Oil Scavenge Filter and Cooler
AN818-20C or MS20819-20C
A4 Inlet duct seal flange (If required)
(optional)
(optional)
A12 Air/oil separator discharge 3.00 inch (76.2 mm) line from air/oil separator to
atmospheric vent or to exhaust duct (flame
arrestor)
S1 Waterwash manifold 1.00 inch (25.4 mm) line - hot water line to water-
wash manifold on Gas Turbine Inlet Duct
AN818-16C or MS20819-16C

AD-6
GEK 97310
VOLUME I
ADDENDUM AD
Table 2. SUPPLY CONNECTIONS - 7LM2500-PE-MGA - Continued
Mechanical
Interface
W17/W17A CDP steam manifold supply 3.50 inch (88.9 mm) MS or ANSI type flange
W18/W18A Fuel nozzle steam supply 4.00 inch (101.6 mm) MS or ANSI type flange
from steam supply to fuel nozzle steam manifold
W19 Fuel nozzle steam manifold MS20819-12/MS9197-12
drain
W20 Fuel nozzle steam manifold MS20819-12/MS9197-12
drain
NOTE
• For all other supply connections, see Installation Drawings,
• In addition, refer to Gas Turbine Packager’s Manual.
b. The steam manifolds and gas/steam c. The minimum permissible steam tem-
fuel nozzles are designed to flow steam by perature at the inlets to the manifolds is 50°F
weight equivalent to approximately 5.5 per- (28°C) above saturation. The maximum com-
cent of the high pressure compressor airflow bined combustor and CDP steam flow is
(W25) or 8 pounds per second (3.6 kg/sec) of approximately 30,000 lbs/hr (3,608 kg/hr) @
steam at 675°F (357°C), at a supply pressure to 59°F (15°C) with each system operating with
manifold inlets of 325 psia (2241 kPa), at com- it’s individual maximum steam flow. See Table
pressor discharge pressure (PS3) of 285 psia 3 and figure 1 for more precise values.
(1965 kPa) with steam flow split between fuel
nozzles and CDP manifold. This steam split d. The individual maximum permissible
can be revised from the design point to meet steam flow into the fuel nozzle and CDP mani-
application requirements for NOx reduction folds is a function of compressor discharge
and steam availability. Maximum permissible pressure (PS3) as given in figure 1. At very
steam pressure at the manifold inlet for either high steam to fuel ratios, combustor efficiency
system is 700 psia (4826 kPa) and maximum may be reduced and combustor flame out mar-
steam temperature is 960°F (517°C). gin is reduced.
e. Whenever high pressure steam is
injected into the engine, a minimum flow
should be provided to the fuel nozzle steam
and CDP manifolds as described in Table 3 to
prevent condensation.
AD-7
GEK 97310
VOLUME I
ADDENDUM AD
Figure 1. LM2500-PE-MGA Steam Flow Limits

AD-8
GEK 97310
VOLUME I
ADDENDUM AD
Normal
Alarm/ Operating
NOTE
Lubrication Gas turbine Alarm 8 psig ± 1 psig 20-60 psig Bypass until
System - lube supply (55 kPa ± 6.9 kPa) (138-413 kPa) 4500 rpm
above 8000 rpm
(41 kPa ± 6.9 kPa) (138-413 kPa) 4500 rpm
scavenge (759 kPa ± 69 kPa) (69-690 kPa) charge pressure
discharge shall not exceed
pressure 180 psig
(1242 kPa)
Gas turbine Alarm 180-220°F 140-160°F Normal operating
lube supply (82-104°C) (60-71°C) range reflects tem-
during operation
above idle speed
Gas turbine Trip 330-350°F 160-275°F Normal operating
lube (166-177°C) (71-135°C) range reflects tem-
scavenge perature expected
temperatures - during operation
five above idle speed
Alarm 290-310°F
(143-154°C)
Fuel System Fuel 0-355 psig Supply pressure as
Natural Gas manifold (0-2448 kPa) reflected at the fuel
pressure manifold inlet on
the gas turbine

AD-9
GEK 97310
VOLUME I
ADDENDUM AD
Normal
Alarm/ Operating
Fuel System Fuel supply Alarm 150-170°F -65 to 150°F Starting fuel flow
Natural Gas temperature (66-77°C) (-54 to 66°C) adjustments may be
(cont) required to com-
pensate for fuel
temperature
variation
Starting Starter supply 35-40 psig Starting pressure
System pressure (241-276 kPa) requirement based
(Pneumatic) on engine starter
torque
requirements
fuel and igni-
tion
fuel and igni- start after purge
tion (if purge cycle
cycle is used)
Starting time Trip 1700 ± 100 rpm Activate 30 second
neously with start
initiation
neously with igni-
tion initiation. De-
energize ignition
and starter air sup-
ply at 4500 rpm
if purge cycle completion of
is used) purge. De-energize
ignition systems
and starter air sup-
ply at 4500 rpm

AD-10
GEK 97310
VOLUME I
ADDENDUM AD
Normal
Alarm/ Operating
Power Failure to Trip 380-420°F 900-1200°F Trip if temperature
Turbine Inlet light-off (193-216°C) (482-649°C) does not reach
Temperature at light-off 400°F (204°C)
within 10 seconds
tion are applied
Overtempera- Power Turbine
ture: natural Speed
gas 3600 rpm 3000 rpm
Trip 1575°F 1575°F
(857°C) (857°C)
Alarm 1540°F 1525°F
(Dry) (838°C) (829°C)
Alarm 1520°F 1505°F
(25 ppm (827°C) (818°C)
NOx)
Vibration Gas Trip 7 mils DA 0-3 mils DA Avoid continuous
4 mils
Alarm 4 mils DA
Power Trip 10 mils DA 0-6 mils DA Avoid continuous
7 mils
Alarm 7 mils DA
Gas Trip 10,200 rpm 0-10,050 rpm
Generator (Max. physi-
Speed cal speed)
0-10,100 rpm
(Max. cor-
rected speed)
Power For 60 Hz Trip 3960 rpm 0-3600 rpm
Turbine
Speed
For 50 Hz Trip 3300 rpm 0-3000 rpm

AD-11
GEK 97310
VOLUME I
ADDENDUM AD
Normal
Alarm/ Operating
NOTE
Refer to packager’s manual for specific alarm and trip levels.
Loss of Fuel Combustor Trip Close and lockout
Flame flame fuel shut-off valve
upon loss of flame
(both detectors)
Alarm Loss of flame on
one detector
Thrust Recoup See remarks Recoup Refer to GEK
Balance pressure pressure: 97310, Volume I,
0-200 psig Paragraph 5-3.30,
(0-1379 kPa) for acceptable oper-
ating envelope
(corrected recoup
Pressure P5.4: 0-60 psig pressure vs. cor-
(0-414 kPa) rected exhaust gas
total pressure, P5.4)
Maximum Steam Supply Temperature 960°F (516°C)
Minimum Steam Supply Temperature 50°F (28°C) above saturation refer-
enced to manifold inlet pressure
Maximum Steam Flow:

- Total high pressure steam flow See figure 1
- Fuel nozzle steam - steam/fuel ratio (variable) flow See figure 1
- CDP manifold steam flow See figure 1
Minimum Steam Flow
The 7LM2500-PE-MGA gas turbine does not require any particular minimum steam flow
through either the fuel nozzle steam manifold or CDP manifolds, however considerations
must be given to the system external to the engine with respect to line lengths, volumes,
pipe lagging, cooling air flow over the lines, etc., to prevent condensate from developing
due to an inadequate superheat and/or insufficient flow through the external pipes and
components.

AD-12
GEK 97310
VOLUME I
ADDENDUM AD
Normal
Alarm/ Operating
Steam Scheduling Relative to Fuel Flow During Transients See Text
Steam Metering Valve Opening Rate, Maximum 0.07 lb/sec/sec
(0.0318 kg/sec/
sec)
Steam Initiation PS3 > 125 psig
(862 kPa)
Steam Shutoff PS3 < 120 psig
(827 kPa)
Maximum Engine Compressor Discharge Pressure (PS3)
During Steam Injection* 282 psia*
NOTE
* This pressure is for sea level operation and must be corrected for altitude
for each engine installation.
LM2500 Operational Limits and Interlocks
STEAM
METERING
(1) VALVES (2)
• Steam
- Steady State X - Steam flow less than site require-
Flow to Combuster ment for NOx
X - Steam flow is >2.70 times fuel flow
X X - Exceeds figure 1 requirements
- Steam Temperature at X <525°F (274°C)
Engine Manifold X <500°F (260°C)
X >960°F (516°C)
Metering Valve Inlet X ≥1000 psia (6895 kPa)
• PS3 X X <120 psia (827 kPa)
X X >282 psia (1944 kPa)

AD-13
GEK 97310
VOLUME I
ADDENDUM AD
STEAM
METERING
(1) VALVES (2)
(1) ALARM REQUIRES POSITIVE CORRECTIVE ACTION.
(2) SPECIFIED LIMITS ARE EXTREME VALUES OUTSIDE OF THE RANGE OF
NORMAL OPERATION.
f. Depending on the specific type of gas/ 6-3 HIGH PRESSURE STEAM

steam system selected, a crossover line may be SYSTEM.
included in the Packager’s steam supply sys-
tem to connect the CDP steam manifold supply a. It is recommended that steam be sched-
to the fuel nozzle steam manifold supply. The uled as a function of high pressure compressor
crossover line provides purge and preheat air discharge static pressure (PS3). Limits on high
for the steam manifolds when no steam is pressure steam flow vs. PS3 are shown in
being injected. The static pressure difference figure 1, with a maximum total flow of
between the inner flowpath at the CDP steam 30,000 lb/hr.
discharge and the combustor dome at the fuel
nozzle tip is sufficient to provide circulation of b. During normal transient accelerations
compressor discharge air from the CDP steam or decelerations of the gas generator when the
manifold, through the crossover and into the decel or accel limits are not encountered, the
fuel nozzle steam manifold to ensure that steam flow is to be within the limits provided
purge flow is into the combustor and not from in figure 1. The steam flow rate shall never
the combustor. The crossover line contains a increase more rapidly than 0.07 lb/sec/sec
low pressure drop check valve that prevents (0.0318 kg/sec/sec) (Table 3). Steam flow shall
flow of steam from the fuel nozzle steam sup- be reduced during engine decel as rapidly as
ply to the CDP steam supply. Premix type fuel necessary to follow engine PS3 changes such
systems do not use this preheating method. that the metered steam shall not exceed the
scheduled steam limit by more than 5 percent.
g. Levels of steam contamination must For engine shutdowns or step decrease power
not exceed those defined in paragraph 6-7. change transients the steam shall be shutdown
6-2.2 Steam Control and Scheduling valves. For gradual reductions in power to lev-
Requirements. (Ref. Schematic GE L31859). els below schedule limits, the metering valves
shall be ramped closed at a rate that reduces
steam at 0.07 lb/sec/sec (0.0318 kg/sec/sec) or
less from the scheduled value to a value of
zero.

AD-14
GEK 97310
VOLUME I
ADDENDUM AD
c. Steam flow shall be initiated only after folds; however consideration must be given to
the engine is stabilized at power when the CDP the system external to the engine with respect
is within the limits given in figure 1. The to line lengths, volumes, pipe lagging, cooling
steam should be shut-off when engine horse- air flow over the lines, etc., to prevent conden-
power is below the CDP limits of figure 1. The sate from developing due to an inadequate
General Electric Company should be consulted superheat and/or insufficient flow through the
when operation with steam is desired outside external pipes and components.
the figure 1 limits.
6-4 STEAM SCHEDULING.
d. Liquid water shall be prevented from
entering the steam manifolds during engine a. Steady state steam flow is scheduled as
operation. Before initiating steam flow, steam a function of compressor discharge static pres-
supply lines and components shall be purged sure (PS3). The steam flow operational limits
(preheated) until their metal temperatures are are provided in figure 1. The control system
at least 50°F (28°C) above the saturated steam shall limit the CDP to the maximum value
temperature. Precautions must be exercised to shown in figure 1 as a function of altitude
ensure that any steam condensation in the fuel (CDP x P2/14.7).
nozzle and CDP steam supply lines during
engine operation is continuously being b. On all emergency conditions requiring
removed through the bleed drain systems. immediate reduction in power level, it will be
necessary to close both steam metering valves
e. The steam supply system shall be pro- at least as rapidly as the fuel shutoff valves.
tected by check valves to prevent hot engine This rapid shutdown of the steam system
gases from back flowing into the Purchaser avoids a high steam to fuel ratio in the com-
supplied steam system when steam is not being bustor during rapid transients and, coupled
used for engine operation. with the specified downstream volumes, will
reduce the probability of combustor flameout.
f. The steam system volume downstream
of the metering valve affects transient opera- c. The steam control system shall remove
tion. It is recommended that the piping volume all water and saturated steam and raise the pipe
from the metering valve to the steam manifold or component metal temperature to at least
be no greater than 1272 inch3 (0.021 m3) for 50°F (28°C) above steam saturation tempera-
each of the two systems, the fuel nozzle supply ture prior to initiation of steam injection into
and the CDP manifold supply. the engine manifolds. When the preheating
valves are open, the steam metering valves
g. Both metering valves in the steam sys- shall be closed. When steam temperature at the
tem must have a 100 percent travel shutdown preheating valves is 50°F (28°C) or more
time of less than 100 milliseconds (same as gas above saturation temperature. The control then
fuel shutdown valve). The steam shutoff signals preheating values to close and provides
valves shall close within 1.0 second. a permissive signal for steam metering valves
to open. The steam metering valves must be
h. The gas turbine does not require any opened in 30 seconds, if not, the preheating
particular minimum steam flow through either cycle must be reinitiated.
the fuel nozzle steam manifold or CDP mani-

AD-15
GEK 97310
VOLUME I
ADDENDUM AD
6-5 STEAM PURITY/CONTAMINA- (1) The maximum total solids is
TION LIMITS. dependent upon the maximum steam to fuel
ratio at which the engine is to operate in the
a. Sodium + Potassium (Na + K): specific application. The value is determined
from figure 2. Maximum contaminant size
(1) The maximum amount of Na + K shall not exceed 20 microns.
allowed in the steam injected into M&I engine
depends upon the total Na + K contamination (2) With the exception of silica, there
from all sources; i.e., from the fuel, air, and is no differentiation between types of solids as
steam. long as other limitations of this section are
met. Silica in the steam is limited to 20 ppb.
(2) Therefore, the maximum Na + K
allowed in the steam is determined from the (3) There is no differentiation
equation: between types of solids as long as other limita-
tions of this paragraph are met.
(PPBFuel) + (PPBAir)A/F + (PPBSteam)S/F = (4) Calculate maximum steam to fuel
200 PPB ratio by dividing the total high pressure steam
Where: (fuel nozzles plus CDP) by fuel flow (WF36)
for site operating conditions. Where steam
PPBFuel = Parts Per Billion Na + K in flow may vary widely, the operating condition
Fuel with the highest steam to fuel ratio should be
used.
PPBAir = Parts Per Billion Na + K in
(5) From the curve, determine the
Air Total Solids Permissible and apply this limit to
PPBSteam = Parts Per Billion Na + K in the high pressure steam supplied to the gas tur-
bine.
Steam
A/F = Air/Fuel Ratio (Wt. Basis) d. Steam Sampling.
S/F = Steam/Fuel Ratio (Wt. Basis) (1) Steam samples should be taken in
accordance with ASTM 1066 Procedures.
(3) By this equation, if there was zero
Na + K in the air and fuel, the maximum 7-0 OPTIONAL HARDWARE KITS -
allowed in the steam in PPB would be 200 7LM2500-PE-MGA.
divided by S/F.
b. Total Conductivity [Cation + Anion @ a. Refer to your GE, M&I Customer Ser-
77°F (25°C)]. vice Manager for a detailed list of optional kits
currently available for this particular gas tur-
Normal: 0.5-1.5 micro-ohm/cm bine model.
(95 percent of operating time)
Abnormal: As high as 8-0 GAS TURBINE OPERATION.
2.0 micro-ohm/cm (5 percent of a. These instructions contain the detailed
operating time) gas turbine operating procedures and limits
c. Total Solids. recommended by the General Electric Com-
pany for the 7LM2500-PE-MGA Gas Turbine.

AD-16
GEK 97310
VOLUME I
ADDENDUM AD

AD-17
GEK 97310
VOLUME I
ADDENDUM AD
b. The instructions are intended to pro- • Performance data with steam injec-
vide operating personnel with the information tion are available from the General
required to operate the gas turbine. They per- Electric Company. Purchaser’s
tain to routine and emergency conditions and request should include site conditions,
procedures. When a fault exists, refer to Vol- fuel heating valve and chemical com-
ume I, Chapter 4, TROUBLESHOOTING. position, steam quantities, steam tem-
perature and steam supply pressure at
c. It is possible that these instructions the entrance to the steam manifolds.
equipment and contingency to be met in con- 8-1.1 Performance Ratings.
nection with the operation of the gas turbine.
Refer requests for additional information to: a. The nominal average rated perfor-
General Electric Company mance of the 7LM2500-PE-MGA gas turbine
Marine and Industrial Engine Division in the new and clean condition is as follows:
Cincinnati, Ohio 45215.
Power Turbine Speed
d. Refer also to Gas Turbine Packager’s
Manual. 3600 rpm 3000 rpm
Shaft Horsepower
WARNING - Base 31,200 30,000
IF A QUESTIONABLE CONDITION Heat Rate, BTU/HP-hr
EXISTS, DO NOT OPERATE THE - Average (Base) 6777 7015
BEEN MADE. DO NOT REPEAT Total Steam Flow 0 lbs/hr
HOT STARTS, COMPRESSOR Inlet Air Temperature 59°F (15°C)
STALLS OR OTHER RECOGNIZED
PROBLEMS WITHOUT PRIOR Altitude Sea Level
THOROUGH INVESTIGATION. Inlet Losses 0 in. H2O
IN UNDUE STRESS BEING Exhaust Losses 0 in. H2O
IMPOSED ON GAS TURBINE COM- Relative Humidity 60%
Compressor Bleed 0
FAILURE OF THE GAS TURBINE Accessory Power 0
AND INJURY TO PERSONNEL. Extraction
8-1 PERFORMANCE RATINGS AND Power Turbine Inlet
OPERATING LIMITS. Gas
NOTE Temperature, T5.4
Maximum
• Ratings published in this manual apply
to the gas turbine. The driven unit rat- - At Base Rating (Dry)
ings/limits may be lower in some cases (3600 rpm) 1535°F (835°C)
turbine manual limits. (3000 rpm) 1520°F (827°C)

AD-18
GEK 97310
VOLUME I
ADDENDUM AD
- At Base Rating (25 ppm NOX) NOTE
(3600 rpm) 1515°F (824°C) If any operating limit is exceeded, ver-
(3000 rpm) 1500°F (816°C) ify instrumentation accuracy before
b. Starting fuel flow for the generator.
7LM2500-PE-MGA model gas turbine is nor- 8-2 INITIAL OPERATION.
mally set by the minimum stop on the gas fuel
metering valve. The proper fuel flow setting 8-2.1 General. Initial operational period is
for the minimum stop, on a heat consumption that period of operation immediately following
basis, is 10.45 x 106 ± 0.46 x 106 BTU/hour gas turbine replacement or major maintenance
commencing fuel and ignition at 1700 ± 100 on the system.
rpm. Where a minimum stop is not utilized, 8-2.2 Instrumentation Required for
acceptable lightoffs can be obtained in the sub- Operation.
idle region, however during such starts, igni-
tion should be initiated at that fuel flow corre- Gas generator speed sensor 0-11,000 rpm
sponding to the minimum stop with its Lube oil scavenge
associated tolerance. If starts in the sub-idle temperature 0-400°F
region are required, refer to Gas Turbine sensors (A, B, C, D-sumps (-18 to 204°C)
Installation Design Manual MID-IDM-2500-9. and accessory gearbox)
c. Refer to Installation Design Manual Lube oil supply temperature 0-400°F
MID-IDM-2500-9 for 7LM2500 gas turbine sensor (-18 to 204°C)
transient fuel flow requirements. Vibration indicators
0-10 mil DA
and possible stall of the gas turbine. Accelera- power turbine 0-2 in/sec or
tion fuel rates lower than those shown can 0-15 mil DA
result in hung starts in the below idle speed Power turbine speed sensor 0-5000 rpm
range. Power turbine inlet gas 0-2000°F
eration fuel rates will not harm the gas turbine Lube oil supply pressure 0-100 psig
and will only result in slower acceleration (0-690 kPa)
times. Power Turbine Inlet 0-100 psig
Pressure (P5.4) (0-690 kPa)
HP Recoup Pressure (HPRC) 0-200 psig
power settings, the changes should be made
(0-1380 kPa)
section repairs and the life of the gas turbine. Compressor Discharge 0-300 psig
Pressure (PS3) (0-2070 kPa)
g. Refer to paragraph 6-2 for description
of the steam injection system. Refer also to Gas Turbine Packager’s Manual
8-1.2 Operating Limits. Refer to Table 3. for instrumentation required for monitoring

AD-19
GEK 97310
VOLUME I
ADDENDUM AD
8-2.3 Additional Instrumentation Required f. All service connections
for Monitoring and Troubleshooting. made and secure _________
g. All lines have been flushed
Fuel manifold pressure 0-400 psig per Packager’s manual _________
sensor (0-2760 kPa) h. All instrumentation connec-
Compressor inlet total 10-16 psia tions made and secure _________
pressure sensor (69-110 kPa) i. All accessories are secure
Fuel supply pressure 0-500 psig per Packager’s manual _________
(0-3448 kPa) j. Gas turbine assembly free
Fuel supply temperature 0-250°F of loose objects and all
(-18 to 121°C) lines/electrical leads
connected _________
Gas turbine inlet air -65 to 150°F
temperature (-54 to 66°C) k. Gas turbine inlet air area
Lube oil scavenge pressure 0-200 psig screen secure _________
(0-1379 kPa)
Remote reading variable frame leakage ports, struts
vane indicator -5 to 45 degrees 7 and 10, are open (not
Starter air supply pressure 0-50 psig capped) _________
(optional) (0-345 kPa) m. Continuous lube supply
Steam supply temperature 0-1000°F starter is initially serviced
(-18 to 538°C) per Packager’s manual (if
applicable) _________
8-2.4 Preparation. The gas turbine and asso- n. Lube oil storage tank ser-
ciated systems must be inspected and checked viced to full level _________
out for proper installation and operation before o. Lube oil supply valves open _________
normal operation can commence. p. All filters are serviced per
Packager’s manual _________
8-2.5 Gas Turbine and Associated Equip- q. Fire alarm/extinguish sys-
ment Checklist. Complete the following tem ON and operative _________
checklist. r. T5.4 thermocouple system
a. Gas Turbine Assembly S/N _________ s. Vibration system operative _________
b. Mounting base secured to t. Ignition system operative _________
foundation _________
u. Compressor inlet total pres-
c. Intake air and exhaust gas sure probe aligned properly
ducts in place and secured _________ and free of damage (if
d. Bonding straps in place and applicable) _________
secure _________ v. Steam manifolds aligned _________
e. Gas turbine and exhaust w. Steam HP recoup system
duct support mounts and installed _________

AD-20
GEK 97310
VOLUME I
ADDENDUM AD
x. Variable stator vane system THE CUSTOMER’S
secure _________ PROCEDURES.
y. Required checks and
inspections specified in • SECONDARY AIR TO THE
Packager’s manual for gas ENCLOSURE SHALL BE SHUT
turbine control have been OFF. HIGH SECONDARY AIR-
performed _________ FLOW MAY PREVENT OPEN-
ING OR CLOSING THE
8-2.6 Governor and Manual Control Check. ENCLOSURE DOOR.
a. Steam supply system sequencing and SHALL BE KEPT OPEN. IF THE
control. Refer to gas turbine Packager’s GAS TURBINE IS OPERATING,
manual. AN OBSERVER SHALL BE STA-
8-2.7 Start-up and Checkout. DOOR AND CONFINED SPACE
BE FOLLOWED.
WARNING
NECESSARY.
UNDER SUCH CONDITIONS. a. When entering enclosure during gas
SYSTEM SHALL BE MADE b. Perform prestart checks per Table 4.
INACTIVE ACCORDING TO c. Perform ignition checkout per
paragraph 8-2.8.

AD-21
GEK 97310
VOLUME I
ADDENDUM AD
paragraph 8-2.9. WARNING
e. Perform false start per paragraph • ASSURE POWER TO IGNITION

8-2.10. SYSTEMS IS OFF WHEN DIS-
f. Perform governor check per paragraph ING IGNITION EXCITER INPUT
8-2.11. LEAD. TAG SWITCH OUT OF
g. Perform a wet prestart per paragraph VERTENT ACTIVATION.
8-2.12.
h. Perform a manual start and operate per CLOSED THROUGHOUT THIS
paragraph 8-2.13. PROCEDURE.
i. Operate to maximum power per para- a. To purge the gas turbine system of any
graph 8-2.14. residual fuel, motor gas turbine at full motor-
j. Check automatic operation per para- ing speed for several minutes depending on
graph 8-2.15. actual inlet and exhaust volumes. Refer to
packager’s manual for requirement. Allow gas
8-2.8 Ignition Check. turbine to coast down.

Item Requirement
Maintenance requirements and Cleared
discrepancies
Fuel valves Closed
Ignition Off
Ventilation Inlet Air Off-air temp. below 70°F (21°C)
(secondary cooling air)
Oil tank level Full
Lube oil temperature Above 20°F (-7°C) for MIL-L-23699
Fuel supply - natural gas pressure Ambient
at manifold inlet

AD-22
GEK 97310
VOLUME I
ADDENDUM AD
b. Disconnect number one ignition exciter d. Repeat motoring and bleeding proce-
input lead at exciter. Temporarily secure input dure until an indication of oil pressure appears.
c. Turn on electrical power to the ignition follows:
audible report (approximately two sparks per a. With ignition leads disconnected and
second) should be heard when the No. 2 spark manual gas valve closed, make automatic start
igniter fires. of gas turbine per Packager’s manual.
d. Turn off electrical power to the ignition b. Gas generator should go through nor-
system. Reconnect input lead to ignition mal start cycle and then abort because of lack
exciter and safety wire connector. of flame (T5.4 < 400°).
e. Repeat steps b, c, and d, disconnecting 8-2.11 Governor Check. Perform governor
the No. 2 exciter. check per Packager’s manual.
f. If an audible report is not heard on No.
1 and/or No. 2 igniters, check out the system to 8-2.12 Wet Prestart. Perform wet prestart as
isolate the problem, and take appropriate cor- follows:
rective action.
a. With ignition leads disconnected, but
8-2.9 Motoring. After all preliminary checks
system operating, make automatic start of the
gas turbine per Packager’s manual.
systems inoperative as follows: b. Gas generator should accelerate to
(1) Disconnect power supply to igni- should open and fuel manifold pressure should
tion unit. be approximately 3 psig (21 kPa). Adjust fuel
(2) Close natural-gas manual shutoff
valves to fuel control unit. because of lack of flame (T5.4 < 400°).
b. Depress MOTORING pushbutton. Gas c. Allow gas turbine to coast to a stop;

generator will start to rotate. If it does not, then motor it to purge any remaining natural
refer to Packager’s manual for supply pressure gas from gas turbine. Continue to motor for at
to starter. least 60 seconds to purge fuel from gas turbine
and ducting.
until gas generator speed stabilizes, and check 8-2.13 Manual Start and Operation. Perform
for oil pressure. If there is no indication of oil manual start per Packager’s manual with fuel
pressure, release MOTORING pushbutton; valve open and with ignition lead connected.
while gas generator is coasting down, loosen Refer to Table 5.
minimum of 2200 RPM, with full supply
pressure.

AD-23
GEK 97310
VOLUME I
ADDENDUM AD
CAUTION occur within 30 to 40 minutes follow-
ing gas turbine operation. Thermal
DO NOT EXCEED 6000 RPM NGG seizure is the condition where the
AND 30 SECONDS OF GAS TUR- power turbine rotor is prevented from
BINE OPERATION WITHOUT rotating by hard contact between LPT
POWER TURBINE ROTATION. blades and shrouds, interstage seals
a. The power turbine must rotate by the and other internal interference. This
time the gas generator speed reaches 6000 rpm condition is the result of unequal
NGG. If power turbine speed indication is not cooling rates of the various power tur-
obtained and it is determined that a thermal bine components. The possibility of
seizure of the power turbine has occurred, pro- thermal seizures can be reduced by
ceed as follows: operating the gas turbine at idle power
for at least five minutes prior to shut-
NOTE down to achieve proper cooling of the
• Power turbine except in a new or power turbine.
newly overhauled installation should
be rotating when gas generator idle (1) Shutdown gas turbine.
speed is attained.
• Thermal seizure of the power turbine stops rotating, re-start and stabilize at idle
rotor can occur when a hot gas turbine speed (5000 ± 250 rpm) for 30 seconds.
is shut down and is most likely to

1. Assure that prestart checks Investigate cause of condition. If
are completed per Table 4 T5.4 start limit is exceeded per
form overtemperature inspection
CAUTION
ABORT START.
NOTE
A start may be aborted at any time by closing the fuel valve, allowing the
gas generator to motor for 60 seconds, then closing the starter shutoff
valve.
NOTE
If purge cycle is required, step 3 should be preceded by high speed motor-
ing cycle.

AD-24
GEK 97310
VOLUME I
ADDENDUM AD
3. At 1600 to 1800 rpm NGG
a. Ignition on
8-1.12 step b
c. Note time to light-off 10 seconds maximum Abort start-automatic shutdown.
[T5.4 above 400°F Investigate and correct cause.
(204°C)] from fuel
and ignition on
4. Note time to 4500 ±200 rpm 90 seconds maximum Troubleshoot system and take cor-
from initiation of ignition rective action if rpm stops increas-
ing or if it takes longer than 90
seconds to reach 4300 rpm
5. At 4300 to 4700 rpm NGG
a. Starter shutoff valve Valve closed Manually close starter supply
should close auto-
matically
c. T5.4 1000°F (538°C) Emergency shutdown - Table 7
maximum
d. NPT (unloaded) 1200-1900 rpm Troubleshoot and take corrective
action
e. Gas generator 0 to 3 mils DA Alarm set at 4 mils. Automatic
vibration normal shutdown if above 7 mils.
action

AD-25
GEK 97310
VOLUME I
ADDENDUM AD
f. Power turbine 0 to 6 mils DA Alarm set at 7 mils. Automatic
rective action
g. Compressor inlet Approximately equal to Troubleshoot sensing and indicat-
temperature (T2) outside air temperature ing system. Correct as required
leaks
i. Maximum NGG 6000 rpm NGG maxi- Shut down, investigate and correct
with power turbine mum for 30 seconds cause per paragraph 8-2.13
seizure (thermal
seizure)
sient operation
a. T5.4 Less than alarm limit Ref. Note 1
b. NGG Ref. Note 1
NOTE
The maximum allowable speed is 10,100 rpm.
c. NPT 0-3960 rpm Ref. Note 1
d. Oil pressure See applicable table and Emergency or automatic shut-
figure in Chapter 5 down if below 15 psig (103 kPa)
e. Scavenge oil temper- 160-275°F (71-135°C) Alarm at 290-310°F (143-154°C);
atures (A, B, C, D Automatic shutdown if above
sumps and acces- 340°F (171°C)
sory gearbox)
f. Gas generator 3 mils maximum Ref. Note 1.
shutdown

AD-26
GEK 97310
VOLUME I
ADDENDUM AD
g. Power turbine 6 mils max Ref. Note 1.
vibration 7 mils max (Alarm) Troubleshoot
shutdown
h. Fuel manifold 355 psig (2448 kPa) Ref. Note 2
pressure maximum
i. Fuel inlet -65 to 150°F Ref. Note 2
j. Scavenge oil filter Refer to Packager’s Analyze any debris found. Check
∆P manual screens and chip detector
k. Lube oil supply filter Refer to Packager’s
∆P manual
m. Stator vane angle See applicable figure in
Correct as required per
WP 118 00 WP 118 00
n. HP recoup pressure Per figure 4-4 Correct as required per paragraph
4-12.28
Note 1. Reduce power to stay within limits. If reducing power does not bring parameters within
limits, shut down. Troubleshoot any step changes in trends of operating parameters.
Note 2. If all other parameters are normal, correct discrepancy at next opportunity.
(3) Repeat steps (1) and (2) for two unlatching. If blades have become unlatched,
additional start-up and shutdown cycles. they may be relatched. LPT blades that have
encountered shingling may be bent, thereby
(4) If the power turbine does not necessitating power turbine replacement.

rotate, shut down and investigate/correct the
blades in stages 4, 5, and 6 for shingling and

AD-27
GEK 97310
VOLUME I
ADDENDUM AD
matic operation per Packager’s manual.
CAUTION
a. Accelerate to idle or synchronous idle.
(refer to Packager’s manual) to increase gas e. Check for fuel or lube oil leaks.
log all instrument readings, paying particular f. After a total of five minutes at idle,
attention to variable stator vane position and shut down gas turbine.
within limits, adjust it per WP 118 00. If vibra- g. Check lube oil filters, chip detectors,
tions are not within limits, consult local Gen- and strainers; clean or replace as necessary.
eral Electric Company representative. h. Correct any leaks observed.
b. Operate gas turbine up to rated power, i. Remove all temporary instrumentation.
perature (T5.4) limit. Hold at this power set- j. Check gas turbine and mounting sys-
ting until all temperatures stabilize. If tem for loose parts; tighten as necessary.
ager’s manual.


stabilizing for three minutes, record all instru-



AD-28
GEK 97310
VOLUME I
ADDENDUM AD

AD-29
GEK 97310
VOLUME I
ADDENDUM AD
ING OR CLOSING THE
operation for normal operation, refer to Pack- SHALL BE KEPT OPEN. IF THE
8-3.2 Interlocks. Refer to Packager’s manual TIONED AT THE ENCLOSURE
turbine operation. ENTRY PROCEDURES SHALL
BE FOLLOWED.
8-3.3 Operation.
LATED GLOVES AS
NECESSARY.
MET:
OPERATING.
SHUT DOWN.
ENCLOSURE OR IN THE
ENTRY SHOULD BE
MOTORING THE GAS
TURBINE.
Table 3.
THE CUSTOMER’S
PROCEDURES.
d. If required, emergency shutdown the
gas turbine per Table 7.

AD-30
GEK 97310
VOLUME I
ADDENDUM AD
e. Refer to applicable table in Chapter 5 from any power setting by closing fuel valves
for oil pressure correction factors. and steam metering valves simultaneously.
f. Idle lube oil pressure is 29 psig b. Emergency shut-down shall be made

(200 kPa) maximum after five minutes per Table 7.
stabilization.
g. The corrected operating pressure of the
lube oil shall be per applicable table in Chapter a. During a normal shutdown, exhaust
5 at standard conditions of 9000 rpm gas gen- gas temperature should decrease. If, during
erator speed and 150°F (66°C) at lube pump time gas turbine is coasting to stop, tempera-
discharge temperature. Oil pressure measured ture increases instead of decreases, it indicates
at conditions other than standard shall be cor- that combustion is still taking place because of
rected to standard conditions using applicable a leaking fuel valve. (A slight temperature
table in Chapter 5. increase after rotation stops is normal.) Make
8-4 EMERGENCY OPERATION. bine. This will blow out the fire. As soon as
8-4.1 Emergency Shutdown. motoring.
a. In an emergency, when limits are

exceeded, the gas turbine may be shut down

following:
c. T5.4 Approximately Troubleshoot system and take
1000°F (538°C) corrective action

AD-31
GEK 97310
VOLUME I
ADDENDUM AD

e. Gas generator 3 mils maximum Alarm above 4 mils. Automatic

vibration shutdown if above 7 mils. Trou-
action
f. Power turbine 6 mils maximum Alarm above 7 mils. Automatic
vibration shutdown if above 10 mils. Trou-
action
g. Fuel inlet -65 to 150°F
h. Scavenge oil filter Refer to Packager’s
∆P manual
i. Lube oil supply filter Refer to Packager’s
∆P manual
decreases

AD-32
GEK 97310
VOLUME I
ADDENDUM AD

CAUTION
WILL FREE ITSELF AFTER A COOLING PERIOD OF 2 HOURS. CHECK FOR
1. Conditions permitting, decelerate gas T5.4 drops below 400°F Manually shut off fuel
turbine to idle and close fuel valves (204°C) and NGG and supply
NPT decelerate
2. Observe T5.4 for 3 minutes after 700°F (371°C) max Motor gas turbine.
until temperature
decreases
power setting (T5.4) greater than
1150°F (621°C) has occurred, and a
hot restart is required, proceed as
follows:
a. If a hot restart is to be per-
formed less than 2 hours fol-
lowing the emergency shut-
down, motor the gas turbine at
5 minutes. At the end of the
5 minute motoring cycle, allow
gas turbine to decelerate to
1700 rpm. When 1700 rpm is
obtained, restart the gas turbine
and accelerate to idle. Acceler-
ation to the desired power set-
ting can then be accomplished
b. After 2 hours following coast-
down of the HPC rotor, restart
starting procedure

AD-33
GEK 97310
VOLUME I
ADDENDUM AD
8-5 SPECIAL GAS TURBINE 8-5.3 Lube Oil Supply Pressure. The lube
CONSTRAINTS. oil supply pressure limits given in the limit
table are distress limits. Protective devices
ditions, the gas turbines are constrained by the because the proper pressure is dependent on
operating limits published in the limits table. gas generator speed, oil type, oil temperature,
Continuous operation between the alarm and and number of oil jets. An operator must there-
shutdown or trip level should not be practiced. fore derive a corrected oil pressure as directed
on the appropriate pressure correction table to
In the event that any of the following situations determine if the lube system is performing
or events occur, the associated special action within the high-low limits stated on each table.
assure the gas turbines continued normal oper- 8-5.4 High Speed Stall. Stalls incurred at gas
ation. These events may not be detected or pre- generator rotational speeds above 7500 rpm
vented by the customary protective devices of can result in high pressure compressor blade
control systems. fracture. The gas turbine can be operated after
• Overtemperature During Starting through 6 verifies that blade tip clanging has
• Lube Oil Pressure not occurred. If tip clanging has occurred, fur-
• High Speed Stalls ther inspection and stress relief of the blades is
• Starter Duty Cycle (if applicable) from the spool.
• No Power Turbine Rotation 8-5.5 Starter Duty Cycle - Air or Natural Gas
a. With starter inlet air pressure set at 40
psig (276 kPa):
acceleration to idle, cooling flows to compo- • 45 seconds on, 2 minutes off for any
nents of the gas turbine hot section are not suf- number of cycles,
ficient to protect the metals at T5.4 alarm and
trip levels specified in the limits table. A lower or
levels acceptable provided they exist for lim- • 2 minutes on, 5 minutes off with two
ited times as depicted on the Transient Tem- such cycles in any 30 minute period.
perature Limits for Starts curve in figure 3. b. With starter inlet air pressure set at 15
This must be monitored by the operator. The psig (103 kPa):
into area B requires hot section disassembly • 5 minutes on, 2 minutes off with two
and inspection in a qualified facility. such cycles in any 30 minute period.
or

number of cycles.

AD-34
GEK 97310
VOLUME I
ADDENDUM AD
c. There is no duty cycle limit on the b. Restart and repeat step a.
hydraulic starter.
c. Restart and repeat step a.
In the event that re-start of the gas turbine is d. Restart and accelerate to 6000 rpm. Do
required within 2 hours following a trip or not exceed 6000 rpm. Power turbine rotor
rapid shutdown from high power, a 5 minute should break away. If not, shut down and
motoring at 2000 to 2500 rpm must precede investigate for unlatched or shingled blades, or
the fire up. The objective is to cool the high other cause.
tain clearance with the more rapidly cooling 8-5.8 Windmilling.
case.
8-5.7 No Power Turbine Rotation. A ther- the gas turbine is allowed at gas generator
mally bound power turbine rotor could occur speeds above 1000 rpm provided the lube oil
under extreme conditions following a rapid temperature limits are not exceeded. At these
shutdown from high power. Power turbine speeds, the lube supply and scavenge systems
rotation should initiate during gas turbine are in normal operation.
the following procedure should be used: b. Below 1000 rpm gas generator speeds,
windmilling is allowed up to 5 minutes, with
a. Remain at idle for 30 seconds and successive periods allowed if preceded by nor-
shutdown. mal gas turbine operation.

AD-35
GEK 97310
VOLUME I
ADDENDUM AD
Figure 4. Deleted

AD-36
Gas Turbines
GEK 97310
Volume II
FOR GE
AND
GAS TURBINES

Mail Drop S-133
One Neumann Way
P.O. Box 156301
Gas Turbines
GEK 97310
Volume II
FOR GE
AND
GAS TURBINES
GE PROPRIETARY INFORMATION
The information contained in this document is GE proprietary information and is
disclosed in confidence. It is the property of GE and shall not be used, disclosed to
others, or reproduced without the express written consent of GE, including, but
without limitation, it is not to be used in the creation, manufacture, development, or
derivation of any repairs, modifications, spare parts, design, or configuration
changes or any other government or regulatory approval to do so. If consent is given
for reproduction in whole or in part, this notice and the notice set forth on each page
of this document shall appear in any such reproduction in whole or in part. The
information contained in this document may also be controlled by U.S. export control
laws. Unauthorized export or re-export is prohibited.
COPYRIGHT 1989-2003 General Electric Company, USA
NOTE: THIS REVISION REPLACES GEK 97310 VOLUME II DATED 1 APRIL 1988,
CHANGE 1 DATED 15 AUGUST 1990, CHANGE 2 DATED 15 APRIL 1993,
CHANGE 3 DATED 31 MARCH 1994, CHANGE 4 DATED 15 DECEMBER 1995,
ICN GEK 97310-30 DATED 31 DECEMBER 1996, ICN GEK 97310-31 DATED
31 DECEMBER 1996, ICN 97310-32 DATED 30 JUNE 1997, ICN GEK 97310-33
DATED 8 OCTOBER 1997, ICN GEK 97310-36 DATED 29 JANUARY 1999

Mail Drop S-133
One Neumann Way
P.O. Box 156301
30 JUNE 2003
GEK 97310
VOLUME II
LIST OF EFFECTIVE PAGES
This On-Site Operation and Maintenance Manual is part of an industrial LM2500 set which includes:
GEK 50336 LM2500 IPB
GEK 97310 O&M Vol I
GEK 99418 LM2500 IRM
GEK 108730 CD-LM2500 Series Gas Generator/Gas Turbine
While this manual has been carefully prepared, there may be occasions when inconsistencies occur with respect to
a given gas generator. If such event occurs, contact GE Aircraft Engines, Marine & Industrial Engines and Service
Division for clarification. In no event is this manual to be considered a part of the gas generator Specification under
which any gas generator is purchased nor is it to be otherwise considered a part of any purchase contract except to
the extent specifically referenced therein and then subject to obtaining clarification of inconsistencies as pointed
out above.
Insert latest change pages (if required); dispose of the superseded pages in accordance with applicable regulations.
NOTE: On a change page, the portion of text affected by the latest change is indicated by a vertical line (change
bar) in the outer margin of the page. Changes to wiring diagrams are indicated by shaded areas.
Dates of issue for original and changed pages are:
Original . . . . . . . . . . . 0 . . . . . . . . . .30 June 2003
Total number of pages in this manual is 1786 consisting of the following:

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GEK 97310
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B/(C, blank)
GEK 97310
VOLUME ll
TABLE OF CONTENTS
WP/SWP NO. Title

GENERAL
WP 001 00 Numerical List of Support Equipment and Consumable Materials
LEVEL 1 MAINTENANCE
WP 100 00 Replacement of Variable Vane Actuators
WP 101 00 Replacement of Variable Stator Feedback Cable
SWP 101 01 Replacement of Variable Stator Feedback/Demand Cable
SWP 101 02 Replacement of Variable Stator Vane Position Transducer
WP 102 00 Replacement of Speed Sensor
SWP 102 01 Replacement of Speed Sensor (GA101)
WP 103 00 Replacement of Servo Valve
SWP 103 01 Replacement of Servo Valve (GA101)
SWP 103 02 Replacement of Variable Stator Vane Control
WP 104 00 Replacement of Fuel Nozzles (Liquid)
SWP 104 01 Replacement of Fuel Nozzles (Natural Gas)
SWP 104 02 Replacement of Dual Fuel Nozzles (Liquid and Natural Gas)
SWP 104 03 Replacement of Fuel Nozzles (Natural Gas with Water Injection)
SWP 104 04 Replacement of Dual Fuel Nozzles (Duplex Dual Fuel)
SWP 104 05 Replacement of Steam Manifolds, Steam Supply Tubes, and Fuel/Steam Nozzles (Natural
Gas with Steam Injection)
SWP 104 06 Removal/installation of NOx Manifold HP Recoup Steam Augmentation Kit
SWP 104 07 Removal/Installation of CDP HP Recoup System Steam Augmentation Kit
SWP 104 08 Replacement of Steam Manifolds, Steam Supply Tubes, and Fuel Nozzles (Dual Fuel with
Steam Injection)
SWP 104 09 Replacement of Fuel Nozzles (Dual Fuel with Steam Injection)
WP 105 00 Replacement of Lube and Scavenge Pump
SWP 105 01 Replacement of Lube and Scavenge Pump and Forward Scavenge Pump (GA101)
SWP 105 02 Removal/Installation of Six Scavenge Element Lube and Scavenge Pump
WP 106 00 Replacement of Spark Igniters
SWP 106 01 Replacement of Spark Igniters (GA101)
WP 107 00 Replacement of Ignition Exciter
WP 108 00 Replacement of Gas Generator Speed Pickup
SWP 108 01 Replacement of Gas Generator Speed Pickup (GA101)
WP 109 00 Replacement of Power Turbine Speed Pickup Leads
WP 110 00 Replacement of Power Turbine Speed Transducer
WP 111 00 Replacement of Thermocouple Leads and Harnesses (Gas Turbines)
SWP 111 01 Replacement of Thermocouple Leads and Harnesses (Gas Generator)
SWP 111 02 Replacement of Thermocouple Harnesses (GA101)
WP 112 00 Replacement of Compressor Inlet Temperature (CIT) Sensor
SWP 112 01 Replacement of Compressor Inlet Temperature (CIT) Sensor (GA101)
WP 113 00 Replacement of Lube System Temperature Sensors
WP 114 00 Replacement of Power Turbine Vibration Transducer Lead
WP 115 00 Replacement of Vibration Transducers (Gas Turbine)
SWP 115 01 Replacement of Vibration Transducer (Gas Turbines)
SWP 115 02 Replacement of Vibration Transducer (Gas Generator)
SWP 115 03 Replacement of Vibration Transducers (GA101)
SWP 115 04 Replacement of Accelerometer (Gas Generator)
WP 116 00 Replacement of Pressure Probes-Gas Generator Inlet and Power Turbine Inlet (Pt2 and
Pt5.4)
SWP 116 01 Replacement of Gas Generator Power Turbine Inlet Pressure Probes (GA101)
i
GEK 97310
VOLUME ll
TABLE OF CONTENTS
WP/SWP NO. Title

LEVEL 1 MAINTENANCE - Continued
WP 117 00 Replacement of Outside Piping and Wiring (Gas Turbines)
SWP 117 01 Replacement of Outside Piping and Wiring (Gas Generators)
SWP 117 02 Replacement of Outside Piping and Wiring (GA101)
WP 118 00 Variable Stator Vane System Rigging and Calibration
SWP 118 01 Variable Stator Vane System Rigging and Calibration (GA101)
WP 119 00 Intentionally Omitted
WP 120 00 Replacement of Air/Oil Separator
WP 120 01 Replacement of Air/Oil Separator Cover
WP 121 00 Replacement of Hydraulic Supply Pump
WP 122 00 Replacement of Pneumatic Starter
SWP 122 01 Replacement of Pneumatic Starter (GA101)
SWP 122 02 Replacement of Continuous Lube Starter (Non-shrouded)
SWP 122 03 Replacement of Continuous Lube Starter (Shrouded)
SWP 122 04 Replacement of Hydraulic Starter
WP 123 00 Replacement of Fuel Manifolds (Liquid)
SWP 123 01 Replacement of Fuel Manifold (Natural Gas)
SWP 123 02 Replacement of Fuel Manifolds (Dual Fuel-Liquid and Natural Gas)
SWP 123 03 Replacement of Fuel Manifolds (Natural Gas with Water Injection)
SWP 123 04 Replacement of Fuel Manifolds, Fuel Feeder Tubes and Fuel/Tube Hoses (Duplex Dual Fuel)
SWP 123 05 Replacement of Fuel Flow Divider Valve (Off Engine) Duplex Dual Fuel
WP 124 00 Replacement of Fuel Pump
WP 125 00 Replacement of Air/Oil Cooler (GA101)
WP 126 00 Replacement of Flame Sensing System Components
WP 127 00 Replacement of Accessory Gearbox Carbon Seals
LEVEL 2 VERTICAL MAINTENANCE
WP 200 00 Translation of Gas Generator from Horizontal to Vertical
WP 201 00 Replacement of Turbine Mid Frame (Gas Turbines)
SWP 201 01 Replacement of Turbine Mid Frame (Gas Generators)
WP 202 00 Replacement of HPT Twin Shank Rotor/Stage 2 Nozzle Assembly
SWP 202 01 Replacement of HPT Single Shank Rotor/Stage 2 Nozzle Assembly
WP 203 00 Replacement of Stage 1 HPT Nozzle and Nozzle Vane Segments (Twin Shank)
Configuration
SWP 203 01 Replacement of High Pressure Turbine Stage 1 Nozzle Single Shank Configuration
WP 204 00 Replacement of Combustor
WP 205 00 Replacement of Accessory Gearbox
WP 206 00 Replacement of Variable Stator Vane Actuating Mechanism
WP 207 00 Removal/Installation of Compressor Stator Casings (Gas Turbines)
SWP 207 01 Removal/Installation of Compressor Stator Casings (Gas Generators)
SWP 207 02 Removal/Installation of Compressor Stator Variable Vanes (VSV)
SWP 207 03 Removal/Installation of Variable Vane Position Indicator (VPI)
SWP 207 04 Removal/Installation of Compressor Stator Variable Vane Shrouds
SWP 207 05 Removal/Installation of Compressor Stator Fixed Vanes
LEVEL 2 HORIZONTAL MAINTENANCE
WP 208 00 Replacement of Turbine Mid Frame (Gas Turbines)
SWP 208 01 Replacement of Turbine Mid Frame (Gas Generators)
WP 209 00 Replacement of HPT (Twin Shank) Rotor/Stage 2 Nozzle Assembly
SWP 209 01 Replacement of HPT Single Shank Rotor/Stage 2 Nozzle Assembly
ii
GEK 97310
VOLUME 1
TABLE OF CONTENTS
Chapter Title Page

LEVEL 2 HORIZONTAL MAINTENANCE - Continued
WP 210 00 Replacement of Stage 1 HPT Nozzle and Nozzle Vane Segments (Twin Shank)
Configuration
SWP 210 01 Replacement of Stage 1 HPT Nozzle and Nozzle Vane Segments (Single Shank)
Configuration
WP 211 00 Replacement of Combustor
WP 212 00 Replacement of Inlet Duct
WP 213 00 Replacement of Centerbody
WP 214 00 Replacement of Accessory Gearbox
WP 215 00 Replacement of Radial Drive Shaft
WP 216 00 Replacement of Inlet Gearbox
WP 217 00 Replacement of Variable Stator Vane Actuating Mechanism
WP 218 00 Replacement of Compressor Front Frame
WP 219 00 Replacement of Compressor Stator Casings (Gas Turbines)
SWP 219 01 Removal/Installation of Compressor Stator Casings (Gas Generators)
WP 220 00 Separation/Reassembly of Power Turbine and Gas Generator (Gas Turbines)
WP 221 00 Inspection and Replacement of Miscellaneous Sump Components
WP 222 00 Replacement of Compressor Rotor Blades
WP 223 00 Removal/Reinstallation of Power Turbine Casings and Power Turbine Inspection
WP 224 00 Replacement of Power Turbine Aft Shaft (Gas Turbines)
WP 225 00 Replacement of Stage 1 LPT Rotor Blades
WP 226 00 Inspection of Power Turbine Rotor Blades Inspection Stages 1 and 6
WP 228 00 Replacement of Stage 1 Power Turbine Nozzles
GAS GENERATOR, POWER TURBINE AND GAS TURBINE CHANGEOUT
WP 300 00 Replacement of Gas Turbine
WP 301 00 Replacement of Gas Generator
SWP 301 01 Replacement of Gas Generator (GA101)
WP 302 00 Replacement of Power Turbine Assembly
CLEARANCES AND DRAWINGS
WP 400 00 Assembly Clearances and Drawings
SWP 400 01 Assembly Clearances and Drawings (20GB104)
STORAGE MAINTENANCE
WP 500 00 Storage Maintenance of Gas Turbine, Gas Generator, and Power Turbine
PRESERVATION
WP 501 00 Gas Generator/Gas Turbine Shipping Preservation, Depreservation, and Storage Mainte-
nance in Non-pressurized Container Only
EXTENDED STORAGE
WP 502 00 Gas Generator/Gas Turbine Shipping Universal Container Only
TRANSFER TO/FROM SHIPPING CONTAINER
WP 503 00 Transfer of Gas Generator to/from Shipping Container and Shipping Container Maintenance
SWP 503 01 Transfer of Gas Generator to/from Shipping Container (GA101)
WP 504 00 Transfer of Power Turbine to/from Shipping Container
WP 505 00 Transfer of Gas Turbine to/from Shipping Container
WP 506 00 Shipping Container Inspection and Reconditioning Universal Container Only
iii/(iv, blank)
GEK 97310
VOLUME II
WP 001 00
WORK PACKAGE
TECHNICAL PROCEDURES
NUMERICAL LISTINGS OF SUPPORT EQUIPMENT

AND CONSUMABLE MATERIALS
(LEVEL 1 AND 2 MAINTENANCE)
EFFECTIVITY: LM2500 ENGINE MODELS - ALL
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 28
Page Change Page Change Page Change

No. No. No. No. No. No.
1 - 28 . . . . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
List of Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Mechanics Field Hand Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Torque Multipliers and Adapters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1
GEK 97310
VOLUME II
WP 001 00
1. INTRODUCTION. This work package provides a numerical list of special support
equipment required to maintain the LM2500 engine models contained herein. Also included in
this work package, is a list of the recommended mechanics hand tools, consumable materials and
torque multipliers and adapters.
The tabulation for special support equipment coverage is sectionalized by usage, i.e.,
Cold Section-Vertical, Cold Section-Horizontal, Hot Section-Vertical and Hot Section-Horizontal.
Tool listings are repeated where application applies to both vertical or horizontal.
NOTE
Recommended Spare Parts are those items which are recommended
as the minimum required to be stocked on-site to support the gas
turbine for scheduled (level 1) maintenance. Recommended spare
parts list can be obtained from your Customer Service Manager. If
a particular item or part is needed, refer to the appropriate
Illustrated Parts Breakdown or contact:
GE Aircraft Engines
Marine & Industrial Engines
Customer Service
Mail Drop S155

2
GEK 97310
VOLUME II
WP 001 00
2. MECHANICS FIELD HAND TOOLS.
NOTE
The following tabulation represents a breakdown of the
recommended mechanics hand tools needed to perform the routine
and corrective on-site maintenance of the LM2500 engines. The
hand tools listed herein are buyer local purchase.
RECOMMENDED MECHANICS HAND TOOLS
Part Vendor
Tool Type Size Quantity Number Code
Wrench, Box - 12 Pt 3/16 x 7/32 2 XS-67

1/4 x 5/16 2 XS-810
3/8 x 7/16 2 XS-1214
1/2 x 9/16 2 XS-1618
Wrench, Box - 12 Pt 7/32 x 1/4 2 66069 1
(thin wall)
5/16 x 3/8 2 66040 1
7/16 x 1/2 2 66042 1
Wrench, Box - 12 Pt 7/16 x 1/2 1 CX-1416
(half-moon)
Wrench, Box - 12 Pt 1/4 x 5/16 2 R-810A
Ratchet 3/8 x 7/16 2 R-1214A
Wrench, Open End 5/32 x 5/32 2 DS1010
3/16 x 3/16 2 DS1212
1/4 x 5/16 1 VO810
5/16 x 3/8 1 VO1012
3/8 x 7/16 1 VO1214
7/16 x 1/2 1 VO1416
1/2 x 9/16 1 VO1618
9/16 x 5/8 1 VO1820

3
GEK 97310
VOLUME II
WP 001 00
RECOMMENDED MECHANICS HAND TOOLS - Continued
Part Vendor
5/8 x 11/16 1 VO2022

5/8 x 3/4 1 VO2024
3/4 x 13/16 1 VO2426
13/16 x 7/8 1 VO2628
7/8 x 15/16 1 VO2830
1 x 1-1/16 1 VO3234
1-1/8 x 1-3/16 1 VO3638
Wrench, Combination - 12 Pt 1/4 2 OEX-80
5/16 2 OEX-10
3/8 4 OEX-12
7/16 2 OEX-14
1/2 2 OEX-16
9/16 2 OEX-18
5/8 2 OEX-20
11/16 1 OEX-22
3/4 2 OEX-24
13/16 1 OEX-26
7/8 1 OEX-28
15/16 1 OEX-30
1 1 OEX-32
1-1/16 1 OEX-34
1-1/8 1 OEX-36
1-1/4 1 OEX-40
1-5/16 1 OEX-42
1-3/8 1 OEX-44

4
GEK 97310
VOLUME II
WP 001 00
Part Vendor
Wrench, Spline #8 and #10 2 GXDES-810

#12 and #14 2 GXDES-1214
#18 and #20 1 GXDES-1820
#24 and #30 1 GXDES-2430
Wrench, Adjustable 6 inch 1 D-76
12 inch 1 D-712
Socket - 12 Pt 5/32 Hex Bit 1 TMA-5
(1/4 Drive)
1/4 2 TMD-8
5/16 2 TMD-10
3/8 2 TMD-12
3/8 Deep 2 STMD-12
7/16 2 TMD-14
7/16 Deep 2 STMD-14
Socket, Universal - 12 Pt 1/4 2 TMU-81
(1/4 Drive)
5/16 2 TMU-101
3/8 2 TMU-121
7/16 2 TMU-141
1/2 2 TMU-161
Socket, Spline #10 2 GTES-10
(1/4 Drive)
#10 Deep 2 TEL-10
#10 Universal 2 TESU-10
Socket - 12 Pt #3 Phillips 1 FP-32A
(3/8 Drive)
1/4 Hex Bit 1 FA-8A

5
GEK 97310
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Part Vendor
3/8 2 F-121
3/8 Deep 2 SF-121
3/8 Square Female 2 PP-412
7/16 2 F-141
7/16 Deep 2 SF-141
1/2 2 F-161
9/16 2 F-181
5/8 2 F-201
11/16 2 XD-222T
3/4 1 F-241
13/16 1 F-261
Socket - Universal - 12 Pt 3/8 2 FU-12A
(3/8 Drive)
7/16 2 FU-14A
1/2 2 FU-16A
Socket - Spline #12 2 GTES-120
(3/8 Drive)
#12 Deep 2 FEL-120
#12 Universal 2 FESU-120
#14 2 GTES-140
#14 Deep 2 FEL-140
#14 Universal 2 FESU-140
Socket - 12 Pt 3/4 1 SW-241
(1/2 Drive)
13/16 1 SW-261
7/8 1 SW-281

6
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WP 001 00
Part Vendor
15/16 1 SW-301
1 1 SW-321
1-1/16 1 SW-341
1-1/8 1 SW-361
Socket, Spline #18 1 GTES-181
(1/2 Drive)
#20 1 GTES-201
#26 1 GTES-261
#30 1 GTES-301
Socket - 12 Pt 1-1/4 1 LDH-402
(3/4 Drive)
1-1/2 1 LDH-482
1-5/8 1 LDH-522
1-3/4 1 LDH-562
2 1 LDH-642
2-3/8 1 LDH-762
Socket - 6 Pt 2-5/8 1 L-843
(1 inch Drive)
Crowsfoot - 12 Pt 1/4 1 TMRX-8
(1/4 Drive)
5/16 1 TMRX-10
3/8 1 AN-8508-6
7/16 1 AN-8508-7
1/2 1 AN-8508-8
9/16 1 AN-8508-9

7
GEK 97310
VOLUME II
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Part Vendor
Crowsfoot - 12 Pt 5/8 1 AN-8508-10

(3/8 Drive)
11/16 1 AN-8508-11
3/4 1 AN-8508-12
13/16 1 AN-8508-13
7/8 1 AN-8508-14
Crowsfoot - 12 Pt 15/16 1 AN-8508-15
(3/8 Drive)
1 1 AN-8508-16
1-1/16 1 AN-8508-17
Crowsfoot, Open End 3/8 2 FCO-12
Crowsfoot, 12 Pt 1-1/8 1 AN-8508-18
(1/2 Drive)
1-3/16 1 AN-8508-19
1-1/4 1 AN-8508-20
1-5/16 1 AN-8508-21
1-3/8 1 AN-8508-22
1-7/16 1 AN 8508-23
1-1/2 1 AN-8508-24
1-9/16 1 AN-8508-25
1-5/8 1 AN-8508-26
1-11/16 1 AN-8508-27
1-3/4 1 AN-8508-28
1-13/16 1 AN-8508-29
1-7/8 1 AN-8508-30
1-15/16 1 AN-8508-31

8
GEK 97310
VOLUME II
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Part Vendor
2 2 AN-8508-32
2-1/16 1 AN-8508-33
2-1/8 1 AN-8508-34
2-1/4 1 AN-8508-36
2-1/2 1 AN-8508-40
Speed Handle 1/4 Drive 2 TMS-4D
3/8 Drive 2 F-4LA
1/2 Drive 1 S-4
Ratchet Handle 1/4 Drive 5-27/64 inch 2 TM-75
3/8 Drive 7-9/16 inch 2 F-71G
1/2 Drive 10-1/4 inch 2 SL-710
3/4 Drive 24 inch 1 L-72TJ
Breaking Bar 1/4 Drive 6 inch 1 TM-10F
3/8 Drive 9-1/2 inch 1 F-10LB
1/2 Drive 15 inch 1 SN-15A
3/4 Drive 18-30 inch 1 SWE-63
Adapter, Torque 1/4F x 3/8M 1 TH-3
3/8F x 1/4M 1 TM-1
1/2F x 3/8M 1 A-4A
3/8F x 1/2M 1 LA-72
Swivel Socket Etension
3/8 Drive 3/8 inch 1 RC312-3/8 4
3/8 Drive 7/16 inch 1 RC312-7/16 4

9
GEK 97310
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Part Vendor
Torque Adapters - Thin Wall 5/16 2 FRDH-101

12 Pt 3/8 2 FRDH-121
(3/8 Drive - 2 inch Offset) 7/16 2 FRDH-141
1/2 2 FRDH-161
9/16 2 FRDH-181
Torque Adapters - Spline #10 2 GFRES-10
(3/8 Drive - 2 inch Off set)
#12 2 GFRES-12
#14 2 GFRES-14
Universal Joint 1/4 Drive TMU-8
3/8 Drive 1 FU-8A
Torque Wrench 1/4 Drive 5-150 lb in 1 TC1-150R 1
3/8 Drive 100-750 lb in 1 TC1-750R 1
1/2 Drive 30-250 lb ft 1 QJR-3200B
3/4 Drive 0-600 lb ft 1 TEC-602FU
Strap Wrench 1-6 inch 1 A-91B
1-3/4 x 29-1/4 inch 1 #5 5
Hook Wrench, 1/4 inch Pin 1 474B
Spanner
Allen Wrench Set 3/64 - 3/8 2 AW-1013K
Hammer Soft Face 2 lb 1 BH-232-2
Machinist 2 lb 1 BPN-32A
Punch Drift Starter 2 PPC-905A
and Pin Set 1 PPSD-120K

10
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Part Vendor
Screwdriver Common 6 inch 2 SSD-6

Common 8 inch 2 SSD-8
Common 12 inch 2 SSD-12A
Phillips #2 8 inch 2 SSDP-82
Jewelers 1 S555-6 2
(with case)
Measuring Micrometer 0-6 inch 1 445A-GRL 2
Depth Gage
Vernier 0-6 inch 1 448-GME 2
Depth Gage
Steel Rule 6 inch 1 622R 2
Feeler Gage 26 blade 1 66 2
MISCELLANEOUS
Inspection Mirror 1-1/4 inch Dia 1 JT-3
2-1/4 inch Dia 1 GA-295
Mechanical Fingers 17-3/4 inch 1 GA-265A
Magnetic Pickup 17-27 inch 1 K2 1
Pry Bar 16 inch 2 1658
Scriber 1 CM-3031
Flashlight 2 Cell 1 ECF-35
Tool Box 31 x 15 x 17 inch 1 KRA-61D
Drop Light 60 watts 2
Vendor Code: (1) Utica (Bonney)
(2) Starrett
(3) Sweeney
(4) Apex Company, Dayton, Ohio
(5) Ridgid
(6) Williams
NOTE
All line hand tool part numbers are Snap-On brand unless
otherwise identified by vendor code.

11
GEK 97310
VOLUME II
WP 001 00
3. TORQUE MULTIPLIERS AND ADAPTERS. The following list of torque multipliers
and adapters are recommended to accomplish the level 2 corrective maintenance tasks described
in Volume II of this manual.
Adapters
Max Torque Ref. Table1
Nomenclature lb ft Power Supply for Applications
SWEENEY
Model 8100D 10,000 None None
Model 8102-5A 800 Air (Pneumatic) None
Model 8108 (2) 18,000 None None
Model 8112 50,000 None None
ADVANCED HYDRAULICS
Model AH-1043 10,000 AH-P39 Hand Pump with AH-1043-20 (1)
Hoses and Fittings AH-2000-109
or
AOB-2727 Electric/Pneumatic AD-2000-126
Pump with Hoses AD-2000-129
and Fittings AD-2000-130
Model AH-2043 (2) 20,000 AOB-2727 Electric/Pneumatic AH-1043-20 (1)
Pump with Hoses AD-2000-109
and Fittings AD-2000-126
Model AHX-T550 80,000 AOB-2657 Electric/Pneumatic None
Pump with Hoses
and Fittings
NOTES:
(1) AH-1043-20 adapter is supplied with new procurement of Model AH-1043 advanced
hydraulics torque multipliers.
(2) Newly identified torque multipliers which are in the 15,000-20,000 lb ft capacity range.
GENERAL:
Sweeney Model 8111 torque multiplier has 83,500 lb ft torque capacity, utilizing the
1C6950G03 HPT coupling nut wrench and an adapter for the 1C8111 provided by
Sweeney Co., the 1C8111 can be used in removing the HPT rotor.
Sweeney Model 8104 pneumatic torque multiplier can be used with Sweeney Models 8100D
and 8112 to run nuts on and off, but not for final torquing to close values.

12
GEK 97310
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Table 1. GAS TURBINE COMPONENT INSTALLATION/REMOVAL TORQUES
INSTALLATION
INSTALLATION RECOMMENDED
ENGINE PART TORQUE TORQUE MULTIPLIER
NOMENCLATURE SSE P/N LB FT (MAX) INSTALLATION
1. Nut, Ret. 2C6001G01 1050, Break & Retorque Sweeney Model 8100D
to 450-500 lb ft or
#3 Brg.
Adv. Hyd. Model - AH-1043
Inner Race with Adapters:
AH-1043-20
AD-2000-129
AD-2000-126
AD-2000-130
2. Nut, Ret. 2C6084G03 450-500 lb ft Sweeney Model 8100D
or
#5 Brg.
Inner Race with adapter:
AH-1043-20
3. Nut, Ret. 1C6856G01 300-350 lb ft Same as above plus
Adv. Hyd. adapters:
#6 Brg.
AD-2000-126
AD-2000-128
4. Nut, Cplg. 2C6062G08 Torque 2000 lb ft Sweeney Model 8108
or
HPTR 1C6950G03 Torque 28-30° to
12,000 lb ft max with adapter:
AH-1043-20
5. Nut, Cplg. 1C6950G03 Torque 2000 lb ft Same as above
HPTR Torque 28-30° to
12,000 lb ft max
6. Oil, Tube, 2C6058G04 Torque 1000 lb ft Sweeney Model 8100D
or
HPTR 2C6084G03 Break Torque and
Retorque to with adapter:
1000-1200 lb ft AH-1043-20

13
GEK 97310
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WP 001 00
NORMAL REMOVAL
RECOMMENDED TORQUE
MULTIPLIER SSE
NORMAL REMOVAL - INTERFACE
ENGINE PART 4-5 TIMES INSTALLATION MODIFICATION
NOMENCLATURE SSE P/N TORQUE REQUIRED
NOTE
The following do not include gearbox torque values
1. Nut, Ret. 2C6001G01 Sweeney Model 8100D No
#3 Brg. or
Inner Race Adv. Hyd. Model - AH-1043 with No
adapters:
AH-1043-20
AD-2000-129
AD-2000-126
AD-2000-130
2. Nut, Ret. 2C6084G03 Sweeney Model 8100D No
#5 Brg. or
Inner Race Adv. Hyd. Model - AH-1043 with No
adapter:
AH-1043-20
3. Nut, Ret. 1C6856G01 Same as above plus Adv. Hyd. No
#6 Brg. adapters:
AD-2000-126 No
AD-2000-128
4. Nut, Cplg. 2C6062G08 Sweeney Model 8112 No
HPTR 1C6950G03 or
Adv. Hyd. Model - AHX-T550 No
5. Nut, Cplg. 1C6950G03 Same as above No
HPTR or
Sweeney Model 8111 with adapter: No
194495
6. Oil, Tube, 2C6058G04 Sweeney Model 8100D No
HPTR 2C6084G03 or
Adv. Hyd. Model - AH-1043 with No
adapter:
AH-1043-20

14
GEK 97310
VOLUME II
WP 001 00
ABNORMAL REMOVAL
RECOMMENDED TORQUE
MULTIPLIER
ABNORMAL REMOVAL SSE INTERFACE
ENGINE PART IN EXCESS OF 5 TIMES MODIFICATION
NOMENCLATURE SSE P/N INSTALLATION TORQUE REQUIRED
NOTE
The following do not include gearbox torque values.
1. Nut, Ret. 2C6001G01 Same as Normal Removal No
#3 Brg.
Inner Race Same as Normal Removal No

#5 Brg.
Inner Race Same as Normal Removal No

#6 Brg.
Same as Normal Removal No
4. Nut, Cplg. 2C6062G08 Adv. Hyd. Model - AHX-T550 No for (AHX-T550)
HPTR 1C6950G03
5. Nut, Cplg. 1C6950G03 Sweeney Model 8111 No
HPTR or
Adv. Hyd. Model - AHX-T550 No
6. Oil, Tube, 2C6058G04 Sweeney Model 8112 Yes for (8112)
HPTR or
2C6084G03
Adv. Hyd. Model - AH-1043 with No for (2043)
adapter:
AH-1043-20

15
GEK 97310
VOLUME II
WP 001 00
4. LIST OF CONSUMABLE MATERIALS. The following list of consumable materials is
recommended to support on-site level 1 and 2 corrective maintenance tasks. For a listing of con-
sumable materials required to support an individual maintenance task, refer to the specific work
package covering that task requirements.
Material Specification
Lubricating Oil, Gas Turbine MIL-L-23699
Petrolatum, Soft-White GE Spec A50TF142
Safety Wire AMS 5689/R297P04
0.020 inch diameter
0.032 inch diameter
Leak-Tek Solution
Grease MIL-G-23827
Nitrogen Commercial
Adhesive, Silicone Rubber RTV-106 (Red)
Antiseize Compound GE Spec A50TF201
Solvent, Cleaning P-D-680, Type II
Prussian Blue No. 1
*Penetrating Oil (Liquid Wrench No. 1) GE Spec A50TF54, C1 A
Adhesive (No. 77 or 1870) 3M Company
Dry Ice Commercial
Solvent (Acetone) O-A-51
Methyl ethyl ketone (MEK) TT-M-261
Preformed Wax Strips (Pressure Sensitive)
Sealing Compound (Plastiseal F, Johns-Manville Co., GE Spec A50TF74, C1 A
New York, New York)
Tape, Tuck Double Coated Tissue
Sealing Compound, Permatex No. 2 GE Spec A50TF26, C1 A
Masking Tape Commercial
Solvent MIL-C-5564A
Ultra-Chem Assembly Fluid No. 1 GE Spec A50TF92
Ultra-Chem Assembly Fluid No. 6
Desiccant Bags MIL-D-3464, Type III
Petrolatum Technical (Yellow Protopet) VV-P-236

16
GEK 97310
VOLUME II
WP 001 00
The following materials shall not be used for marking gas path components:
z All graphite pencils

z Blue Dykem DX-100
z White Dykem DXX-327
z Aero Brand, Black Opaque Stamping Ink
The following inks and markers are recommended for marking gas path components:
z Marco Ink
z Carters Marks-A-Lot-Black
z Carters Marks-A-Lot-Blue
z Eberhard Faber #7500 Watercolor (Black)
z Dixon Black (Ink)
z Dixon Yellow (Ink)
z Dixon Lead-free yellow lumber crayons
*Liquid Wrench No. 1 shall be used in applications where the use of penetrating oil is
specified. Do not use WD-40 on gas generators or gas turbines.

17
GEK 97310
VOLUME II
WP 001 00
5. SPECIAL TOOLS. Refer to table 2.
Table 2. SPECIAL TOOLS
Part No. Description

NOTE
For General Electric designed tooling, equivalent tooling may be
furnished by the Original Equipment Manufacturer.
LEVEL 1
1C3569G03 Hydraulic Actuator Unit

1C6096G01 Gage, Immersion Depth - Spark Igniter
1C6344G02 Wrench Set - Air Tube Coupling
1C6345G01 Gage, Clearance - Overspeed Transducer
1C6361G01 Tool Set - Radial Drive Shaft
1C6366G01 Fixture, Lift - Inner Exhaust Deflector (for GE Exhaust Duct)
1C6789G02 Gage, Sight - Compressor Stator Vane Arms (Alt tool 2C6962G02)
1C6795G02 Gage, Sight - Compressor Stator Vane Act Arms (Alt tool 2C6966G05)
1C6881G01 Leak Check - Fuel Manifold (Liquid)
1C6889G02 Support, Stabilizer - Inner Exhaust Deflector (for GE Exhaust Duct)
1C6913G0l Fixture Support - Outer Cone (for GE Exhaust Duct)
1C6936G04 Sling, Lift - Gas Generator/Gas Turbine, Horizontal
1C6955G02 Fixture, Lift - Power Turbine, Horizontal
1C6977G05 VSV Position Indicator Transmitter
1C6977G05 or G06 VPI Kit - Remote Reading
1C6981G01 Stand, Horizontal - Gas Generator Changeout
1C6982G01 Stand, Horizontal - Power Turbine Changeout
1C6986G01 Tool Set - AEG Field Maintenance
1C8006G01 Fixture, Gas Generator/Power Turbine - Heavy Duty Separator
1C8032G02 Hinge Fixture - LTS Case
1C8033G01 Adapter, Manual Drive - Borescope Drive
1C8039G01 Fixture, Lift Jack - Compressor Stator Cases
1C8042G01 Fixture, Lift - LTS Case
1C8048G01 Cart - Lube
1C8060G01 Dolly, Universal - Changeout
1C8060G02 Dolly, Universal - Changeout

18
GEK 97310
VOLUME II
WP 001 00
Table 2. SPECIAL TOOLS - Continued

1C8062P01 Wrench, Speed Sensor
1C8065G01 Guide, Installation Gas Generator/Power Turbine
1C8067G01 Adapter, Motor Drive Remote Control - Borescope Drive (90 psi Air
Supply Required)
1C8070G01 Electronic Protractor - Portable
1C8080G01 Fixture, Lift - GG/GT Horizontal
1C8085G01 Fixture, Manual - Motoring, GG
1C8182G01 Fixture Set, Mating Seal Removal
2C6081G05 Wrench - Fuel Manifold
2C6103G04 Tool Set - Engine Rigging
2C6962G03 Gage Set, Sight - VSV Arms (Alt to 1C6789G02)
2C6966G05 Gage Set - VSV Arms (Alt to 1C6789G02)
9415M88G01 Puller, Bearing - Air Oil Separator
9442M44G01 Interface Control - Horizontal Rail System - Industrial Application
HORIZONTAL RAIL SET (9442M44G01)
1C6983G01 Support - Power Turbine, Forward
1C6991G01 Adapter Support - Front Frame
1C6992G01 Support - Horizontal Maintenance (90 inch [2286 mm])
1C6994G01 Support - Compressor Rear Frame/Turbine Mid Frame
1C8058G01 Fixture Set, Strap - Front Frame
1C8065G01 Fixture - Alignment No. 5 and 6 Bearing
1C8072G01 Fixture Set, Alignment - Maintenance Supports
9442M44G01 Horizontal Rail System - Industrial Application
SHIPPING AND STORAGE CONTAINERS
106C7144G03 or G04 Container - Gas Turbine
106C7144G02 Container - Gas Generator
1067265G01 Container - Power Turbine

19
GEK 97310
VOLUME II
WP 001 00

STANDARD CATALOG TOOLS-BUYER LOCAL PURCHASE
Borescope Set - Fiber Light
Vibration Analyzer - 8 Channel, Variable Filter
Multimeter
Digital Voltmeter
NOTE
Tools required for Level 2 Maintenance are in addition to Level 1
requirements.
LEVEL 2. VERTICAL (Recommended)
COLD SECTION
1C5635G01 Fixture, Lift - Power Turbine Case

1C5662G01 Protractor Set - Compressor Rotor Rear Shaft
1C5671G01 Protector Set - Compressor Rotor Blade Tips
1C5691G04 Puller - No. 6R Bearing Inner Race and Seal
1C5702G01 Pusher - No. 6R Bearing Inner Race
1C5976G01 Fixture, Lift - Compressor Stator Half
1C6119G01 Guide, Expandable Bushing - Transfer Gearbox
1C6793G01 Wrench, Torque Break - Compressor Stator Vane Nuts
1C6794P01 Wrench, Torque - Compressor Stator Vane Nuts
1C6794P02 Wrench, Torque, Nut Retaining (Used at Stage 5 & 6 VSV, Horizontal
Flanges)
1C6803G01 Fixture, Lift - Gas Generator Turnover, Front Frame
1C6804G04 Jackscrew Set
1C6841G03 Stand Assy Storage, Accessory Gearbox
1C6847G03 Sling, Lift - Frames
1C6855G01 Fixture, Lift - Accessory Gearbox - Horizontal
1C6874G01 Fixture, Lift - Accessory Gearbox
1C6892G01 Pusher, Bolt - Frame Gearbox Bracket
1C6898G01 Pins, Guide - Bearings and Seals Installation
1C6899G01 Wrench, Horizontal /Vertical - High Pressure Turbine Rotor

20
GEK 97310
VOLUME II
WP 001 00

LEVEL 2. VERTICAL (Recommended)
COLD SECTION
1C6902G01 Fixture, Removal Installation - Compressor Stator - Vertical

1C6905G01 Clamp Set - O-rings Installation
1C6980G01 Stand, Vertical Maintenance - Gas Generator
1C8000G01 Spreader-Compressor Rotor Stage 1 Blades
1C8021G01 Cage, Measuring - Concentricity, Compressor Rotor Shaft
1C8035G01 Fixture, Lift and Turn - Compressor Stator Forward Flange
1C8052G01 Tool, Removal/Installation - Stage 1 Retainer (Alt to 2C6601G01)
1C8062P01 Wrench, Box 3/8 inch-12 Point, Reduced Thickness
1C8070G01 Electronic Protractor
1C8099P01 Protector - Front Frame Sump Cavity
1C8115G01 Protector, Compressor Rotor (CIP)
2C6001G01 Wrench, Spanner Nut - No. 3R Bearing
2C6003G01 Puller - No. 3R Bearing Inner Race
2C6015G01 Gage Set - Borescope Opening, Compressor Stator
2C6018G01 Tool Set - VSV Holding
2C6019G01 Drive Set - Compressor Stator Vanes
2C6050G02 Wrench No. 4 Bearing Spanner Nut Collar
2C6139G02 Puller - No. 3R Bearing Outer Race
2C6145G04 Fixture, Concentricity - Front Frame No. 3R Bearing Seals
2C6171G01 Holder Set Variable Stator Vanes
2C6172G02 Case, Dummy - Compressor Stator
2C6175G04 Fixture, Lift - Compressor Stator Upper Case
2C6177G02 Positioner - Blades, Compressor Rotor
2C6183G01 Puller - No. 6 Roller Bearing
2C6259G04 Fixture Set, Secure - Variable Stator Arms 2-6
2C6599G01 Tool, Prebend - Compressor Rotor Blades, Stage 1 Retainer

21
GEK 97310
VOLUME II
WP 001 00

2C6600G02 Tool, Seating - Compressor Rotor Blades, Stage 1 Retainer
2C6601G01 Tool, Install/Remove - Compressor Rotor Blades, Stage 1 Retainer
2C6609P01 Wrench, Compressor Case - Forward and Rear Flanges
2C6610G01 Pin Set, Guide - HPT Nozzle, Stage 2 (Alt to 1C8052G01)
2C6646G01 Gage Block, Compressor Stator Vane Actuation Arm Stages 5 & 6
2C6647G01 Wrench, Spanner, Compressor Stator Vane Spacer
2C6912G03 Fixture, Torque Measuring, Half Ring & Vanes Stages 3-6
2C6925G02 Gage Set - VSV Clevis Assy
2C6964G03 Wrench, Torque, Bracket - VSV Nut (Alt to 1C6793G01)
2C6965P01 Wrench, Torque - VSV Nut (Alt to 1C6794P01)
2C6967G07 Tool, Installation - Stage 2 Blade Retainer
2C6968G01 Tool, Remove - Compressor Rotor, Stage 2 Retainer
HOT SECTION
1C5691G04 Puller, No. 6 Bearing - Inner Race and Seal

1C5702G01 Pusher - No. 6 Bearing Inner Race
1C5874G01 Fixture, Lift - HPT Nozzle Assy, Stage 1
1C5937G01 Gage, Concentricity - No. 5R Bearing
1C5964G01 Sling, Lift - HPT Nozzle Assy, Stage 2
1C5992G02 Fixture, Lift - Engine Turn Over - Turbine Mid Frame
1C6803G01 Fixture, Lift/Turnover - Front Frame
1C6804G04 Set - Jackscrew
1C6847G03 Sling, Lift - Frames
1C6856G01 Wrench, Spanner Nut - No. 6 Bearing
1C6898G01 Pins, Guide - Bearing Seal Installation
1C6899G01 Wrench - Horizontal/Vertical-HPTR Nut
1C6905G01 Clamp Set - O-ring Installation
1C6950G03 Wrench - Horizontal and Vertical HPT Rotor Coupling Nut
1C6958G01 Gage, Concentricity - TMF
1C6988G02 Fixture, Lift - Engine Turnover, TMF

22
GEK 97310
VOLUME II
WP 001 00

1C8011G01 Pilot Guide, No. 5 Bearing/TMF
1C8020G01 Wrench, Horizontal /Vertical - HPT Rotor Nut
1C8027G01 Fixture, Lift - Turn Over - Engine CRF
1C8034G01 Protector Set - No. 5 and 6 Bearings
1C8059G01 Stand HPT Rotor
1C8062P01 Wrench - Speed Sensor
2C6002G01 Pusher - No. 3 Bearing Inner Race
2C6003G01 Puller - No. 3 Bearing Inner Race
2C6015G01 Gage Set - Borescope Open - Compressor Stator
2C6025G01 Protector - Fuel Nozzle Port, CRF
2C6058G04 Wrench, Spanner - Oil Tube, HPT Rotor
2C6060G01 Fixture, Lift - HPT Stage 1 Nozzle (Horizontal /Vertical)
2C6062G08 Wrench, Horizontal /Vertical - HPT Rotor Nut
2C6063G01 Puller, Retaining Ring
2C6084G03 Wrench, Spanner - No. 5R Bearing Retaining Nut
2C6139G02 Puller - 2R/3R Bearing Outer Race
2C6141G01 Eye, Lift - HPT Rotort, Aft
2C6148G01 Clamp Set - Turbine Mid Frame Liner/TMF
2C6183G01 Puller - No. 6 Roller Bearing
2C6187G02 Fixture, Lift - HPT Rotor
2C6196P02 Pusher - No. 5R Bearing Inner Race
2C6203G01 Fixture, Lift - Combustion Liner
2C6281G02 Gage Set - CRF Concentricity
2C6341G01 Wrench, Spanner - Hand Runup
2C6505G02 Gage, Open Area - High Pressure Turbine Nozzle, Stg-l
2C6563G01 Tool, Install/Remove - HPT Rotor Damper Sleeve
2C6610G01 Pin Set, Guide - HPT Nozzle, Stage 2
2C6988G02 Fixture, Lift-Engine T/O - Turbine Mid Frame

23
GEK 97310
VOLUME II
WP 001 00

LEVEL 2. HORIZONTAL (Recommended)
COLD SECTION
1C3569G03 Hydraulic Actuator Unit

1C5634G03 Jack, Lowering - Engine Components
1C5654G03 Jack Lowering - Engine Compartment
1C5756G01 Fixture Supt - LPTS Lower
1C5937G01 Gas Generator Concentricity - No. 5 Bearing, Vertical/
Horizontal, Similar Tool 2C4157
1C5964G01 Sling, Lift-High Pressure Turbine Nozzle Stage-2
1C5976G01 Fixture, Lift-Vertical C/S Half
1C6793G01 Wrench, Torque Break - Compressor Stator Vane Nuts
1C6794P01 Wrench, Torque - Compressor Stator Vane Nuts
1C6794P02 Wrench, Torque, Nut Retaining (Used at Stage 5 & 6 VSV, Horizontal
Flanges)
1C6795G02 Gage - Compressor Stator Vane Actuator Arms
1C6803G01 Fixture, Lift - Gas Generator Turnover, Front Frame
1C6804G04 Set, Jackscrew
1C6881G01 Leak Check - Fuel Manifold
1C6892G01 Pusher, Bolt - Front Frame/Gearbox Bracket
1C6898G01 Pins, Guide - Bearings and Seals Installation
1C6905G01 Clamp Set - O-ring Installation
1C6977G06 VSV Position Indicator Transmitter
1C6981G01 Stand, Horizontal - Gas Generator
1C6991G01 Adapter, Maintenance - Compressor Front Flange
1C6992G01 Support - Horizontal Maintenance
1C6993G02 Adapter, Maintenance - Compressor Mid Flange

24
GEK 97310
VOLUME II
WP 001 00

LEVEL 2. HORIZONTAL (Recommended)
COLD SECTION (Cont.)
1C6996G01 Fixture, Check - Actuator, Variable Stator - Retrofit

1C8000G01 Spreaden, C/R Stg-l Blades
1C8031G03 Fixture, Hinge - Compressor Stator Cases
1C8039G01 Fixture, Lift Sack - Compressor Stator Cases
1C8060G03 Dolly, Universal - Change Out
1C8062P01 Wrench, Box - 3/8 inch-12 Point, Reduced Thickness
1C8063G01 Fixture, Lift - Turbine Mid Frame - Horizontal
1C8070G01 Protractor, Electronic - Portable
1C8080G02 Fixture, Lift-Gas Generator/Gas Turbine Horizontal
1C8099P01 Protector - Front Frame - Sump Cavity
1C8115G01 Protector, Compressor Rotor
2C6001G01 Wrench Spanner Nut - No. 3R Bearing
2C6003G01 Puller - No. 3R Bearing
2C6015G01 Gage Set - Borescope Opening, Compressor Stator
2C6019G01 Drive Set - Compressor Stator Vanes
2C6050G02 Wrench, No. 4 Bearing Spanner Nut Collar
2C6081G05 Wrench - Fuel Manifold
2C6119G02 Shim Set - Blade Tip, Compressor Rotor
2C6139G02 Puller - No. 3R Bearing Outer Race
2C6145G04 Fixture, Concentricity - Front Frame No. 3R Bearing Seals
2C6171G01 Holder Set - Variable Stator Vanes
2C6172G02 Case, Dummy - Compressor Stator
2C6175G04 Fixture, Lift - Compressor Stator Case, Upper
2C6177G02 Positioner - Blades, Compressor Rotor
2C6219G02 Protector Set - Gas Generator Forward and Rear
2C6259G04 Fixture Set, Secure - Variable Stator Arms 2-6

25
GEK 97310
VOLUME II
WP 001 00

2C6301G01 Jack, Lowering - Engine Components Alt tool 1C5654G03
2C6341G01 Wrench, Spline - Direct Drive, Hand Pump
2C6599G01 Tool, Prebend - Compressor Rotor Blades, Stage 1 Retainer
2C6600G02 Tool, Seating - Compressor Rotor Blade, Stage 1 Retainer
2C6601G01 Tool, Install/Remove - Compressor Rotor Blade, Stage 1 Retainer
2C6609P01 Wrench - Compressor Case, Forward and Rear Flanges
2C6646G01 Gage Block, Compressor Stator Vane Actuation Arm Stage 5 & 6
2C6647G01 Wrench, Spanner, Compressor Stator Vane Spacer
2C6912G03 Fixture, Torque Measuring, Half Rings & Vanes Stage 3-6
2C6925G02 Gage Set, VSV Clevis Assy
2C6962G03 Gage Set, Sight - VSV Arms
2C6964G03 Wrench, Torque, Bracket - VSV Nut (Alt to 1C6793G01)
2C6965P01 Wrench, Torque - Variable Stator Vane Nut (Alt to 1C6794P01)
2C6965P02 Wrench, Torque - Variable Stator Vane Nut (Used at Split Line)
2C6965P03 Wrench, Torque - Variable Stator Retaining Nut (Alt to 1C6794P02)
2C6966G05 Gage Set, VSV Arms
2C6967G05 Tool, Install - Compressor Rotor, Stage 2 Retainer
2C6968G01 Tool, Remove - Compressor Rotor, Stage 2 Retainer
2C7373G01 Tool, Seating - C/S Liners (Required to Install New Liners) Stage 7, 9 &
12
2C7373G02 Tool, Seating - C/S Liners (Stage 8)
2C7373G03 Tool, Seating - C/S Liners (Stage 10 & 13)
2C7373G04 Tool, Seating - C/S Liners (Stage 11)
2C8016G01 Cage, Sight, Variable Stator Vane Stage 5 & 6
1C5634G01 Lift Fixture, LPTS Lower
1C5635G01 Fixture, Lift, PT Case
1C5654G03 Jack, Lowering Engine Components
1C5691G04 Puller - No. 6 Bearing Inner Race and Seal
1C5702G01 Pusher - No. 6R Bearing Inner Race
1C5937G01 Gage, Concentricity - No. 5R Bearing

26
GEK 97310
VOLUME II
WP 001 00

LEVEL 2. HORIZONTAL (Continued)
HOT SECTION
1C5964G01 Sling, Lift - HPTN - Stage 2

1C6364G02 Wrench, Nut Forward Adapter
1C6702G01 Tool Set, LPT Rotor Retainer
1C6804G04 Jackscrew Set
1C6868G01 Fixture, Drive - Power Turbine
1C6897G02 Wrench, Spanner Nut, No. 5 Bearing
1C6950G03 Wrench - Horizontal and Vertical, HPT Rotor Coupling Nut
1C6953G02 Puller, Oil Tube - No. 5 Bearing
1C6958G01 Gage, Concentricity - TMF
1C8020G01 Wrench, Horizontal/Vertical, HPTR Nut
1C8027G01 Fixture, Dummy -Turbine Mid Frame
1C8032G03 Hinge Fixture - Low Pressure Turbine Case
1C8042G01 Lift Fixture - Low Pressure Turbine Case
1C8059G01 Restraining Tool - (Used with 9442M44)
1C8058G01 Stand - HPT Rotor
1C8062P01 Wrench - Speed Sensor
1C8065G01 Fixture, Alignment - No. 5 and No. 6 Bearings
1C8069G01 Fixture, Lift HPTR - Horizontal
1C8080G02 Fixture, Lift-Gas Generator/Gas Turbine Horizontal, Pin Adjust CG
1C8118G03 Fixture, Alignment - GG/PT Mating (Alt Tool 1C8065).
2C6058G04 Wrench, Spanner - Oil Tube, HPT Rotor
2C6059G01 Fixture Lift - High Pressure Turbine Rotor - Horizontal
2C6060G02 Fixture, Lift HPT Nozzle, Stage-1
2C6062G09 Wrench, Horizontal/Vertical, HPTR (Alt 1C6950)
2C6063G01 Puller, Retaining Ring - No. 5R Bearing
2C6066G03 Fixture, Lift - Combustor
2C6084G03 Wrench, Spanner - No. 5R Bearing Retaining Nut

27
GEK 97310
VOLUME II
WP 001 00

2C6141G01 Eye, Lift - HPT Rotor, Aft
2C6183G01 Puller - No. 6 Roller Bearing Outer Race
2C6194G03 Puller - No. 5 Bearing Inner Race (Alt 1C68999)
2C6196P01 Pusher - No. 5R Bearing Inner Race
2C6341G02 Wrench, Spanner - Hand Runup
2C6563G01 Tool, Install/Remove HPT Rotor Damper Sleeve
2C6610G01 Pin Set, Guide - HPT Nozzle, Stage-2

28
GEK 97310
VOLUME II
WP 100 00
WORK PACKAGE
REPLACEMENT OF VARIABLE VANE ACTUATORS
(LEVEL 1 MAINTENANCE)

1 - 10 . . . . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Installation of Variable Vane Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Removal of Variable Vane Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1
GEK 97310
VOLUME II
WP 100 00
1. INTRODUCTION. This work package contains instructions for removal and installation of
a variable vane actuator. If, during replacement of an actuator, any of the system linkage is dis-
turbed, it will be necessary to rig the system per WP 118 00 or SWP 118 01, as applicable.
NOTE
The S.I. units shown in this work package are direct mathematical
conversions and may be rounded off in most instances at the user’s
discretion. Examples of units that may be rounded off are those uti-
lized for temperatures, torque values, pressures, etc. Examples
where S.I. units may not be rounded off are those utilized for drop
checks, rigging adjustments, runouts, etc.
2. APPLICABLE SUPPORT EQUIPMENT.

5 Quart Container, Plastic
1C6996 Checking Fixture
3. CONSUMABLE MATERIAL.

A50TF201 Antiseize Compound
A50TF142 (VV-P-236) Petrolatum
Safety Wire
MIL-L-23699 or Lubricating Oil, Gas Turbine
MIL-L-7808

2
GEK 97310
VOLUME II
WP 100 00
4. REMOVAL OF VARIABLE VANE ACTUATOR. See figures 1 and 2.
NOTE
z The only difference in the variable stator actuator installed on
the GA 101 model engine is the configuration of the actuator
hydraulic parts. There is a separate drain fitting as part of the
actuator (figure 2).
z There are two variable vane actuators on the gas turbine.
Removal procedures are the same for both.
z It may be necessary to loosen one or more clamps on the actua-
tor tubes to ease actuator removal.
a. Disconnect head-end tube (4) from the actuator. Remove union (3). Remove and discard
O-ring (2). Drain residual oil into a plastic container.
b. Disconnect rod-end manifold (11) and drain tube (12) from the drain manifold (10). Drain
residual oil into a plastic container.
c. Remove drain manifold (10) from the actuator. Remove and discard O-ring (9).
d. Disconnect rod-end tube assembly (7) from the rod-end port union (6). Remove and
discard O-ring (8).
e. Remove union (6). Remove and discard O-ring (5).
f. Remove the bolt, nut and washers (15 and 16) which attach the actuator to the mounting
bracket (1).
CAUTION
BEFORE RETRACTING ACTUATOR ROD-END, INSTALL A
SMALL DIAMETER HOSE (FROM HEAD-END TO ROD-END)
INTO PORTS OF ACTUATOR TO PREVENT OIL FROM
SQUIRTING ONTO PERSONNEL OR GAS TURBINE.
NOTE
After incorporation of Service Bulletin LM2500-IND-049, there
will be no washers installed on the bolt that attaches the actuator to
the mounting bracket.
g. Retract actuator rod to full closed position. Pivot the actuator away from the gas turbine.

3
GEK 97310
VOLUME II
WP 100 00
Figure 1. Variable Stator Vane Actuator

4
GEK 97310
VOLUME II
WP 100 00
Figure 2. Variable Stator Vane Actuator (GA101)

5
GEK 97310
VOLUME II
WP 100 00
CAUTION
AFTER INCORPORATION OF SERVICE BULLETIN
LM2500-IND-049, THERE WILL BE A BODY-BOUND BOLT
INSTALLED IN THE MIDDLE BOLTHOLE OF THE THREE
HOLE SECTION OF THE MOUNTING BRACKET. CARE-
FULLY DRIVE THE BOLT OUT USING A SUITABLE DRIFT.
h. Remove the five nuts, bolts and washers (if installed) that secure mounting bracket (1) to
the gas turbine. Remove the second bolt CCW from horizontal splitline of compressor casing.
Rotate bracket and slide it off of the guide (14).
i. Turn guide (14) 90 degrees and slide it and the actuator off the trunnion of the actuator
lever (13).
5. INSTALLATION OF VARIABLE VANE ACTUATOR. See figures 1 and 2.
CAUTION
z REPLACEMENT ACTUATORS ARE SHIPPED FROM THE
FACTORY WITH THEIR ROD-END EXTENDED LENGTH
(DIMENSION E) PRESET TO THE CORRECT DRAWING
DIMENSION. IF THE PART NUMBER OF THE
REPLACEMENT ACTUATOR IS NOT COMPATIBLE
WITH THE PART NUMBER OF THE SPEED SENSOR/VSV
CONTROL INSTALLED ON THE GAS TURBINE,
ADJUSTMENT OF THE ACTUATOR ROD-END WILL BE
REQUIRED.
z IMPROPER ACTUATOR ROD ADJUSTMENT WILL
CAUSE OFF-SCHEDULE VARIABLE STATOR VANE
OPERATION WHICH COULD CAUSE A COMPRESSOR
STALL.
a. Check compatibility of part number of replacement VSV actuator against the part number
of the speed sensor/VSV control installed on the gas turbine. Part numbers must be compatible
and the actuator extended rod-end length (dimension E) shall be within the limits set with
checking fixtures (figure 3).

6
GEK 97310
VOLUME II
WP 100 00
Figure 3. Variable Stator Vane Actuator Adjustment (Dimension E)
b. If adjustment is necessary, make adjustment as follows:
(1) Install the assembled actuator on checking fixture, 1C6996, by inserting the head pin
through bushings in lugs of actuator (figure 4).
(2) Fully extend the actuator piston and adjust the rod-end bearing until the inside diam-
eter of the bearing is aligned with the extend pin in the fixture. With the piston in the fully
extended position, the set-extended pin must slide through the inside diameter of the rod-end
bearing.
(3) Secure the rod-end bearing in this position by setting the locking key and tightening
the locking nut. Tighten the nut to 70-90 lb in. (7.9-10.2 N·m) of torque.
(4) Upon satisfactory completion of adjustments, safety-wire nut to the locking key and
log length of actuator in gas turbine records.

7
GEK 97310
VOLUME II
WP 100 00
Figure 4. Actuator Check Fixture, 1C6996
CAUTION
ENSURE THE RAISED LETTERS AFT ON THE FACE OF THE
GUIDE (14, FIGURE 1) ARE FACING AFT WHEN
INSTALLED. INCORRECT ASSEMBLY MAY CAUSE THE
ACTUATING SYSTEM TO BIND.
c. Install actuator rod-end over the actuator lever (13) trunnion. Install guide (14) on the
actuator lever and turn the guide 90 degrees.
d. Coat the five bolts of mounting bracket (1) with antiseize compound, A50TF201, and
slide mounting bracket over the guide. Secure the bracket to the front frame with bolts, nuts, and
washers (if required). Tighten bolts to 200-210 lb in. (22.6-23.7 N·m) of torque.

8
GEK 97310
VOLUME II
WP 100 00
NOTE
After incorporation of Service Bulletin LM2500-IND-049, install
body bound bolt in middle bolt hole of three hole section of the
mounting bracket.
e. Install bolt (head aft) in second bolthole CCW from horizontal split-line by applying
antiseize compound, A50TF201, to bolt threads. Install washers under bolthead to obtain
minimum clearance of 0.005 in. (0.12 mm) between bolt tip and compressor front frame. Secure
with nut and tighten to 210-230 lb in. (22.6-26.0 N·m) of torque.
f. Place a thick washer (15) on actuator mount bolt. Place the actuator against mounting
bracket (1) so the lug on the bracket is between the lugs on the actuator and insert the bolt (head
forward) through the lugs. Place a thin washer (16) on the bolt and then a nut. Tighten the nut to
145-155 lb in. (16.4-17.5 N·m) of torque.
NOTE
After incorporation of Service Bulletin LM2500-IND-049, delete
washers (15 and 16) at the variable stator actuator/actuator mount-
ing bracket connection.
g. Lubricate and install O-ring (2) on union (3) and install union in the actuator head-end
port. Tighten union to 90-110 lb in. (10.2-12.4 N·m) of torque.
h. Lubricate and install O-ring (5) on union (6) and install union in the actuator rod-end port.
Tighten union to 90-110 lb in. (10.2-12.4 N·m) of torque.
i. Connect rod-end tube (7) to union (6). Tighten coupling to 135-150 lb in.
j. Ensure that end of connecting tubes can be easily aligned by hand prior to connecting tube
fittings. Loosen adjacent tube clamps to allow alignment.
CAUTION
LUBRICANT MUST BE APPLIED TO DRAIN MANIFOLD TO
PREVENT DAMAGE TO O-RINGS DURING INSTALLATION
TO THE ACTUATOR.
k. Apply light coat of petrolatum (VV-P-236) to O-rings (8 and 9), and to lead chamfer on
the inner diameter of drain manifold (10).
l. Install O-ring (8) over installed rod-end tube (7) O-ring grooved fitting.
m. Install O-ring (9) to the face of the drain manifold (10) sleeve nut.

9
GEK 97310
VOLUME II
WP 100 00
n. Carefully slide drain manifold (10) over tube assembly until drain manifold nut is aligned
with actuator fittings.
CAUTION
O-RING MAY BE DAMAGED IF SLEEVE NUT ALIGNMENT
IS NOT MAINTAINED WHILE INSTALLING SLEEVE NUT
TO THE ACTUATOR.
o. Continue sleeve nut installation and hand-tighten until nut is bottomed out.
p. Safety-wire sleeve nut to actuator.
q. Connect head-end tube (4) to the union (3) and rod-end manifold (11) to the rod end tube
assembly (7). Connect drain tube (12) to the drain manifold (10). Tighten couplings to
135-150 lb in. (15.3-16.9 N·m) of torque and safety-wire.
r. Tighten bolts at all clamps loosened during actuator removal and alignment check.
Tighten bolts to 24-27 lb in. (2.7-3.1 N·m) of torque.
NOTE
If other variable stator vane linkage has been disturbed, rig the
system per WP 118 00 or SWP 118 01.

10
GEK 97310
VOLUME II
WP 101 00
WORK PACKAGE
REPLACEMENT OF VARIABLE STATOR

FEEDBACK CABLE
EFFECTIVITY: LM2500 GAS GENERATOR MODELS - ALL

1-5.......... 0 6 Blank . . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Installation of Variable Stator Feedback Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Removal of Variable Stator Feedback Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
WP 101 00
the variable stator feedback cable. Following installation of the feedback cable the system must
be rigged per WP 118 00 or SWP 118 01.
NOTE


MIL-L-23699 or Lubricating Oil, Gas Turbine
MIL-L-7808
Safety Wire
4. REMOVAL OF VARIABLE STATOR FEEDBACK CABLE. See figure 1.
a. Remove clamp (18).
CAUTION
DO NOT LET SPRING-LOADED CABLE SNAP BACK INTO
SERVO VALVE SPEED CONTROL. INTERNAL STOPS
COULD BE DAMAGED.
b. Hold cable end with rod-end bearing (12), and remove bolt and nut securing rod-end bear-
ing to the variable stator vane (VSV) actuator bellcrank (16). Release cable end slowly to prevent
damage to servo valve.
c. Remove nut and bolt securing rod-end bearing (12) to servo valve arm (11).
d. Remove safety wire and unscrew retaining jamnuts (15) from swivel tubes at brackets.

2
GEK 97310
VOLUME II
WP 101 00
Figure 1. Variable Stator Vane Actuating System (Sheet 1 of 2)

3
GEK 97310
VOLUME II
WP 101 00
Figure 1. Variable Stator Vane Actuating System (Sheet 2 of 2) - Continued

4
GEK 97310
VOLUME II
WP 101 00
e. Remove rod-end bearings and jamnuts from each end of cable.
f. Remove rubber boots and swivel tubes from each cable end.
g. Slide cable out of brackets.
5. INSTALLATION OF VARIABLE STATOR FEEDBACK CABLE. See figure 1.
a. Remove sleeve and rubber boot assembly from forward end of cable by loosening jamnut
(15, figure 1).
b. At bellcrank (16), insert end of feedback cable from aft side through mounting
bracket (21) or micro-adjust (22) on compressor stator. Install sleeve assembly (14) to end of
cable and finger-tighten jamnut (15).
c. Remove sleeve assembly (14) from aft end of cable by loosening jamnut (15).
d. At input lever (11), insert end of cable from aft side through mounting bracket on gearbox.
Install sleeve assembly (14) to end of cable and finger-tighten jamnut (15).
e. Install rod-end bearing (12) on each end of feedback cable to maximum threaded depth
and then back off 4 turns. Tighten rod-end bearing jamnuts (13).
f. Rig the variable stator vane feedback cable per WP 118 00 or SWP 118 01.

5/(6 Blank)
GEK 97310
VOLUME II
SWP 101 01
SUBORDINATE WORK PACKAGE
REPLACEMENT OF VARIABLE STATOR

FEEDBACK/DEMAND CABLE
EFFECTIVITY: LM2500 GAS GENERATOR MODELS - GA101
LIST OF EFFECTIVE SWP PAGES
Total Number of Pages in this SWP is 8

1-7.......... 0 8 Blank . . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Installation of Variable Stator Feedback/Demand Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Removal of Variable Stator Feedback/Demand Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
SWP 101 01
1. INTRODUCTION. This subordinate work package contains instruction for removal and
installation of the variable stator feedback/demand cable. Following installation of the feedback/
demand cable, the system must be rigged per SWP 118 01.
NOTE
None

MIL-L-23699 or Lubricating Oil, Gas Generator
MIL-L-7808
4. REMOVAL OF VARIABLE STATOR FEEDBACK/DEMAND CABLES.
CAUTION
DO NOT LET SPRING-LOADED CABLE SNAP BACK INTO
SERVO VALVE SPEED CONTROL. INTERNAL STOPS
COULD BE DAMAGED.
a. Feedback Cable. See figure 1.
(1) Remove clamp (6) located at approximately mid point of cable, that secures cable to
bracket (7) attached to the compressor rear casing flange.
(2) Hold cable end securely, and remove bolt and nut securing cable end to the variable
stator vane (VSV) actuator bellcrank (1). Release cable end slowly to prevent damage to servo
valve.
(3) Remove nut and bolt securing cable end to servo valve arm (8).
(4) Unscrew retaining nuts from swivel tubes at brackets (figure 1, detail B).

2
GEK 97310
VOLUME II
SWP 101 01
Figure 1. Variable Stator Vane Feedback Cable - GA101

3
GEK 97310
VOLUME II
SWP 101 01
(5) Remove rod-end bearings from each end of cable.
(6) Slide cable out of brackets.
b. Demand Cable. See figure 2.
(1) Hold cable rod end bearing (5) securely and remove bolt and nut securing rod end
bearing to servo valve lever arm (4). Release cable end slowly, in the direction of the spring ten-
sion, until the cable reaches the end of its travel.
(2) Remove bolt and nut securing cable rod end bearing (12) and remove bolt and nut
securing rod end bearing to speed sensor lever arm (13).
NOTE
When removing ball joint (7) assembly from cable rod ends, count
number of turns required so that ball joints can be located at
approximately same position on reassembly.
(3) Remove ball joints (7) from each end of the demand cable.
NOTE
If demand cable (18) was never replaced, the bellows (19) at each
end of the cable will not be installed.
(4) Remove a scraper ring seal assembly from end of each cable conduit sleeve.
NOTE
When removing cable from engine, measure relative position of
jam nuts to mounting brackets (11 and 15) and use this data at reas-
sembly to locate cable in approximately same position.
(5) Remove the forward (8) (nearest cable end) of the two jam nuts which secure each
end of the cable conduit to mounting brackets (11 and 15). Do not disturb the location of the aft
jam nut.
NOTE
Retaining the location of the aft nut on cable sleeve will facilitate
reassembly of cable to its proper position.
(6) Remove cable assembly from engine by first moving the cable to full retract position
toward servo valve and, then, sliding cable conduit aft out of mounting bracket (11) at speed
sensor.

4
GEK 97310
VOLUME II
SWP 101 01
Figure 2. Demand Cable - GA101

5
GEK 97310
VOLUME II
SWP 101 01
5. INSTALLATION OF VARIABLE STATOR FEEDBACK/DEMAND CABLES.
See figure 1.
a. Feedback Cable.
(1) Remove sleeve assembly (4) from forward end of VSV cable by loosening
jamnut (5).
(2) Insert end of cable from aft side through mounting bracket on compressor stator.
Attach sleeve assembly (4) to forward end of cable and finger-tighten jamnut (5).
(3) Remove sleeve assembly (4) from aft end of cable by loosening jamnut (5).
(4) Insert end of cable through mounting bracket (9) located on compressor rear frame
forward flange. Attach sleeve assembly to aft end of cable and finger-tighten jamnut (5).
(5) Screw rod end bearing (2) and jamnut (3) on each end of feedback cable until
threaded end of cable can be seen in inspection hole.
(6) Secure aft rod end bearing to servo valve lever arm (8) with bolt and nut (bolthead
forward). Torque to 33-37 lb in. (3.7-4.2 N·m) and safety-wire to rod end bearing.
(7) Torque jamnut (5) at aft mounting bracket to 300-360 lb in. (33.9-40.7 N·m) and
safety-wire.
(8) Secure forward rod end bearing to bellcrank (1) with bolt and nut. Torque to
33-37 lb in. (3.7-4.2 N·m) and safety-wire to rod end bearing (2).
(9) Torque jamnut (5) at forward mounting bracket to 300-360 lb in. (33.9-40.7 N·m) and
safety-wire.
(10) Install clamp (6) to secure center portion of feedback cable to bracket (7) on
compressor stator mid flange. Secure with bolt and nut, and torque to 33-37 lb in. (3.7-4.2 N·m).
b. Demand Cable. See figure 2.
(1) Install jamnut and washer (10) on servo valve input cable and run nut to approximate
mid point of threaded portion of cable.
(2) Insert cable end into hole in mounting bracket (11). Secure cable to bracket with
washer and jamnut (9) fingertight.
(3) Install jamnut (16), no washer, on other end of cable and run nut to approximate mid
point of threaded portion of cable.

6
GEK 97310
VOLUME II
SWP 101 01
(4) Insert cable end through hole in mounting bracket (15). Secure cable to bracket with
jamnut (14), no washer, fingertight.
(5) Install rod end bearings on cable ends as follows:
(a) Install jamnut (8) on end of cable.
(b) Screw ball joint (7) on cable until it bottoms out on end of cable.
(c) Install jamnut (6) on end of cable.
(d) Screw rod end bearings (5 or 12) on end of cable until cable can be seen in
inspection hole of rod end bearing and a No. 54 drill will not pass through inspection hole.
(e) Finger-tighten jamnuts.
(f) Repeat steps 1 through 5 on other end of cable.
(6) Attach rod end bearing on input cable to lever arm (4) on servo valve. Secure with
bolt and nut fingertight. Attach other end of cable to speed sensor lever arm (13). Secure with
bolt and nut fingertight.
(7) If cable length is too long or too short, adjust cable length using jamnuts on sliding
brackets. Both the VSV stator feedback cable and servo valve demand cable sliding
brackets (1 and 11) should be approximately centered in slot travel.
(8) Rig the system per SWP 118 01.

7/(8 Blank)
GEK 97310
VOLUME II
SWP 101 02
REPLACEMENT OF VARIABLE STATOR VANE

POSITION TRANSDUCER

1-6.......... 0
ALPHABETICAL INDEX
Subject Page
Installation of Variable Stator Vane Position Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Removal of Variable Stator Vane Position Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1
GEK 97310
VOLUME II
SWP 101 02
1. INTRODUCTION. This subordinate work package contains instructions for removal and
installation of the variable stator vane position transducer.
NOTE
The S.I. units shown in this subordinate work package are direct
mathematical conversions and may be rounded off in most
instances at the user’s discretion. Examples of units that may be
rounded off are those utilized for temperatures, torque values, pres-
sures, etc. Examples where S.I. units may not be rounded off are
those utilized for drop checks, rigging adjustments, runouts, etc.

1C9079 Set, Transmitter - VSV Position

Commercial Safety Wire

2
GEK 97310
VOLUME II
SWP 101 02
4. REMOVAL OF VARIABLE STATOR VANE POSITION TRANSDUCER.
See figure 1.
WARNING
OBSERVE SAFETY PRECAUTIONS OF VOLUME I,
CHAPTER 1.
a. Turn off electrical supply and disconnect electrical connect at transducer (10, figure 1).
b. Remove nut (7) and bolt (6) from clevis (5) at variable vane actuator lever.
c. Remove actuation push rod (4) and jamnuts (8, 9) from clevis (5).
d. Remove bolt (11), nut (13), and washer (12) attaching transducer (10) to bracket (1 or 17).
e. Remove transducer (10).
5. INSTALLATION OF VARIABLE STATOR VANE POSITION TRANSDUCER.

See figure 1.
NOTE
Use tool set 1C9079G01 with kit 682L407 or tool set 1C9079G02
with kit 682L407 containing digital voltmeter or 1C9079G03 with
kit 682L407 containing digital voltmeter and power supply.
a. Install transducer (10, figure 1) on bracket (1 or 17).
b. Install bolt (11), washer (12), and nut (13) through transducer (10) and bracket (1 or 17).
Torque nut to 55-70 lb in. (63-81 kg cm).
c. Disconnect VSV actuator head and rod end lines from variable geometry control. Catch
leakage in suitable container.
d. Connect actuator lines to a controlled source of pressure and pump VSV system to the
open stop.
e. Install push rod (4) with jamnuts (8, 9) on clevis (5) and attach to transducer (10).
f. Attach clevis (5) to variable vane actuator lever with bolt (6) and nut (7). Torque to
20-23 lb in. (23-27 kg cm). Back off jamnuts. Do not safety-wire.
g. Connect signal conditioner (14) to power source and to transducer (10) with electrical
cable provided. Signal conditioner requires 28 volts/dc.

3
GEK 97310
VOLUME II
SWP 101 02
Figure 1. Removal and Replacement of Variable Stator Vane (VSV) Position Transducer
(Sheet 1 of 2)

4
GEK 97310
VOLUME II
SWP 101 02
Figure 1. Removal and Replacement of Variable Stator Vane (VSV) Position Transducer
(Sheet 2 of 2)

5
GEK 97310
VOLUME II
SWP 101 02
h. Connect voltmeter or readout to read signal conditioner output voltage. Use a
0 to 5 volts/dc scale of 0.2 percent accurate voltmeter.
i. With variable vane system remaining on the open mechanical stop, adjust transducer (10)
extension to obtain a reading of zero plus or minus 0.02 volt/dc by rotating the transducer stud end
relative to adjusting nut in clevis (5).
j. Secure adjustment with jamnuts (8, 9) and recheck voltage output. Voltage should still
read zero plus or minus 0.02 volt/dc.
k. Torque large jamnut (8) to 90-100 lb in. (104-115 kg cm).
l. Torque small jamnut (9) to 90-100 lb in. (104-115 kg cm).
m. Recheck voltage per substep i.
n. Close vanes and check reading. Reading should be 4.773 VDC.
o. Safety-wire jamnuts (8, 9) and clevis (5).
NOTE
The following electro-mechanical relationship is found in conjunc-
tion with the stator vane schedule and the main engine control.
VSV Position Mechanically Open Mechanically Closed
Beta-Degrees -6.5 +42.2

Transducer Stroke 0.000 inch (mm) 2.864 inch (72.74 mm)
Transducer Output Zero ± 0.02 volts/dc 4.773 ± 0.02 volts/dc
p. Transducer stroke from rig position is 3.000 inches (76.2 mm). The equation for this sys-
tem is: Beta (Degrees) = 10.203V - 6.500 (where V = signal conditioner output voltage).
q. Disconnect pressure source and reconnect VSV lines to VGC. Torque to 135-150 lb in.
(156-173 kg cm). No leakage permitted.

6
GEK 97310
VOLUME II
WP 102 00
WORK PACKAGE
REPLACEMENT OF SPEED SENSOR
EFFECTIVITY: LM2500 GAS GENERATOR MODELS - ALL (EXCEPT GA101)

1-6 .......... 0
ALPHABETICAL INDEX
Subject Page
Installation of Speed Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Removal of Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
WP 102 00
1. INTRODUCTION. This work package contains the instructions for removal and
installation of the speed sensor. Refer to WP 118 00 for rigging the variable stator vane system.
NOTE
discretion. Examples of units that may be rounded off are those
utilized for temperatures, torque values, pressures, etc. Examples

1C8062 Wrench

Safety Wire
4. REMOVAL OF SPEED SENSOR. See figures 1 and 2.
a. Remove nut, bolt, and washer that secure speed sensor output lever (5, figure 1) to rod-end
bearing (6).
b. Remove clamps (2) securing capillary tube (3).
c. Remove the 4 bolts and washers that secure CIT sensor (1) to right side of front frame.
CAUTION
DO NOT DAMAGE CAPILLARY TUBE (3). AVOID SHARP
BENDING OF TUBE.
d. Carefully disengage the CIT sensor (1) from front frame. Remove gasket (11).

2
GEK 97310
VOLUME II
WP 102 00
Figure 1. Speed Sensor Orientation

3
GEK 97310
VOLUME II
WP 102 00
Figure 2. Speed Sensor Removal/Installation

4
GEK 97310
VOLUME II
WP 102 00
NOTE
Speed sensor hoses may have oil in them. Provide suitable
container to catch oil when disconnecting hoses.
e. Disconnect oil supply and return hoses from speed sensor (4). Cap hoses.
NOTE
Difficulty may be encountered in removing speed sensor lower left
mounting nut (as viewed forward looking aft). Use 1C8062 wrench
to ease removal (figure 2).
f. Remove the 4 nuts (8, figure 2) and washers (9) that secure speed sensor to transfer
gearbox. Carefully remove speed sensor and gasket (1).
g. Remove nipples (2, 5, and 6) from speed sensor and discard O-rings (3, 4, and 7).
5. INSTALLATION OF SPEED SENSOR. See figures 1 and 2.
CAUTION
WHEN INSTALLING A SPEED SENSOR OF A DIFFERENT
PART NUMBER FROM THAT OF THE ONE REMOVED,
ENSURE THE VARIABLE VANE ACTUATOR RODS ARE
PROPERLY ADJUSTED. REFER TO WP 100 00.
a. Install new O-rings (3, 4, and 7, figure 2) on nipples (2, 5, and 6) and install nipples in
speed sensor. Torque nipple (2) to 270-300 lb in. (30.5-33.9 N·m). Torque nipple (5) to
180-200 lb in. (20.3-22.6 N·m). Torque nipple (6) to 135-150 lb in. (15.3-16.9 N·m).
b. Install gasket (1) and speed sensor on front of gearbox, being careful to align drive splines.
NOTE
Difficulty may be encountered in installing speed sensor lower left
mounting nut (as viewed forward looking aft). Use 1C8062 wrench
to ease installation (figure 2).
c. Install 4 nuts and washers (8 and 9) to secure speed sensor to gearbox. Torque to
55-70 lb in. (6.2-8.0 N·m).
d. Connect oil supply and return hoses to speed sensor. Torque hose to nipple (2) to
450-550 lb in. (50.8-62.1 N·m). Torque hose to nipple (5) to 270-300 lb in. (30.5-33.9 N·m).
Torque hose to nipple (6) to 135-150 lb in. (15.3-16.9 N·m).

5
GEK 97310
VOLUME II
WP 102 00
e. Install CIT sensor (1, figure 1) and gasket (11) on right side of front frame. Secure with 4
bolts and washers. Torque to 24-27 lb in. (2.7-3.1 N·m) and safety-wire.
f. Install clamps (2) on CIT capillary tube (3). Torque clamp nuts to 24-27 lb in.
(2.7-3.1 N·m).
g. Attach connecting link rod-end bearing (6) to output lever (5). Secure with nut, bolt, and
washer. Torque to 24-27 lb in. (2.7-3.1 N·m).
h. After installation of speed sensor, perform variable vane schedule check per addendum for
the model being operated. Should variable vane system require further adjustment, refer to
WP 118 00.

6
GEK 97310
VOLUME II
SWP 102 01
REPLACEMENT OF SPEED SENSOR
EFFECTIVITY: LM2500 GAS GENERATOR MODEL - GA101

1-4.......... 0
ALPHABETICAL INDEX
Subject Page
Installation of Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Removal of Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
SWP 102 01
installation of the speed sensor. Refer to SWP 118 01 for rigging the variable vane system.
NOTE
Use standard torque values in accordance with GEK 97310,
Volume I, Chapter V, when installing speed sensor.
None

Safety Wire
4. REMOVAL OF SPEED SENSOR. See figure 1.
NOTE
Observe position of CIT sensor on front frame. Direction of
airflow through CIT sensor must be maintained.
a. Remove 4 screws securing CIT sensor to front frame.
CAUTION
USE CARE NOT TO BREAK TUBE. AVOID ANY SHARP
BENDS IN TUBE.
b. Remove CIT sensor and gasket. Disconnect clamps securing tube.
c. Remove bolt and nut attaching demand cable to lever arm.
NOTE
Speed sensor and hoses may have oil in them at time of removal.
Drain the oil into suitable container.
d. Disconnect oil supply and return hoses from speed sensor. Cap hoses.
e. Loosen V-band clamp and carefully remove speed sensor.
f. Remove fittings and O-rings from speed sensor.

2
GEK 97310
VOLUME II
SWP 102 01
Figure 1. Accessories - Lower Right Side Gas Generator

3
GEK 97310
VOLUME II
SWP 102 01
5. INSTALLATION OF SPEED SENSOR. See figure 1.
CAUTION
WHEN INSTALLING A SPEED SENSOR OF A DIFFERENT
PART NUMBER FROM THAT OF THE ONE REMOVED,
ENSURE THE VARIABLE VANE ACTUATOR RODS ARE
PROPERLY ADJUSTED. REFER TO WP 100 00.
NOTE
Use standard torque values in accordance with GEK 97310,
Volume I, Chapter V.
a. Install new O-rings on fittings and install fittings on replacement sensor. Torque fittings.
b. Install speed sensor on mounting pad, carefully engaging spline and aligning locating pin.
c. Position V-band clamp on flanges and tighten. Tap rim of clamp, using plastic mallet, to
enable clamp to seat properly. Torque.
d. Connect oil supply and return hoses to speed sensor. Torque and safety-wire.
e. Install CIT sensor and gasket on front frame, using 4 bolts and washers. Torque and
safety-wire.
f. Install clamps on tube, and secure.
g. Attach demand cable to lever arm, using bolts and nut.
h. Rig variable stator vane control system per SWP 118 01.

4
GEK 97310
VOLUME II
WP 103 00
WORK PACKAGE
REPLACEMENT OF SERVO VALVE
EFFECTIVITY: LM2500 ENGINE MODELS (EXCEPT GA101)

1-4.......... 0
ALPHABETICAL INDEX
Subject Page
Installation of Servo Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Removal of Servo Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
WP 103 00
1. INTRODUCTIONS. This work package contains instructions for removal and installation
of the servo valve. Following installation of the servo valve the system must be rigged per
WP 118 00.
NOTE

None
4. REMOVAL OF SERVO VALVE. See figures 1 and 2.
a. Remove nut and bolt that secure lever arm (11, figure 1) to rod-end bearing (9).
b. Remove nut and bolt that secure sleeve assembly (14) to lever arm (11).
NOTE
Servo valve hoses may have oil in them. Provide suitable container
to catch oil when disconnecting hoses.
c. Disconnect the 4 hydraulic line hoses (3, 4, 9, and 10, figure 2) from the servo valve.
d. Remove the 4 nuts, washers and bolts (13) that secure servo valve to bracket
(21, figure 1). Remove servo valve.
e. Remove the 4 nipples (2, 5, 8 and 11, figure 2) from servo valve and discard O-rings
(1, 6, 7 and 12).

2
GEK 97310
VOLUME II
WP 103 00
Figure 1. Variable Stator Vane Actuating System

3
GEK 97310
VOLUME II
WP 103 00
Figure 2. Servo Valve
5. INSTALLATION OF SERVO VALVE. See figures 1 and 2.
a. Install new O-rings (1, 6, 7 and 12, figure 2) on the 4 nipples (2, 5, 8 and 11) and install the
nipples in the servo valve. Torque nipples (11 and 5) to 180-200 lb in. (20.3-22.6 N·m). Torque
nipples (2 and 8) to 270-300 lb in. (30.5-33.9 N·m).
b. Install valve on mounting bracket (21, figure 1) and secure with 4 nuts, washers and
bolts (13). Torque to 55-70 lb in. (6.2-7.9 N·m).
c. Connect the 4 hydraulic lines (3, 4, 9 and 10, figure 2) to the servo valve. Torque hoses (3
and 9) to 450-550 lb in. (50.9-62.2 N·m). Torque hoses (4 and 10) to 270-300 lb in.
(30.5-33.9 N·m).
d. Connect rod-end bearing (9, figure 1) to servo valve lever arm (11). Secure with nut and
bolt. Torque to 24-27 lb in. (2.7-3.1 N·m).
e. Connect sleeve assembly (14) to servo valve lever arm (11). Secure with nut and bolt.
Torque to 24-27 lb in. (2.7-3.1 N·m).
f. Rig the variable stator vane control system per WP 118 00.

4
GEK 97310
VOLUME II
SWP 103 01
REPLACEMENT OF SERVO VALVE
EFFECTIVITY: LM2500 GAS GENERATOR MODEL - GA101

1-4.......... 0
ALPHABETICAL INDEX
Subject Page
Installation of Servo Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Removal of Servo Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
SWP 103 01
1. INTRODUCTION. This subordinate work package contains instructions for the removal
and installation of the servo valve. Following installation of the servo valve, the variable stator
vane system must be rigged per SWP 118 01.
NOTE
None
None
4. REMOVAL OF SERVO VALVE. See figure 1.
a. Remove bolts and nuts securing demand and feedback cables to servo valve lever arm.
NOTE
Servo valve and hoses may have oil in them at time of removal.
Drain oil into a suitable container.
b. Disconnect all hoses at servo valve.
c. Remove bolts securing valve to mounting bracket and remove valve.
d. Remove threaded fittings from valve and remove and discard O-rings.

2
GEK 97310
VOLUME II
SWP 103 01
Figure 1. Servo Valve

3
GEK 97310
VOLUME II
SWP 103 01
5. INSTALLATION OF SERVO VALVE. See figure 1.
a. Install new O-rings on fittings and install fittings in valve. Torque large fittings to
270-300 lb in. (30.5-33.9 N·m) and small fittings to 180-200 lb in. (20.3-22.6 N.m).
b. Install valve on mounting bracket and secure with bolts. Torque to 55-70 lb in.
(6.2-7.9 N·m).
c. Connect supply drain and two discharge hoses to servo valve fittings. Torque small hoses
to 270-300 lb in. (30.5-33.9 N·m). Torque large hoses to 450-550 lb in. (50.8-62.1 N·m).
d. Attach demand and feedback cables to lever arms, using bolts and nuts previously
removed. Torque to 24-27 lb in. (2.7-3.1 N·m).
e. Check rigging of variable stator vane control system per SWP 118 01.

4
GEK 97310
VOLUME II
SWP 103 02
REPLACEMENT OF VARIABLE STATOR VANE

CONTROL
EFFECTIVITY: LM2500 ENGINE MODELS

1-7.......... 0 8 Blank . . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Installation of the Variable Stator Vane Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Removal of Variable Stator Vane Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
SWP 103 02
installation of the variable stator vane (VSV) control. Refer to WP 118 00 for rigging the VSV
system.
NOTE
rounded off are those utilized for temperatures, torque values,
pressures, etc. Examples where S.I. units may not be rounded off
are those utilized for drop checks, rigging adjustments, runouts, etc.

3. CONSUMABLE MATERIALS.

R297P04 Safety Wire
4. REMOVAL OF VARIABLE STATOR VANE CONTROL. See figures 1 and 2.
a. Remove nut and bolt securing feedback cable rod end bearing to VSV control lever
(7, figure 2).
NOTE
z Release VSV control lever slowly against spring load while dis-
connecting feedback cable rod end bolt.
z VSV control hoses may have oil in them. Provide suitable con-
tainer to catch oil when disconnecting hoses.
b. Disconnect 5 hydraulic line hoses (5, 6, 10, 14, and 16) from VSV control (20). Plug
hoses.
c. Remove 5 nipples (2, 4, 9, and 18) and elbow fitting (13) from VSV control (20) and dis-
card O-rings (1, 3, 8, 11, and 17). Install protective plugs in VSV control.
d. Remove clamps (2 and 3, figure 1) and 4 bolts (6) and washers (7) securing CIT sensor (4)
to right side of front frame.

2
GEK 97310
VOLUME II
SWP 103 02
Figure 1. Variable Stator Vane Control

3
GEK 97310
VOLUME II
SWP 103 02
Figure 2. Removal/Installation of the Variable Stator Vane Control

4
GEK 97310
VOLUME II
SWP 103 02
CAUTION
DO NOT DAMAGE CIT SENSOR CAPILLARY TUBE. AVOID
SHARP BENDING.
e. Carefully disengage CIT sensor (4) from the front frame. Remove gasket (5).
f. Remove coupling clamp (15, figure 2) that secures the VSV control (20) to the transfer
gearbox. Carefully remove VSV control and gasket (19), and discard O-ring (22). Install protec-
tive cover on gearbox mount pad.
5. INSTALLATION OF THE VARIABLE STATOR VANE CONTROL.

See figures 1, 2, and 3.
a. Install O-ring (22, figure 2), gasket (19), and coupling clamp (15) on VSV control (20).
Install assembly on gearbox mount pad. Engage locating dowel pin of VSV control into gearbox
recess. Tighten coupling clamp to 70-80 lb in. (7.9-9.0 N·m) of torque.
CAUTION
USE CARE TO AVOID DAMAGE TO CIT SENSOR
(4, FIGURE 1) AND CAPILLARY TUBE DURING
INSTALLATION.
b. Install CIT sensor (4) and gasket (5) on right side of front frame. Secure with 4 bolts and
washers. Tighten bolts to 24-27 lb in. (2.7-3.1 N·m) of torque and safety-wire. Install clamps
(2 and 3). Tighten clamps to 24-27 lb in. (2.7-3.1 N·m) of torque.
c. Install new O-rings on nipples (2, 4, 9, and 18, figure 2) and elbow fitting (13), and install
fittings in VSV control (20). Tighten nipple (2) to 180-200 lb in. (20.3-22.6 N·m) of torque.
Tighten nipples (4, 9, and 18) to 270-300 lb in. (30.5-33.9 N·m) of torque. Tighten jamnut (12) to
360-400 lb in. (40.7-45.2 N·m) of torque.
d. Connect hydraulic line hoses (5, 6, 10, 14, and 16) to VSV control (20). Tighten
coupling nut on hose (6) to 270-300 lb in. (30.5-33.9 N·m) of torque. Tighten coupling nuts on
hoses (5, 10, and 16) to 450-550 lb in. (50.8-62.1 N·m) of torque. Tighten coupling nut on hose
(14) to 650-770 lb in. (73.4-87.0 N·m) of torque.
e. Connect feedback cable to VSV control system as follows:
(1) Visually set micro-adjust bracket (1, figure 3).
(2) Align clamping screw in center of slot on bracket (1) by loosening clamping screw,
rotating adjustment screw, and relocking clamping screw.
f. Adjust two rod end bearings (2) on feedback cable (3) to maximum threaded depth. Back
off four turns each. Tighten locknuts (4).

5
GEK 97310
VOLUME II
SWP 103 02
Figure 3. Variable Stator Vane Control and Feedback Cable

6
GEK 97310
VOLUME II
SWP 103 02
g. Connect feedback cable (3) to VSV control feedback lever arm (7, figure 2) and stator
vane bellcrank (5, figure 3).
h. Refer to WP 118 00 for rigging VSV system.

7/(8 Blank)
GEK 97310
VOLUME II
WP 104 00
WORK PACKAGE
REPLACEMENT OF FUEL NOZZLES (LIQUID)

1-6.......... 0
ALPHABETICAL INDEX
Subject Page
Installation of Fuel Nozzles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Removal of Fuel Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
WP 104 00
liquid fuel nozzles. Following fuel nozzle installation a leak check must be performed per
WP 123 00.
NOTE
conversions and may be rounded off in most instances at the user's

2C6081 Wrench Set

MIL-G-23827 Grease
R297P04 Safety Wire
4. REMOVAL OF FUEL NOZZLES. See figures 1 and 2.
NOTE
z There are 30 fuel nozzles on the gas generator. Removal
procedures are the same for all.
z Identify fuel nozzles by position as they are removed to
facilitate inspection and troubleshooting.
a. Remove all safety wire from fuel nozzle assembly.

2
GEK 97310
VOLUME II
WP 104 00
Figure 1. Removal/Installation of Fuel Nozzle

3
GEK 97310
VOLUME II
WP 104 00
Figure 2. Fuel Nozzle Wrench Set, 2C6081

4
GEK 97310
VOLUME II
WP 104 00
CAUTION
USE WRENCH SET, 2C6081, WHEN BREAKING TORQUE
AT THE SHROUD TUBE COUPLING NUT (11), FUEL MANI-
FOLD END, TO PREVENT SHROUDED TUBE (1) FROM
TWISTING AND DAMAGING ALIGNMENT PINS (12).
b. Position wrench, 2C6081P14, over shrouded tube (1, figure 1) and break torque of tube
coupling nut (11) with wrench, 2C6081P10, P13, or P15. See figure 2. Remove tooling and
disconnect coupling nut.
c. Disconnect tube coupling nut (8, figure 1) from fuel nozzle (4), and move shrouded
tube (1) forward to expose fuel tube coupling nuts (10).
d. Remove safety wire from fuel tube coupling nuts (10), and disconnect fuel tube (7) from
fuel manifold and fuel nozzle (4).
e. Remove and discard O-ring (2) from fuel nozzle and metal seal (6) from fuel manifold
seating surface. Place shrouded tube assembly in a plastic bag and record position.
f. Remove 3 bolts (3) securing fuel nozzle (4) to compressor rear frame, and remove nozzle.
Place fuel nozzle in a plastic bag to prevent damage to nozzle tip.
g. Remove and discard metal ring seal (5) located between fuel nozzle and CRF, and cover
all openings in CRF.
5. INSTALLATION OF FUEL NOZZLES. See figures 1 and 2.
CAUTION
CAREFULLY INSTALL FUEL NOZZLE INTO THE
COMBUSTION LINER TO PREVENT DAMAGING THE
NOZZLE TIP.
a. Install metal ring seal (5, figure 1) on compressor rear frame nozzle port and install fuel
nozzle (4). Secure with bolts (3). Ensure nozzle and metal ring seal seats on CRF boss. Tighten
bolts to 55-70 lb in. (6.2-7.9 N·m) of torque and safety-wire.
b. Lubricate O-ring (2) with grease, MIL-G-23827, and install O-ring on fuel nozzle (4).

5
GEK 97310
VOLUME II
WP 104 00
NOTE
Lubricant, MIL-G-23827, may be used on the metal seal to hold
seal in place and on ferrule to nut interface of the fuel tube.
c. Install metal seal (6) on fuel manifold seating surface and position shrouded tube
assembly (1) between fuel manifold and nozzle.
CAUTION
WHEN APPLYING TORQUE TO THE FUEL TUBE
COUPLING NUTS, HOLD SLIGHT HAND PRESSURE ON
THE SHROUDED TUBE ASSEMBLY TO PROVIDE AN
OPPOSING TORQUE AND THUS PREVENT TWISTING OF
THE FUEL TUBE INSIDE THE SHROUDED TUBE.
d. Install fuel tube coupling nut (10) on fuel nozzle (4) and finger-tighten. Connect coupling
nut on other end of fuel tube (7) to fuel manifold and hand-tighten. Tighten coupling nuts (10), at
each end, to 130-150 lb in. (14.7-17.0 N·m) of torque.
e. Slide shrouded tube (1) over O-ring (2) and fuel nozzle end. Connect coupling nut (8) to
fuel nozzle. Do not torque at this time.
CAUTION
TO AVOID DAMAGING METAL SEAL (6), ENSURE SEAL IS
PROPERLY POSITIONED BEFORE TIGHTENING THE
SHROUDED TUBE COUPLING NUT TO THE FUEL
MANIFOLD.
f. Connect shrouded tube coupling nut (11), by installing alignment pins (12) of shrouded
tube (1), into alignment slots (13) of fuel manifold and hand-tighten coupling nut.
CAUTION
USE WRENCH SET, 2C6081, TO APPLY FINAL TORQUE TO
THE SHROUDED TUBE COUPLING NUT, FUEL MANIFOLD
END, TO PREVENT SHROUDED TUBE FROM TWISTING
AND DAMAGING THE ALIGNMENT PINS.
g. Position wrench, 2C6081P14, over shrouded tube (1). Tighten coupling nut (11), using
wrench, 2C6081P10, P13, or P15, to 360-500 lb in. (40.7-56.5 N·m) of torque and safety-wire.
See figure 2.
h. Hand-tighten coupling nut (8, figure 1) until nut bottoms on fuel nozzle and safety-wire.
i. Perform leak checks per WP 123 00.

6
GEK 97310
VOLUME II
SWP 104 01
REPLACEMENT OF FUEL NOZZLES (NATURAL GAS)
EFFECTIVITY: LM2500 GAS GENERATOR G SERIES MODELS

1-7.......... 0 8 Blank . . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Installation of Fuel Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Installation of Fuel Nozzle (682L310G11 Fuel System) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal of Fuel Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal of Fuel Nozzle (682L310G11 Fuel System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1
GEK 97310
VOLUME II
SWP 104 01
installation of natural gas nozzles.
NOTE
None

MIL-G-23827 Grease
Safety Wire
4. REMOVAL OF FUEL NOZZLE. See figures 1 and 2.
NOTE
It is recommended that the fuel nozzle be identified by position as it
is removed to facilitate inspection and troubleshooting.
a. Remove two bolts that secure fuel nozzle to manifold.
b. Remove and discard O-rings located between fuel nozzle and manifold.
c. Remove three bolts that secure fuel nozzle to frame. Remove nozzle and discard metal
seal ring located between nozzle and frame.

2
GEK 97310
VOLUME II
SWP 104 01
Figure 1. Fuel Manifold and Nozzles (Gas Turbine Models Only)

3
GEK 97310
VOLUME II
SWP 104 01
Figure 2. Fuel Manifold and Nozzles (Gas Generator Models Only)

4
GEK 97310
VOLUME II
SWP 104 01
5. REMOVAL OF FUEL NOZZLE (682L310G11 FUEL SYSTEM).
NOTE
z It is recommended that the fuel nozzle be identified by position
as it is removed to facilitate inspection and troubleshooting.
z This fuel nozzle configuration uses three different gas tube
assemblies.
a. Disconnect coupling nut securing fuel nozzle to manifold (figure 3).
b. Disconnect coupling nut from gas tube to fuel nozzle.
c. Remove three bolts that secure fuel nozzle to frame.
d. Remove fuel nozzle and discard seal ring.
6. INSTALLATION OF FUEL NOZZLE. See figures 1 and 2.
NOTE
Fuel nozzle must be compatible with combustion liner. Refer to
parts list.
a. Place metal seal over head of two igniter fuel nozzles. Install nozzles in number 11 and 13
fuel nozzle ports (aft looking forward). Secure to frame with three bolts each fingertight.
b. Install the remaining 28 fuel nozzles and seals. Fingertighten the bolts.
c. Place O-ring in seal groove on aft end of each fuel nozzle and secure to manifold with
bolts and washers fingertight.
d. Torque all fuel nozzle bolts to 55-70 lb in. (6.2-7.9 N·m) of torque. Safety-wire all fuel
nozzle bolts.
e. Check immersion depth of fuel nozzle at each swirler cup in combustor 0.08 inch
(2.0 mm) minimum.

5
GEK 97310
VOLUME II
SWP 104 01
Figure 3. Fuel Manifold and Nozzles (682L310G11 only)

6
GEK 97310
VOLUME II
SWP 104 01
7. INSTALLATION OF FUEL NOZZLE (682L310G11 FUEL SYSTEM).
NOTE
Fuel nozzle must be compatible with the combustion liner. Refer to
parts list.
a. Place seal ring on frame. Insert fuel nozzle tip through seal ring and into combustor.
Secure fuel nozzle in position with three bolts. Finger-tighten bolts.
b. Connect coupling nut to fuel nozzle (figure 3). Finger-tighten coupling nut.
c. Connect coupling nut to fuel manifold. Finger-tighten coupling nut.
d. Repeat steps a through c for all removed fuel nozzles.
e. Tighten all fuel nozzle bolts to 55-70 lb in. (6.2-7.9 N·m) of torque. Safety-wire fuel
nozzle bolts.
f. Tighten coupling nut to fuel nozzle to 900-1100 lb in. (101.7-124.3 N·m) of torque.
g. Tighten coupling nut to fuel manifold to 900-1100 lb in. (101.7-124.3 N·m) of torque.
h. Check immersion depth of fuel nozzle at each swirler cup in combuster 0.08 inch
(2.0 mm) minimum.

7/(8 Blank)
GEK 97310
VOLUME II
SWP 104 02
REPLACEMENT OF DUAL FUEL NOZZLES

(LIQUID AND NATURAL GAS)
EFFECTIVITY: LM2500 PC101A, PC101C, PC104A, PC104C MODELS WITH

ORIGINAL, SHROUDED LIQUID MANIFOLD

1-5.......... 0 6 Blank . . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Installation of Dual Fuel Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Removal of Dual Fuel Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
SWP 104 02
dual fuel (liquid and natural gas) nozzles. Following fuel nozzle installation a leak check must be
performed per SWP 123 02.
NOTE

2C6081 Wrench Set

MIL-G-23827 Grease
Safety Wire
4. REMOVAL OF DUAL FUEL NOZZLE. See figure 1.
a. Disconnect liquid fuel nozzle supply tube shrouds (5) and move the shrouds forward to
expose the fuel supply tube (21) fittings.
b. Disconnect the supply tube (21) from the fuel nozzle and fuel manifold using wrench
set, 2C6081. Remove O-ring (4) and seal (22) and discard.
c. Remove 2 bolts and washers (14) used to attach each fuel nozzle to the gas fuel
manifold (12). Discard O-rings (15).
d. Remove 3 bolts (16) used to attach each fuel nozzle to the compressor rear frame. Unhook
each fuel nozzle from the combustion liner. Remove and discard gaskets (17).
e. Place fuel nozzles in an appropriate container.

2
GEK 97310
VOLUME II
SWP 104 02
Figure 1. Fuel Manifolds and Nozzles (Sheet 1 of 2)

3
GEK 97310
VOLUME II
SWP 104 02

4
GEK 97310
VOLUME II
SWP 104 02
5. INSTALLATION OF DUAL FUEL NOZZLE. See figure 1.
a. Place gasket (17) on fuel nozzle. Install fuel nozzle, making sure that the nozzle tip enters
the ferrule of the combustor and that the gasket (17) seats on the compressor rear frame boss.
Secure each nozzle with 3 bolts. Torque bolts to 55-70 lb in. (6.2-7.9 N·m) and safety-wire.
b. Place gasket (15) on the fuel nozzle and secure nozzle to the gas fuel manifold with 2 bolts
and washers. Torque bolts to 55-70 lb in. (6.2-7.9 N·m) and safety-wire.
c. Lubricate O-rings (4), seals (22), and supply tube nut-to-ferrule interface surfaces with
grease, MIL-G-23827.
d. Install O-rings (4) in groove on nozzles. Install metal seals (22) on liquid fuel manifold
supply ports.
e. Position liquid fuel nozzle supply tube (21) and shroud (5) assembly between the fuel
nozzle and fuel manifold.
NOTE
When applying torque at the fuel tube to fuel nozzle coupling nut,
the fuel shroud must be rotated approximately 1/8 turn in the
opposite direction of tightening torque.
f. Torque coupling nuts at each end of the 30 liquid fuel supply tubes to 130-150 lb in.
(14.7-17.0 N·m) with wrench set, 2C6081.
g. Perform leak checks per SWP 123 02.

5/(6 Blank)
GEK 97310
VOLUME II
SWP 104 03
REPLACEMENT OF FUEL NOZZLES (NATURAL GAS

WITH WATER INJECTION)

1-7.......... 0 8 Blank . . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Installation of Fuel Nozzles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Installation of Fuel Nozzles (682L310G13 Fuel System). . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal of Fuel Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal of Fuel Nozzles (682L310G13 Fuel System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1
GEK 97310
VOLUME II
SWP 104 03
the fuel nozzles (natural gas with water injection). Upon completion of the fuel nozzle
installation, a leak check must be performed per SWP 123 03.
NOTE
conversions and may be rounded off is most instances at the user’s
None

Commercial Lockwire
MIL-G-23827 Lubricant
4. REMOVAL OF FUEL NOZZLES. See figure 1.
a. Disconnect the feeder tubes from the fuel nozzles (30 locations). Exercise care to prevent
damage to the feeder tubes and fuel nozzle fittings. See figure 1, view D-D.
b. Remove the 2 bolts and washers at each fuel nozzle to large gas manifold mating flange
(30 locations).
c. Remove the 3 bolts securing each fuel nozzle to the compressor rear frame mounting
flange and remove the fuel nozzle.
d. Remove and discard ring seal (figure 1, view D-D).

2
GEK 97310
VOLUME II
SWP 104 03
Figure 1. Fuel Manifolds and Nozzles

3
GEK 97310
VOLUME II
SWP 104 03
5. REMOVAL OF FUEL NOZZLES (682L310G13 FUEL SYSTEM).
NOTE
z It is recommended that the fuel nozzle and, if applicable, the
fuel nozzle adapter be identified by position as they are
removed to facilitate inspection and troubleshooting.
z This fuel nozzle configuration uses two different gas tube
assemblies.
a. Disconnect coupling nut (1, figure 2) on gas tube (2) from fuel manifold assembly (3).
b. Disconnect coupling nut (4) on tube (2) from fuel nozzle (5) or, if applicable, fuel nozzle
adapter (6).
c. Remove tube (2).
d. Disconnect coupling nut (7) on water feeder tube (8) from nozzle (5) or, if applicable, fuel
nozzle (9).
e. Remove two nuts (10), if applicable, and bolts (11) securing adapter (6) to nozzle (9).
Remove adapter and seal gasket (12). Discard gasket.
f. Remove lockwire and three bolts (13) securing nozzle (5) or, if applicable, nozzle (9) to
frame (14).
g. Remove nozzle (5 or 9) and seal ring (15) from frame (14). Discard ring.
h. Repeat steps a. through g. for all nozzles (5 or 9) to be removed.
6. INSTALLATION OF FUEL NOZZLES.
a. Install new meal ring seal on fuel nozzle and install fuel nozzle to compressor rear frame.
Secure fuel nozzle to compressor rear frame mounting flange using 3 bolts. Torque bolts to
55-70 lb in. (6.2-7.9 N·m) and lockwire.
b. Assemble preformed packing to fuel nozzle and secure fuel nozzle to large gas fuel
manifold mounting flange using 2 bolts and washers. Verify adequate clearance exists between
adjoining feeder tubes and feeder tubes to igniter plugs. Torque bolts to 55-70 lb in.
(6.2-7.9 N·m) and lockwire.
c. Lubricate water feeder tube nut-to-ferrule interfaces using lubricant, MIL-G-23827.
d. Position feeder tubes as shown in figure 1, view D-D and connect fittings to fuel nozzles.

4
GEK 97310
VOLUME II
SWP 104 03
Figure 2. Fuel Manifold and Nozzles (6822310G13 Fuel System)

5
GEK 97310
VOLUME II
SWP 104 03
e. Torque feeder tube to fuel nozzle fittings to 120-135 lb in. (13.6-15.3 N·M).
f. Perform leak check per SWP 123 03.
7. INSTALLATION OF FUEL NOZZLES (682L310G13 FUEL SYSTEM).
NOTE
Fuel nozzle must be compatible with combustion liner. Refer to
parts list.
a. Place seal ring (15, figure 2) onto fuel nozzle (5) or, if applicable, fuel nozzle (9).
b. Install nozzle (5 or 9) into port (aft looking forward).
c. Install three bolts (13) to nozzle (5 or 9) installed in step a. to frame (14). Finger-tighten
bolts.
d. Repeat steps a. through c. for all nozzles (5 or 9) removed.
e. If applicable, install seal gasket (12) and fuel nozzle adapter (6) onto nozzle (9).
f. If applicable, install two bolts (11) and nuts (10) to secure adapter (6) to nozzle (9).
Finger-tighten nuts.
g. If applicable, repeat steps e. and f. for all removed nozzles (9).
h. Connect coupling nut (4) on gas tube (2) to nozzle (5) or, if applicable, adapter (6). Finger-
tighten nut.
i. Connect coupling nut (1) on tube (2) to fuel manifold assembly (3). Finger-tighten nut.
j. Apply lubricant to coupling nut (7) on water feeder tube (8) and threads of nozzle (5 or 9)
connection.
k. Connect nut (7) to nozzle (5 or 9). Finger-tighten nut.
l. Repeat steps g. through k. for all removed nozzles (5 or 9).
m. Tighten all bolts (13) on nozzles (5 or 9) to 55-70 lb in. (6.2-7.9 N·m) of torque. Lockwire
bolts.
n. If applicable, tighten all nuts (10) on adapter (6) to 55-70 lb in. (6.2-7.9 N·m) of torque.
o. Tighten all coupling nuts (1 and 4) to 900-1100 lb in. (101.7-124.3 N·m) of torque.

6
GEK 97310
VOLUME II
SWP 104 03
p. Tighten all coupling nuts (7) to 120-135 lb in. (13.6-15.3 N·m) of torque.
q. Perform leak check per SWP 123 03.

7/(8 Blank)
GEK 97310
VOLUME II
SWP 104 04
REPLACEMENT OF DUAL FUEL NOZZLES

(DUPLEX DUAL FUEL)

1 - 10 . . . . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Installation of Dual Fuel Nozzles (Nozzle Tube/Hose Configurations) . . . . . . . . . . . . . . . . 8

Installation of Dual Fuel Nozzles (682L310G12 Fuel System) . . . . . . . . . . . . . . . . . . . . . . 10
Installation of Dual Fuel Nozzles (Gas Tube Configurations) . . . . . . . . . . . . . . . . . . . . . . . 9
Removal of Dual Fuel Nozzles (682L310G12 Fuel System) . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal of Dual Fuel Nozzles (Gas Tube Configurations) . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal of Dual Fuel Nozzles (Nozzle Tube/Hose Configurations) . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
SWP 104 04
the fuel nozzles for the duplex dual fuel system. Prior to performing the tasks described herein,
remove all external tubing and electrical leads, as required to gain access to the dual fuel nozzles,
per WP 117 00, SWP 117 01, or SWP 117 02.
NOTE

2C6081 Wrench Set

MIL-G-23827 Grease
Commercial Plastic Bags
Commercial Protective Caps
4. REMOVAL OF DUAL FUEL NOZZLES (NOZZLE TUBE/HOSE

CONFIGURATIONS). See figure 1.
NOTE
z Remove all necessary piping, clamping and electrical leads as
required per WP 117 00, SWP 117 01, or SWP 117 02.
z Wrench set 2C6081 is referenced in this paragraph. If a
required wrench is not a part of this wrench set, use an
equivalent wrench to perform the task specified.
a. Remove safety wire from the secondary (19) and primary (21) fuel feeder tube
connectors (18) and (20) at the dual fuel nozzles (16) or (17) at (30 locations).

2
GEK 97310
VOLUME II
SWP 104 04
1. Compressor Rear Frame Mid Flange 23. Machine Bolt (90 ea)
2. Hinged Bracket (6 ea) 24. Metal Ring Seal (30 ea)
3. Machine Bolt (12 ea) 25. Safety Wire (AR)
4. Flat Washer (12 ea) 26. Gas Fuel Manifold (1 ea)
5. Nut (12 ea) *27. Air Tube (1 ea)
6. Loop Clamp (6 ea) *28. Air Tube (1 ea)
7. Bolt (60 ea) *29. Air Manifold (1 ea)
8. Flat Washer (60 ea) *30. Air Manifold (1 ea)
9. Preformed Packing (60 ea) *31. Air Tube (1 ea)
10. Safety Wire (AR) *32. Air-Recoup Tube (1 ea)
11. Nozzle Tube/Hose (30 ea) *33. Oil Tube (1 ea)
12. Bolt (60 ea) *34. Oil Tube (1 ea)
13. Flat Washer (60 ea) 35. Primary Fuel Manifold (1 ea)
14. Nut (60 ea) 36. Secondary Fuel Manifold
15. Preformed Packing (30 ea)
16. Dual Fuel Nozzle L31421PO3 (30 ea) (PC101C) *NOTE
17. Dual Fuel Nozzle L3142IP04 (30 ea) (PE-MD) These items may require removal,
plus similar items on the left side,
18. Secondary Fuel Feeder Tube Connector (30 ea)
prior to removal of the 30 Dual Fuel
19. Secondary Fuel Feeder Tube (30 ea) Nozzles. Refer to WP 117 00,
SWP 117 01, or SWP 117 02
20. Primary Fuel Feeder Tube Connector (30 ea)
Legend for Figure 1

3
GEK 97310
VOLUME II
SWP 104 04
Figure 1. Dual Fuel Nozzles

4
GEK 97310
VOLUME II
SWP 104 04
b. Using the 2C6081 wrench set, disconnect the secondary (19) and primary (21) fuel feeder
tube connectors (18) and (22) from the dual fuel nozzle's (16) or (17)at (30 locations).
c. Remove the 2 bolts (12), nuts (14) and washers (13). Remove the nozzle tube/hose (11)
from the dual fuel nozzle (16) or (17). Remove and discard preformed packing (15).
d. Remove the safety wire (25) and the 3 bolts (23) securing each dual fuel nozzle to the
compressor rear frame mounting flange. Remove the dual fuel nozzle and discard the metal seal
ring (24).
e. Install protective covers, plugs and caps on all openings.
5. REMOVAL OF DUAL FUEL NOZZLES (GAS TUBE CONFIGURATIONS).
NOTE
z Remove all necessary piping, clamping, and electrical leads as
z Wrench set, 2C6081 is referenced in this paragraph. If a
required wrench is not a part of the wrench set, use an equiva-
lent wrench to perform specified task.
z It is recommended that the fuel nozzles be identified by position
as they are removed to facilitate inspection and troubleshooting.
assemblies.
a. Disconnect coupling nut (1, Figure 2) on gas tube (2) from fuel manifold assembly (3).
b. Disconnect coupling nut (4) on tube (2) from fuel nozzle (5).
c. Remove tube (2).
d. Using wrench set, 2C6081, disconnect coupling nut (6) on secondary fuel tube
assembly (7) and coupling nut (8) on primary fuel tube assembly (9) from nozzle (5).
e. Remove lockwire and three bolts (10) securing nozzle (5) to frame (11).
f. Remove nozzle (5) and seal ring (12) from frame (11). Discard ring.
g. Repeat steps a. through f. for all nozzles (5) to be removed.

5
GEK 97310
VOLUME II
SWP 104 04
6. REMOVAL OF DUAL FUEL NOZZLES (682L310G12 FUEL SYSTEM).
NOTE
required wrench is not a part of this wrench set, use an equiva-
z It is recommended that the fuel nozzle and the fuel nozzle
adapter be identified by position as they are removed to facili-
tate inspection and troubleshooting.
assemblies.
a. Disconnect coupling nut (1, figure 2) on gas tube (2) from fuel manifold assembly (3).
b. Disconnect coupling nut (4, Detail B) on tube (2) from fuel nozzle adapter (13).
c. Remove tube (2).
d. Using wrench set, 2C6081, disconnect coupling nut (6, Section A-A) on secondary fuel
tube assembly (7) and coupling nut (8) on primary fuel tube assembly (9) from nozzle
(14, Detail B).
e. Remove two nuts (15) and bolts (16) securing adapter (13) to nozzle (14). Remove
adapter and seal gasket (17). Discard gasket.
f. Remove lockwire and three bolts (10) securing nozzle (14) to frame (11).
g. Remove nozzle (14) and seal ring (12) from frame (11). Discard ring.
h. Repeat steps a. through g. for all nozzles (14) to be removed.

6
GEK 97310
VOLUME II
SWP 104 04
Figure 2. Duplex Fuel System Assembly

7
GEK 97310
VOLUME II
SWP 104 04
7. INSTALLATION OF DUAL FUEL NOZZLES (NOZZLE TUBE/HOSE
CONFIGURATIONS). See figure 1.
NOTE
z After installation of the dual fuel nozzles, re-install the external
piping, clamps and electrical leads per WP 117 00,
SWP 117 01, or SWP 117 02.
required wrench is not a part of this wrench set, use an
equivalent wrench to perform the task specified.
a. Remove all protective covers, plugs and caps as required to install the dual fuel
nozzles (16) or (17).
b. Install a new metal ring seal (24) on dual fuel nozzle (16) or (17) mounting surface.
Position the dual fuel nozzle on the rear compressor rear frame mounting flange. Secure the dual
fuel nozzle to the compressor rear frame mounting flange with 3 bolts (23). Torque bolts to
55-70 lb in. (6.22-7.91 N·m) and safety wire at (30 locations).
c. Assemble preformed packing (15) to dual fuel nozzle (16) or (17). Secure the nozzle
tube/hose (11) to the dual fuel nozzle with 2 bolts (12), nuts (14) and washers (13). Verify
adequate clearance exists between nozzle tube/hoses (11) and between nozzle tube/hoses (11) and
igniters. Contact between hoses or igniters is not permitted. Torque the bolts (12) to 55-70 lb in.
(6.22-7.91 N·m) at (30 locations).
d. Lubricate the nut-to-ferrule interfaces on the secondary (19) and primary (21) fuel feeder
tubes with MIL-G-23827 grease at 60 locations.
e. Connect the primary fuel feeder tube (21) connector (20) to the dual fuel nozzle (16)
or (17) fitting. Using the 2C6081 wrench set, torque feeder tube connector to dual fuel nozzle
fittings to 120-135 lb in. (13.56-15.26 N·m).
f. Connect the secondary fuel feeder tube (19) connector (18) to the dual fuel nozzle (16)
or (17) (upper) fitting. Using 2C6081 wrench set, torque feeder tube connector to dual fuel nozzle
fittings to 160-180 lb in. (18.1-20.3 N·m).

8
GEK 97310
VOLUME II
SWP 104 04
8. INSTALLATION OF DUAL FUEL NOZZLES (GAS TUBE CONFIGURATIONS).
NOTE
z After installation of dual fuel nozzles, re-install the external
piping, clamping, and electrical leads per WP 117 00,
SWP 117 01, SWP 117 02.
a. Place seal ring (12, figure 2) onto fuel nozzle (5).
b. Install nozzle (5) into port (aft looking forward).
c. Install three bolts (10) to secure nozzle (5) to frame (11). Finger-tighten bolts.
d. Connect coupling nut (4) on gas tube (2) to nozzle (5). Finger-tighten nut.
e. Connect coupling nut (1) on tube (2) to fuel manifold assembly (3). Finger-tighten nut.
f. Apply lubricant to coupling nut (6) on secondary fuel tube assembly (7) and coupling
nut (8) on primary fuel tube assembly (9) and threads of nozzle (5) connections.
g. Connect nuts (6 and 8) to nozzle (5). Finger-tighten nuts.
h. Repeat steps a. through h. for all removed nozzles (5).
i. Tighten all bolts (10) on nozzles (5) to 55-70 lb in. (6.2-7.9 N·m) of torque. Lockwire
bolts.
j. Tighten all coupling nuts (2 and 4) to 900-1100 lb in. (101.7-124.3 N·m) of torque.
k. Using wrench set, 2C6981, tighten all coupling nuts (6 and 8) to 120-135 lb in.
(13.6-15.3 N·m) of torque.

9
GEK 97310
VOLUME II
SWP 104 04
9. INSTALLATION OF DUAL FUEL NOZZLES (682L310G12 FUEL SYSTEM).
NOTE
z After installation of duel fuel nozzles, re-install the external
piping, clamping, and electrical leads per WP 117 00,
SWP 117 01, or SWP 117 02.
z Wrench set 2C6081 is referenced in this paragraph. If a required
wrench is not a part of this wrench set, use an equivalent
wrench to perform specified task.
a. Place seal ring (12, figure 2) onto fuel nozzle (14, Detail B).
b. Install nozzle (14) into port (aft looking forward).
c. Install three bolts (10, Section A-A) to secure nozzle (14) frame (11). Finger-tighten bolts.
d. Install seal gasket (17, Detail B) and fuel nozzle adapter (13) onto nozzle (14).
e. Install two bolts (16) and nuts (15) to secure adapter (13) to nozzle (14). Finger-tighten
nuts.
f. Connect coupling nut (4) on gas tube (2) to adapter (13). Finger-tighten nut.
g. Connect coupling nut (1, Section A-A) on tube (2) to fuel manifold assembly (3). Finger-
tighten nut.
h. Apply lubricant to coupling nuts (6) on secondary fuel tube assembly (7) and coupling (8)
on primary fuel tube assembly (9) and threads of nozzle (14) connections.
i. Using wrench set, 2C6081, connect nuts (6 and 8) to nozzle (14). Finger-tighten nuts.
j. Repeat steps a. through i. for all removed nozzles (14).
k. Tighten all bolts (10) on nozzles (14) to 55 70 lb in. (6.2-7.9 N·m) of torque. Lockwire
bolts.
l. Tighten all nuts (15) on adapters (13) to 55-70 lb in. (6.2-7.9 N·m) of torque.
m. Tighten all coupling nuts (2 and 4) to 900-1100 lb in. (101.7-124.3 N·m) of torque.
n. Using wrench set, 2C6081, tighten all coupling nuts (6 and 8) to 120-135 lb in.
(13.6-15.3 N·m) of torque.

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GEK 97310
VOLUME II
SWP 104 05
REPLACEMENT OF STEAM MANIFOLDS, STEAM

SUPPLY TUBES, AND FUEL/STEAM NOZZLES
(NATURAL GAS WITH STEAM INJECTION)

1 - 11 . . . . . . . . . 0 12 . . . . . . Blank
ALPHABETICAL INDEX
Subject Page
Alignment of Gas Fuel Manifold and Gas Fuel Feeder Tubes.. . . . . . . . . . . . . . . . . . . . . . . 10

Installation of Compressor Discharge Port (CDP) Steam Manifolds.. . . . . . . . . . . . . . . . . . 9
Installation of Fuel/Steam Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation of High Pressure Fuel Nozzle Steam Manifold and Steam Supply Tubes . . . . . 7
Removal of Compressor Discharge Port (CDP) Steam Manifolds . . . . . . . . . . . . . . . . . . . . 4
Removal of Fuel/Steam Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal of High Pressure Fuel Nozzle Steam Manifold and Steam Supply Tubes. . . . . . . 2

1
GEK 97310
VOLUME II
SWP 104 05
high pressure steam manifolds, compressor discharge pressure (CDP) steam manifolds, steam
supply tubes, and fuel/steam nozzles for engines using natural gas with steam injection (STIG).
NOTE
of S.I. units which may not be rounded off are those utilized for
drop checks, rigging adjustments, runouts, etc.

1C8204G01 Coupling Nut Removal/Installation Tool
Hydraulic Jack or Overhead Hoist.

MIL-G-23827 Grease
Commercial Protective Plugs
4. REMOVAL OF HIGH PRESSURE FUEL NOZZLE STEAM MANIFOLD AND

STEAM SUPPLY TUBES. See figure 1.
CAUTION
A HYDRAULIC JACK OR OVERHEAD HOIST SHOULD BE
USED TO SUPPORT STEAM MANIFOLD HALVES. TURN-
BUCKLES WILL BE DAMAGED IF SUPPORTING WEIGHT
OF MANIFOLD ALONE.
a. Remove insulation blankets (1) from area around Detail A by removing safety wire from
insulation blanket capstans.

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GEK 97310
VOLUME II
SWP 104 05
Figure 1. High Pressure Fuel Nozzle Steam Manifold

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GEK 97310
VOLUME II
SWP 104 05
b. Use coupling nut removal/installation tool, 1C8204G01, to break torque on 30 steam sup-
ply tubes (4) by loosening coupling nuts (5 and 6) on steam manifold halves (2 and 3) and fuel/
steam nozzles (7). Do not remove tubes at this time.
c. Remove bolts (11), nuts (12), and washers (13) securing rod ends (14 and 15) to steam
manifold halves (2 and 3) at the 6 o’clock position. Remove rod ends.
d. Remove four bolts (16), nuts (17), and washers (18) securing turnbuckles (19) to
brackets (23 and 35) on steam manifold halves (2 and 3).
e. Remove eight bolts (8), nuts (9), and washers (10) securing steam manifold
halves (2 and 3) together.
f. Remove gasket (26) from the mating flange of the steam manifold halves (2 and 3).
Inspect foil section of gasket for crimping or delamination. Line out existing removal number
marking and mark number of removal on the gasket retainer flange near the outside diameter
using the shallow vibropeen method per GEK 9250, Volume I, Task 70-16-04.
NOTE
Gasket (26) may be used a maximum of five times.
g. Remove steam tubes from manifold half being supported by overhead hoist. Remove
manifold half.
h. Support remaining manifold half. Remove steam tubes. Remove manifold.
i. Remove four bolts (20), nuts (21), and washers (22) securing turnbuckles (19) to
brackets (23 and 35). Remove turnbuckles.
j. Remove bolts (24) and nuts (25) securing brackets (23 and 35) to rear compressor case aft
flange. Remove brackets.
k. Cap or plug all openings.
5. REMOVAL OF COMPRESSOR DISCHARGE PORT (CDP) STEAM MANIFOLDS.
See figure 2.
a. Remove 12 bolts (1), nuts (2), and washers (3) securing each CDP steam manifold
assembly (4) to CDP ports (5). Remove manifold assemblies, brackets (6), and gasket seals (7).
b. Inspect foil section of gaskets (7) for crimping or delamination. Line out existing
removal number marking and mark number of removal on the gasket retainer flange near the
outside diameter using the shallow vibropeen method per GEK 9250, Volume I, Task 70-16-04.
NOTE
Gasket seal (7) may be used a maximum of five times.
c. Cap or plug all openings.

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GEK 97310
VOLUME II
SWP 104 05
Figure 2. Compressor Discharge Port (CDP) Steam Manifold

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GEK 97310
VOLUME II
SWP 104 05
6. REMOVAL OF FUEL/STEAM NOZZLES. See figure 1.
a. Remove fuel supply tubes (28) by loosening coupling nuts (27 and 29) on fuel/steam
nozzles (7) and fuel manifold (30).
b. Remove steam supply tubes (4) by loosening coupling nuts (5 and 6) on steam
manifold halves (2 and 3) and fuel/steam nozzles (7).
CAUTION
REMOVE FUEL/STEAM NOZZLES WITH CARE. ANY
FORCE CAN DAMAGE NOZZLE TIPS.
c. Remove safety wire and bolts (31) from fuel/steam nozzles (7) and remove fuel/steam
nozzles. Remove and discard seal rings (32).
d. Protect flange surfaces of compressor rear frame with plastic caps or locally
manufactured protectors.
e. Cap or plug all openings and fuel/steam nozzle tips with plastic caps or locally
manufactured protectors.
7. INSTALLATION OF FUEL/STEAM NOZZLES. See figure 1.
a. Coat threads of bolts (31) with antiseize compound, A50TF201.
CAUTION
INSERT NOZZLES INTO FRAME WITH CARE. USE OF
FORCE COULD DAMAGE NOZZLE TIPS.
b. Install seal ring (32) and fuel/steam nozzle (7) at each nozzle location and secure with
three bolts (31) each. Tighten bolts to 55-70 lb in. (6.2-7.9 N·m) of torque and safety wire.
c. Apply grease, MIL-G-23837, to threads and seating surfaces of coupling nuts (5 and 6) on
steam supply tubes (4), and to connections on steam manifold halves (2 and 3) and fuel/steam
nozzles (7).
d. Position tubes (4) between manifold halves (2 or 3) and nozzles (7).
e. Connect coupling nuts (5) on tubes (4) to manifold halves (2 or 3) and coupling nuts (6) on
tubes (4) to nozzles (7).
f. Tighten coupling nuts (5 and 6) to 75-91 lb ft (102-123 N·m) of torque.

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GEK 97310
VOLUME II
SWP 104 05
g. Apply grease, MIL-G-23837, to threads and seating surfaces of coupling nuts (27 and 29)
on fuel supply tubes (28) and to connections on fuel/steam nozzles (7) and fuel manifold (30).
h. Position tubes (28) between nozzles (7) and manifold (30).
i. Connect coupling nuts (27) on tubes (28) to nozzles (7) and coupling nuts (29) on tubes
(28) to manifold (30) and coupling nuts (6) to nozzles (7).
j. Tighten coupling nuts (27 and 29) to 75-91 lb ft (102-123 N·m) of torque.
8. INSTALLATION OF HIGH PRESSURE FUEL NOZZLE STEAM MANIFOLD AND

STEAM SUPPLY TUBES. See figure 1.
a. Lubricate threads of 12 bolts (24) with antiseize compound, A50TF201.
NOTE
The four turnbuckle brackets (23 and 35) are mounted on the
forward side of the rear compressor case aft flange by three bolts
each at bolt-hole locations (12, 13, 14), (36, 37, 38), (60, 61, 62),
and, (81, 82, 83).
b. Install two turnbuckle brackets, PN L34859G02 / Alt PN L34753P02 (23) and secure with
bolts (24) and nuts (25). Install two turnbuckle brackets, PN L34859G0l / Alt PN L34753P01
(35) and secure with bolts (24) and nuts (25). Tighten all bolts to 100-130 lb in. (11.3-14.7 N·m)
of torque.
CAUTION
A HYDRAULIC JACK OR OVERHEAD HOIST SHOULD BE
USED TO SUPPORT STEAM MANIFOLD HALVES DURING
INSTALLATION. DAMAGE TO TURNBUCKLES WILL
RESULT, IF MANIFOLD IS SUPPORTED SOLELY BY THE
TURNBUCKLES.
c. Position manifold halves (2 and 3) around engine at approximately the forward

compressor case aft flange position.
d. Apply grease, MIL-G-23827 to threads of all fuel/steam nozzle threaded connectors.
e. Lubricate all the tube connector threads of steam manifold halves (2 and 3) with grease,
MIL-G-23827.

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GEK 97310
VOLUME II
SWP 104 05
NOTE
The 30 steam supply tubes (4) are of two types: L34755G01 and
L34751G01. There are four of L34755G01 located at positions 6, 8,
19, and 20. There are 26 of L34751G01 located at the remaining
positions.
f. Install steam supply tubes L34751G01 (4) to steam manifold halves (2 and 3) at locations
1, 9, 15, 16, 23, and 30. Tighten coupling nuts (5) fingertight.
g. Connect steam supply tubes L34751G01 (4) to fuel/steam nozzles (7), at locations 1, 9,
15, 16, 23, and 30. Tighten coupling nuts (6) fingertight.
CAUTION
A MINIMUM CLEARANCE OF 0.125 INCH (3.18 MM) SHALL
BE MAINTAINED BETWEEN STEAM SUPPLY TUBES (4) OD
AND ADJACENT PARTS. A SLIGHT BENDING OF TUBE (4)
IS PERMITTED TO MAINTAIN CLEARANCE.
h. Install steam supply tubes, L34755G01 (4), to steam manifold halves (2 and 3) at
locations 6, 8, 19, and 20. Tighten coupling nuts (6) fingertight.
i. Connect steam supply tubes L34755G01 (4) to fuel/steam nozzles (7) at locations 6, 8, 19,
and 20. Tighten coupling nuts (6) finger-tight.
j. Connect 20 remaining steam supply tubes, L3475G01 (4) to steam manifold halves
(2 and 3). Tighten coupling nuts (6) finger-tight.
k. Connect 20 remaining steam supply tubes (4) to fuel/steam nozzles (7). Tighten coupling
nuts (6) fingertight.
l. Coat threads of bolts (8) with antiseize compound, A50TF201.
m. Install gasket (26) between flanges of manifold halves (2 and 3) and connect flanges with
bolts (8), nuts (9), and washers (10). Tighten bolts to obtain a gap of approximately 0.020 inch
(0.51 mm) between a flange and the gasket.
n. Coat threads of bolts (11) and rod end (14) with antiseize compound, A50TF201.
o. Adjust rod ends (14 and 15) to a nominal bolthole center-to-center length of 3.00 inches
(76.2 mm). Install rod ends at 6 o’clock position using two bolts (11), nuts (12), and washers
(13). Tighten bolts to 190-230 lb in. (21.4-26 N·m) of torque.
p. Tighten steam manifold flange bolts (8) to 100-130 lb in. (11.3-14.7 N·m) of torque.

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q. Ensure interface flange of steam manifold (3) located at the 12 o’clock position is level, by
placing a level across interface flange of steam manifold.
CAUTION
z THE USE OF COUNTER-TORQUE WHILE TIGHTENING
STEAM SUPPLY TUBES IS CRITICAL TO PART LIFE.
z SHOULD MANIFOLD CLOCK DURING TIGHTENING,
LOOSEN ALL STEAM J-TUBES AND REPOSITION MANI-
FOLD. TRYING TO POSITION MANIFOLD WITH ANY
J-TUBES TIGHTENED CAN RESULT IN STEAM TUBE
FAILURE DURING OPERATION.
r. Tighten coupling nuts (5 and 6) to 75-91 lb ft (102-123 N·m) of torque using tool,
1C8204G01, in a criss-cross pattern, ensuring manifold remains level, by referencing level.
s. Remove hydraulic jack or overhead hoists.
t. Adjust normal bolthole center-to-center length of four turnbuckles (19) to 13.25 inches
(336.6 mm).
u. Coat threads of four bolts (20) and four bolts (16) with antiseize compound, A50TF201.
v. Install four turnbuckles (19) on brackets (23 and 35) and secure with bolts (20), nuts (21),
and washers (22). Tighten bolts to 190-230 lb in. (21.5-26 N·m) of torque.
w. Secure four turnbuckles (19) to steam manifold halves (2 and 3) with bolts (16), nuts (17),
and washers (18). Adjust length of turnbuckles as necessary to install bolts (16). Tighten bolts to
190-230 lb in. (21.5-26 N·m) of torque.
x. Turn each turnbuckle one-half turn outward, taking up play in turnbuckle.
y. Tighten jamnut (33) and four jamnuts (34) to 100-130 lb in. (11.3-14.7 N·m) of torque.
z. Install insulation blanket (1) on steam manifold halves (2 and 3) using safety wire on
insulation blanket capstans.
9. INSTALLATION OF COMPRESSOR DISCHARGE PORT (CDP) STEAM

MANIFOLDS. See figure 2.
a. Coat threads of bolts (1) with antiseize compound, A50TF201.
b. Install gasket seals (7), CDP steam manifold assemblies (4), and angle brackets (6) on
CDP ports (5) and secure with bolts (1), nuts (2), and washers (3). Tighten bolts to 100-130 lb in.
(11.3-14.7 N·m) of torque.

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GEK 97310
VOLUME II
SWP 104 05
10. ALIGNMENT OF GAS FUEL MANIFOLD AND GAS FUEL FEEDER TUBES.
CAUTION
THIS PROCEDURE COVERS ALIGNMENT OF GAS FUEL
MANIFOLD WITH RIGID GAS FUEL FEEDER TUBES ONLY.
FLEXIBLE GAS FUEL FEEDER TUBES ARE NOT
INCLUDED.
NOTE
This procedure is for installed gas manifold systems with no signif-
icant operating experience. Inspection, including fluorescent-pene-
trant-inspection (FPI), of gas fuel feeder tubes may be required,
depending on operational history and alignment results.
a. Prepare gas fuel manifold for inspection as follows:
(1) Visually sight two ends of gas fuel manifold at 1:00 to 2:00 o’clock positions.
(2) Using nipple wrenching flats as guide, measure and record axial difference between
two ends of gas fuel manifold.
(3) Using marking pen, number all gas fuel feeder tubes to aid in reinstallation.
b. Beginning with gas fuel feeder tubes at each end of gas fuel manifold, remove gas fuel
feeder tubes from fuel nozzles and gas fuel manifold. Note and record any displacement of gas
fuel feeder tubes as they are released from fuel nozzles and gas fuel manifold.
c. Disconnect gas fuel manifold from customer interface flexible hose.
d. Loosen all loop clamps on gas fuel manifold.
e. Cut and discard all safety cable or wire from fuel nozzle bolts. Back all bolts out one turn.
f. Unbolt flange joint between gas fuel manifold sections. Remove and discard gasket.
g. Install new gasket between manifold sections. Install bolts into flange joint between sec-
tions. Tighten bolts finger-tight.
h. Position gas fuel manifold on gas generator. Using 1/2-inch to 5/8-inch dowel rods, or
equivalent, maintain concentric alignment of gas fuel manifold to compressor rear frame of gas
generator.

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GEK 97310
VOLUME II
SWP 104 05
i. Install 30 gas fuel feeder tubes onto fuel nozzles and gas fuel manifold nipples as follows:
(1) Install gas fuel feeder tube B-nut on fuel nozzle. Tighten B-nut finger-tight.
(2) While gently wiggling gas fuel feeder tube, install B-nut on gas fuel manifold nipple.
Tighten B-nut finger-tight.
(3) Using crisscross pattern, finger-tighten gas fuel feeder tube B-nuts at fuel nozzles in
groups of three. After snugging, loosen B-nut one flat (60 degrees). Continue until all 30 gas fuel
feeder tube B-nuts have been tightened.
(4) Using crisscross pattern, finger-tighten fuel feeder tube B-nuts at gas fuel manifold in
groups of three. After snugging, loosen B-nut one flat (60 degrees). Continue until all 30 fuel
feeder tube B-nuts have been tightened. Use same sequence as performed in step (3) above.
(5) Tighten all fuel nozzle flange bolts to 55-70 lb in. (6.2-7.9 N·m) of torque and safety-
wire.
(6) Remove positioning dowels from gas fuel manifold. Tighten flange bolts between
manifold sections to 100-130 lb in. (11.3-14.7 N·m) of torque.
(7) Using same sequence as step (3) above, tighten all gas fuel feeder tube B-nuts con-
nected to fuel nozzles to 75-91 lb ft (101.7-123.4 N·m) of torque.
nected to gas fuel manifold nipples to 75-91 lb ft (101.7-123.4 N·m) of torque.
j. Tighten all manifold loop clamp bolts to 33-37 lb in. (3.7-4.2 N·m) of torque.
k. Observe axial alignment of ends of gas fuel manifold.
l. Using 6 bolts, connect gas fuel manifold to customer interface flexible hose. Tighten bolts
per packager’s manual.
m. Perform final check of alignment as follows:
(1) Loosen No. 5 fuel nozzle gas fuel feeder tube B-nut at fuel manifold nipple.
(2) Observe gas fuel feeder for evidence of excessive installation preload.
(3) Retighten gas fuel feeder tube B-nut to fuel manifold nipple. Tighten B-nut to
75-91 lb ft (101.7-123.4 N·m) of torque.

11/(12 Blank)
GEK 97310
VOLUME II
SWP 104 06
REMOVAL/INSTALLATION OF NOX MANIFOLD HP

RECOUP STEAM AUGMENTATION KIT

1 - 10 . . . . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Installation of Left Side NoX HP Recoup Steam Augmentation Kit . . . . . . . . . . . . . . . . . . 9

Installation of Right Side Nox HP Recoup Steam Augmentation Kit. . . . . . . . . . . . . . . . . . 8
Removal of Left Side NoX HP Recoup Steam Augmentation Kit . . . . . . . . . . . . . . . . . . . . 2
Removal of Right Side Nox HP Recoup Steam Augmentation Kit . . . . . . . . . . . . . . . . . . . 7

1
GEK 97310
VOLUME II
SWP 104 06
installation of the HP Recoup System Steam Augmentation Kit, 682L457G01 on LM2500
Engines with gas fuel and steam injection.
NOTE
lized for temperatures, torque values, pressures, etc. Examples of
S.I. units which may not be rounded off are those utilized for drop
None
3. CONSUMABLE MATERIALS..

MIL-G-23827 Grease
4. REMOVAL OF LEFT SIDE NOX HP RECOUP STEAM AUGMENTATION KIT.

See figure 1.
a. Under the engine left side, remove nut, bolt, washer, and loop clamp (8, 6, 7, and 9)
securing the steam bleed tube (10) to bracket (3).
NOTE
Countertorque should be applied when loosening tube fittings and
manifold connections to avoid damage to the thin wall manifold
and tubes.
b. Disconnect the steam tube (10) from the swivel tee (11 and 13), at each end of the tube,
and remove the tube. Install protective plugs in each end of the tube.
c. Disconnect instrumentation line (if used) or tube cap (27) from the strut 6 forward HP
recoup air manifold (1) pressure port. Install protective cap on pressure port, and plug in instru-
mentation line (if used).

2
GEK 97310
VOLUME II
SWP 104 06
Figure 1. Steam Augmented HP Recoup System Kit, 682L457 (Sheet 1 of 4)

3
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VOLUME II
SWP 104 06

4
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d. Disconnect the swivel tees (11 and 13) from the steam manifold assembly (4) and the strut
6 forward HP recoup air manifold (1). Install protective caps and plugs in the swivel tees and
caps on the open fittings on the steam manifold and recoup air manifold.
e. Remove the nuts, bolts, and washers (22, 20, and 21) securing the flanges of the strut 6
forward and aft HP recoup air manifolds (1 and 26). Retain all hardware except
O-ring gaskets (24).
f. Remove the nuts, bolts, and washers (17, 15, and 16) securing the flange of the strut 6
forward HP recoup air manifold (1) to the strut 6 pad on the compressor rear frame (CRF).
Remove the recoup air manifold, retaining all hardware except the O-ring gasket (19). Install pro-
tective plugs in all openings.
5. REMOVAL OF RIGHT SIDE NOX HP RECOUP STEAM AUGMENTATION KIT.

See figure 1.
a. Under the engine right side, remove nut, bolt, washer, and loop clamp (30, 28, 29, and 31)
securing the steam bleed tube (32) to bracket (3).
NOTE
Countertorque should be applied when loosening tube fittings and
manifold connections to avoid damage to the thin wall manifold
and tubes.
b. Disconnect the steam tube (32) from the swivel tee (33 and 35), at each end of the tube,
and remove the tube. Install protective plugs in each end of the tube.
c. Disconnect instrumentation line (if used) or tube cap (49) from the strut 5 forward HP
recoup air manifold (2) pressure port. Install protective cap on pressure port, and plug in instru-
mentation line (if used).
d. Disconnect the swivel tees (33 and 35) from the steam manifold assembly (5) and the strut
5 forward HP recoup air manifold (2). Install protective caps and plugs in the swivel tees and
caps on the open fittings on the steam manifold and recoup air manifold.
e. Remove the nuts, bolts, and washers (39, 37, and 38) securing the flanges of the strut 5
forward and aft HP recoup air manifolds (2 and 40). Retain all hardware except O-ring gaskets
(42).
f. Remove the nuts, bolts, and washers (46, 44, and 45) securing the flange of the strut 5 for-
ward HP recoup air manifold (2) to the strut 5 pad on the CRF. Remove the recoup air manifold
(2) retaining all hardware except the O-ring gasket (48). Install protective plugs in all openings.

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GEK 97310
VOLUME II
SWP 104 06
6. INSTALLATION OF RIGHT SIDE NOX HP RECOUP STEAM AUGMENTATION
KIT. See figure 1.
a. Coat threads of four bolts (44) with antiseize compound, A50TF201.
b. Position the seal retainer (47) and new O-ring gasket (48) on the forward flange of the
strut 5 forward recoup air manifold (2), and hold in place using a bolt and washer (44 and 45)
installed through the flange.
c. Put the forward flange of the air manifold in position on the CRF strut 5 pad, and secure
using four bolts, washers, and nuts (44, 45, and 46). Tighten fingertight.
d. Coat threads of four bolts (37) with antiseize compound, A50TF201.
e. Position two seal retainers (41), two new O-ring gaskets (42), and metering spacer (43) on
the aft flange of the strut 5 forward recoup air manifold, and hold in place using a bolt and washer
(37 and 38) installed through the flange.
f. Position the aft flange of the strut 5 forward recoup air manifold on the strut 5 aft recoup
air manifold forward flange, and secure using four bolts, washers, and nuts (37, 38, and 39)
tightened fingertight.
g. Lubricate the tube connector threads of two swivel tees (33 and 35) using grease,
MIL-G-23827.
h. Install swivel tee (33) on the tube fitting of the strut 5 forward recoup air manifold (next to
the forward/aft recoup air manifold interface) and tighten fingertight.
i. Install swivel tee (35) on the tube fitting of the steam manifold assembly (5) and tighten
fingertight.
j. Lubricate the tube connector threads of the strut 5 forward steam bleed tube (32) using
k. Install the steam bleed tube (32) to the two swivel tees (33 and 35) and tighten tube fittings
fingertight.
l. Coat the threads of bolt (28) with antiseize compound, A50TF201. Install loop clamp (31)
around the steam bleed tube (32) and secure to bracket (3) using bolt, washer, and nut (28, 29, and
30). Tighten fingertight.
m. Adjust the alignment of tubes (2 and 32) and brackets for optimum position.
n. Tighten nut (30) to 55-70 lb in. (6.2-7.9 N·m) of torque.

8
GEK 97310
VOLUME II
SWP 104 06
o. Tighten nuts (39 and 46) to 55-70 lb in. (6.2-7.9 N·m) of torque.
NOTE
Countertorque should be applied when tightening tube fittings to
avoid misalignment and preloading of tubes and manifold.
p. Tighten coupling nut on swivel tee (35), at the steam manifold, to 900 lb in. (101.6 N·m)
of torque.
q. Tighten coupling nut on swivel tee (33), at the recoup air manifold, to 900 lb in.
(101.6 N·m) of torque.
r. Tighten the coupling nut on each end of the steam bleed tube (32) to 900 lb in.
s. Lubricate the threads of two tube caps (34 and 36) using grease, MIL-G-23827, and install
on the open end of each swivel tee. Tighten the tube caps to 900 lb in. (101.6 N·m) of torque.
t. Lubricate the threads of instrumentation line coupling nut (if used), or tube cap (49) using
grease, MIL-G-23827, and install on the pressure port on the recoup air manifold (2). Tighten the
coupling nut or tube cap to 270 lb in. (30.5 N·m) of torque.
7. INSTALLATION OF LEFT SIDE NOX HP RECOUP STEAM AUGMENTATION

KIT. See figure 1.
strut 6 forward recoup air manifold (1), and hold in place using a bolt and washer (15 and 16)
c. Put the forward flange of the manifold in position on the CRF strut 6 pad, and secure using
four bolts, washers, and nuts (15, 16, and 17) tightened fingertight.
f. Position the aft flange of the strut 6 forward recoup air manifold (1) in position on the aft
strut 6 recoup air manifold forward flange, and secure using four bolts, washers, and nuts
(20, 21, and 22) tightened fingertight.

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VOLUME II
SWP 104 06
g. Lubricate the tube connector threads of two swivel tees (11 and 13) using grease,
MIL-G-23827.
h. Install swivel tee (11) on the tube fitting of the strut 6 forward recoup air manifold (1) and
tighten fingertight.
i. Install swivel tee (13) on the tube fitting of the steam manifold assembly (4) and tighten
fingertight.
j. Lubricate the tube connector threads of the strut 6 forward steam bleed tube (10) using
k. Install the steam bleed tube (10) to the two swivel tees (11 and 13) and tighten tube fittings
fingertight.
l. Coat the threads of bolt (6) with antiseize compound, A50TF201. Install loop clamp (9)
around the steam bleed tube (10) and secure to bracket (3) using bolt, washer, and nut
(6, 7, and 8).
m. Adjust the alignment of tubes (1 and 10) and brackets for optimum position.
n. Tighten nut (8) to 55-70 lb in. (6.2-7.9 N·m) of torque.
o. Tighten nuts (17) to 100-130 1b in. (11.3-14.7 N·m) of torque.
p. Tighten nuts (22) to 55-70 lb in. (6.2-7.9 N·m) of torque.
NOTE
avoid misalignment and preloading of tubes and manifold.
q. Tighten coupling nut on swivel tee (13), at the steam manifold, to 900 lb in. (101.6 N·m)
of torque.
r. Tighten coupling nut on swivel tee (11), at the recoup air manifold to 900 lb in.
s. Tighten the coupling nut on each end of the steam bleed tube (1) to 900 lb in. (101.6 N·m)
of torque.
t. Lubricate the threads of two tube caps (12 and 14) using grease, MIL-G-23827, and install
on the open end of each swivel tee. Tighten the tube caps to 900 lb in. (101.6 N·m) of torque.
u. Lubricate the threads of instrumentation tube coupling nut (if used), or tube cap (27) using
grease, MIL-G-23827, and install on the pressure port on the recoup air manifold (1). Tighten the
tube cap to 270 lb in. (30.5 N·m) of torque.

10
GEK 97310
VOLUME II
SWP 104 07
REMOVAL AND INSTALLATION OF CDP HP

RECOUP SYSTEM STEAM AUGMENTATION KIT
EFFECTIVITY: LM2500 ENGINES WITH CDP STEAM INJECTION

1 - 10 . . . . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Installation of Left Side CDP HP Recoup Steam Augmentation Kit . . . . . . . . . . . . . . . . . . 9

Installation of Right Side CDP HP Recoup Steam Augmentation Kit . . . . . . . . . . . . . . . . . 7
Removal of Left Side CDP HP Recoup Steam Augmentation Kit . . . . . . . . . . . . . . . . . . . . 2
Removal of Right Side CDP HP Recoup Steam Augmentation Kit . . . . . . . . . . . . . . . . . . . 7

1
GEK 97310
VOLUME II
SWP 104 07
installation of the CDP HP Recoup System Steam Augmentation Kit, 682L457G02 on LM2500
Engines with steam injection.
NOTE
lized for temperatures, torque values, pressures, etc. Examples of
S.I. units which may not be rounded off are those utilized for drop
None

GE Spec A50TF201 Antiseize Compound
MIL-G-23827 Grease
4. REMOVAL OF LEFT SIDE CDP HP RECOUP STEAM AUGMENTATION KIT.

See figure 1.
a. Under the engine left side, remove nut, bolt, washer, and loop clamp (9, 7, 8, and 10)
securing the strut 6 forward steam bleed tube (11) to bracket (3).
b. Disconnect the steam tube (11) from the swivel tee (12), at the strut 6 forward HP recoup
air manifold (2) and the fitting on the left side CDP steam manifold (4). Remove the tube. Install
protective plugs in each end of the tube.
c. Disconnect the instrumentation line (if used) or tube cap (26) from the strut 6 forward HP
recoup air manifold (2). Install a protective plug in the instrumentation line (if used).
d. Disconnect the swivel tee (12) from the recoup air manifold (2). Install protective caps
and plugs in the open fittings of the swivel tee, CDP manifold, and recoup air manifold.

2
GEK 97310
VOLUME II
SWP 104 07
Figure 1. Steam Augmented CDP HP Recoup System Kit, 682L457G02 (Sheet 1 of 4)

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SWP 104 07

4
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SWP 104 07

5
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SWP 104 07
e. Remove the nuts, bolts, and washers (21, 19, and 20) securing the flanges of the forward
and aft strut 6 HP recoup air manifolds (2 and 25). Retain all hardware except O-ring
gaskets (23).
f. Remove the nuts, bolts, and washers (16, 14, and 15) securing the flange of the forward
strut 6 HP recoup air manifold (2) to the strut 6 pad on the CRF. Remove the recoup air manifold,
retaining all hardware except the O-ring gasket (18). Install protective plugs in all openings.
5. REMOVAL OF RIGHT SIDE CDP HP RECOUP STEAM AUGMENTATION KIT.

See figure 1.
a. Under the engine right side, remove nut, bolt, washer, and loop clamp (29, 27, 28, and 30)
securing the forward strut 5 steam bleed tube (31) to bracket (6).
b. Disconnect the steam tube (31) from the swivel tee (32), at the strut 5 forward HP recoup
air manifold (1), and the fitting on the right side CDP steam manifold (5). Install protective plugs
in each end of the tube.
c. Disconnect the instrumentation line (if used) or tube cap (46) from the strut 5 forward HP
recoup air manifold (1). Install a protective plug in instrumentation line (if used).
d. Disconnect the swivel tee (32) from the strut 5 forward HP recoup air manifold (1). Install
protective caps and plugs in the open fittings on the swivel tee, CDP steam manifold, and recoup
air manifold.
e. Remove the nuts, bolts, and washers (36, 34, and 35) securing the flanges of the forward
and aft strut 5 HP recoup air manifolds (1 and 37). Retain all hardware except O-ring
gaskets (39).
f. Remove the nuts, bolts, and washers (43, 41, and 42) securing the flange of the forward
strut 5 HP recoup air manifold (1) to the strut 5 pad on the CRF. Remove the recoup air
manifold (1) retaining all hardware except the O-ring gasket (45). Install protective plugs in all
openings.
6. INSTALLATION OF RIGHT SIDE CDP HP RECOUP STEAM AUGMENTATION

KIT. See figure 1.
strut 5 forward recoup air manifold (1) and hold in place using a bolt and washer (41 and 42)

7
GEK 97310
VOLUME II
SWP 104 07
c. Put the forward flange of the air manifold in position on the CRF strut 5 pad, and secure
using four bolts, washers, and nuts (41, 42, and 43) tightened fingertight.
f. Position the aft flange of the strut 5 forward recoup air manifold on the strut 5 aft recoup
air manifold forward flange and secure using four bolts, washers, and nuts (34, 35, and 36) tight-
ened fingertight.
g. Lubricate the tube connector threads of the swivel tee (32) using grease, MIL-G-23827.
h. Install swivel tee (32) on the tube fitting of the strut 5 forward recoup air manifold (next to
the forward/aft recoup air manifold interface) and tighten fingertight.
i. Lubricate the tube connector threads of the strut 5 forward steam bleed tube (31) using
j. Install the steam bleed tube (31) to the swivel tee (32) on the recoup air manifold and the
fitting on the CDP steam manifold (5). Tighten tube fittings fingertight.
k. Coat the threads of bolt (27) with antiseize compound, A50TF201. Install loop
clamp (30) around the steam bleed tube (31) and secure to bracket (6) using bolt, washer, and nut
(27, 28, and 29). Tighten nut fingertight.
l. Adjust the alignment of tubes (1 and 31) for optimum position.
m. Tighten nut (29) to 55-70 lb in. (6.2-7.9 N·m) of torque.
n. Tighten nuts (36 and 43) to 55-70 lb in. (6.2-7.9 N·m) of torque.
NOTE
avoid misalignment of tubes.
o. Tighten coupling nut on swivel tee (32) at the recoup air manifold, to 900 lb in.
p. Tighten the coupling nut on swivel tee end of the steam bleed tube (31) to 900 lb in.
(101.6 N·m) of torque. Tighten the coupling nut on the steam manifold assembly end of the steam
bleed tube to 450 lb in. (50.8 N·m) of torque.

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GEK 97310
VOLUME II
SWP 104 07
q. Lubricate the threads of tube cap (33) using grease, MIL-G-23827 and install on the open
end of the swivel tee. Tighten the tube cap to 900 lb in. (101.6 N·m) of torque.
r. Lubricate the threads of instrumentation line coupling nut (if used), or tube cap (46) using
grease, MIL-G-23827 and install on the pressure port on the recoup air manifold (1). Tighten the
coupling nut or tube cap to 270 lb in. (30.5 N·m) of torque.
7. INSTALLATION OF LEFT SIDE CDP HP RECOUP STEAM AUGMENTATION

KIT. See figure 1.
b. Position the seal retainer (17) and new O-ring gasket (18) on the forward flange of the for-
ward strut 6 recoup air manifold (2). Hold in place using a bolt and washer (14 and 15) installed
through the flange.
c. Put the forward flange of the manifold in position on the CRF strut 6 pad, and secure using
four bolts, washers, and nuts (14, 15, and 16) tightened fingertight.
the aft flange of the forward strut 6 recoup air manifold, and hold in place using a bolt and washer
f. Position the aft flange of the forward strut 6 recoup air manifold (2) in position on the aft
strut 6 recoup air manifold forward flange, and secure using four bolts, washers, and nuts
(19, 20, and 21) tightened fingertight.
g. Lubricate the tube connector threads of swivel tee (12) using grease, MIL-G-23827.
h. Install swivel tee (12) on the tube fitting of the recoup air manifold (2) and tighten
fingertight.
i. Lubricate the tube connector threads of the forward strut 6 steam bleed tube (11) using
j. Install the steam bleed tube (11) to the swivel tee (12) on the recoup air manifold, and the
fitting on the CDP steam manifold (4). Tighten tube fittings fingertight.
k. Coat the threads of bolt (7) with antiseize compound, A50TF201. Install loop clamp (10)
around the steam bleed tube (11) and secure to bracket (3) using bolt, washer, and nut
(7, 8, and 9). Tighten the nut fingertight.

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l. Adjust the alignment of tubes (2 and 11) for optimum position.
m. Tighten nut (9) to 55-70 lb in. (6.2-7.9 N·m) of torque.
n. Tighten nuts (16) to 100-130 lb in. (11.3-14.7 N·m) of torque.
o. Tighten nuts (21) to 55-70 lb in. (6.2-7.9 N·m) of torque.
NOTE
avoid misalignment and preload of tubes and manifold.
p. Tighten coupling nut on swivel tee (12) at the recoup air manifold, to 900 lb in.
q. Tighten the coupling nut on the swivel tee end of the steam bleed tube (11) to 900 lb in.
(101.6 N·m) of torque. Tighten the coupling nut on the steam manifold assembly end of the steam
bleed tube to 450 lb in. (50.8 N·m) of torque.
r. Lubricate the threads of tube cap (13) using grease, MIL-G-23827 and install on the open
end of each swivel tee. Tighten the tube cap to 900 lb in. (101.6 N·m) of torque.
s. Lubricate the threads of the instrumentation line coupling nut (if used), or tube cap (26)
using grease, MIL-G-23827 and install on the pressure port on the recoup air manifold (2).
Tighten the tube cap to 270 lb in. (30.5 N·m) of torque.

10
GEK 97310
VOLUME II
SWP 104 08
REPLACEMENT OF STEAM MANIFOLDS, STEAM

SUPPLY TUBES, AND FUEL NOZZLES (DUAL FUEL
WITH STEAM INJECTION)
EFFECTIVITY: LM2500 – PE-MDS & PE-MDA MODELS

1 - 12 . . . . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Compressor Discharge Port (CDP) Steam Manifolds Installation (PE-MDA Model) . . . . . 10

Compressor Discharge Port (CDP) Steam Manifolds Removal (PE-MDA Model) . . . . . . . 5
Fuel Nozzles Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fuel Nozzles Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Gas Fuel Manifold and Gas Fuel Feeder Tubes Alignment . . . . . . . . . . . . . . . . . . . . . . . . . 11
High Pressure Steam Manifold and Steam Supply Tubes Installation. . . . . . . . . . . . . . . . . . 8
High Pressure Steam Manifold and Steam Supply Tubes Removal . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
SWP 104 08
high pressure steam manifolds, compressor discharge pressure (CDP) steam manifolds, steam
supply tubes, fuel feeder tubes, and fuel nozzles for engines using dual fuel with steam
injection (STIG).
2. SUPPORT EQUIPMENT REQUIRED.

1C8204G01 Wrench Set - Steam Tube
2C6081G05 Wrench Set

MIL-G-23827 Grease
736L680G01 Safety Cable
R297P04 (Alt.) Safety Wire
4. HIGH PRESSURE STEAM MANIFOLD AND STEAM SUPPLY TUBES REMOVAL.

See figure 1.
a. Disconnect steam supply at customer interface flange per packagers manual.
b. Remove insulation blankets (1) from steam manifold halves (2 and 3) by removing safety
wire from insulation blanket capstans.
c. Using wrench set - steam tube tool, 1C8204, remove 30 steam supply tubes (4) by
loosening coupling nuts (5 and 6) on steam manifold halves (2 and 3) and fuel nozzles
(7, Section J-J).
d. Remove bolts (8, Detail B), nuts (9), and washers (10) that secure rod ends (11 and 12)
onto steam manifold halves (2 and 3) at 6:00 or 12:00 o’clock position, Detail B. Remove rod
ends.

2
GEK 97310
VOLUME II
SWP 104 08
Figure 1. High Pressure Steam Manifold (Sheet 1 of 2)

3
GEK 97310
VOLUME II
SWP 104 08
Figure 1. High Pressure Steam Manifold (Sheet 2 of 2)
WARNING
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES
TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE
PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN
CAUSE AN INJURY OR DEATH.
NOTE
A hydraulic jack or overhead hoist shall be used to support steam
manifold halves while removing turnbuckles.
e. Remove four bolts (13, Detail C), nuts (14), and washers (15) that secure turnbuckles (16)
to brackets (17 and 18) at steam manifold halves (2 and 3).
f. Remove eight bolts (19, Detail A), nuts (20), and washers (21) that secure steam manifold
halves (2 and 3) together and remove manifold halves.

4
GEK 97310
VOLUME II
SWP 104 08
NOTE
Gasket may be used a maximum of five times.
g. Remove gasket (22) from the mating flange of steam manifold halves (2 and 3). Inspect
foil section of gasket for crimping or delamination. Using shallow vibropeen method per
GEK 9250, Volume I, Task 70-16-04, line out existing removal number marking and mark num-
ber of removal on the gasket retainer flange near outside diameter.
h. Remove four bolts (23, Section J-J), nuts (24), and washers (25) that secure turn
buckles (16) onto brackets (17 and 18). Remove turnbuckles.
i. Remove bolts (26) and nuts (27) that secure brackets (17 and 18) onto rear compressor
case aft flange. Remove brackets.
j. Cap or plug all openings.
5. COMPRESSOR DISCHARGE PORT (CDP) STEAM MANIFOLDS REMOVAL

(PE-MDA MODEL). See figure 2.
a. Remove 12 bolts (1), nuts (2), and washers (3) that secure each CDP steam manifold
assembly (4) to CDP ports (5). Remove manifold assemblies, angle brackets (6), and gasket
seals (7).
NOTE
Gasket seal may be used a maximum of five times.
b. Inspect foil section of gaskets (7) for crimping or delamination. Line out existing removal
number marking and mark number of removal on gasket retainer flange near outside diameter
using shallow vibropeen method per GEK 9250, Volume I, Task 70-16-04.
c. Cap or plug all openings.
6. FUEL NOZZLES REMOVAL. See figure 1.
a. Remove gas supply tube (28, Section J-J) by loosening coupling nuts (29 and 30) on fuel
nozzle (7) and fuel manifold (31).
b. Remove steam supply tube (4) by loosening coupling nuts (5 and 6) on steam on manifold
halves (2 and 3) and fuel nozzle (7).

5
GEK 97310
VOLUME II
SWP 104 08
Figure 2. Compressor Discharge Port (CDP) Steam Manifold

6
GEK 97310
VOLUME II
SWP 104 08
CAUTION
REMOVE FUEL NOZZLES WITH CARE. ANY FORCE CAN
DAMAGE NOZZLE TIPS.
c. Using wrench set, 2C6081, disconnect secondary and primary fuel feeder
tubes (32 and 33) connectors (34 and 35) from fuel nozzle (7).
d. Remove safety wire and bolts (36) that secure fuel nozzle (7) to compressor rear frame.
Remove and discard seal ring (37).
e. Protect flange surface of compressor rear frame with plastic caps or locally manufactured
protectors.
f. Cap or plug all openings and fuel nozzle tips with plastic caps or locally manufactured
protectors.
g. Repeat steps a through f, as required, to remove remaining fuel nozzles (7).
7. FUEL NOZZLES INSTALLATION. See figure 1.
a. Remove all protective covers, plug, and caps as required to install fuel nozzle (7).
b. Coat threads of bolts (36) with antiseize compound.
CAUTION
INSERT NOZZLES INTO COMPRESSOR REAR FRAME WITH
CARE. USE OF FORCE COULD DAMAGE NOZZLE TIPS.
c. Install seal ring (37) and fuel nozzle (7) onto compressor rear frame and secure with three
bolts (36). Tighten bolts to 55-70 lb in. (6.2-7.9 N·m) of torque and safety wire.
d. Connect secondary and primary fuel feeder tubes (32 and 33) connectors (34 and 35) to
fuel nozzle (7). Tighten tube connectors (34 and 35) to 160-180 lb in. (18.08-20.34 N·m).
e. Connect steam supply tube (4) to fuel nozzle (7). Tighten coupling nuts (5 and 6) to
75-91 lb ft (102-123 N·m) of torque.

7
GEK 97310
VOLUME II
SWP 104 08
NOTE
The 30 fuel supply tubes (28) are of three types PN L34868,
L34732, and L34732 or L46301. There are four fuel supply tubes,
PN L34868, located at fuel manifold positions 10, 11, 12, and 13,
aft looking forward and five fuel supply tubes, PN L34732 located
at fuel manifold positions 6, 8, 15, 19, and 23, aft looking forward.
There are 21 fuel supply tubes, PN L34732 or L46301 located at the
remaining positions.
f. Connect gas supply tube (28) to fuel nozzle (7). Tighten coupling nuts (29 and 30) to
75-91 lb ft (103-123 N·m ) of torque.
g. Repeat steps a through f, as required, to install remaining fuel nozzles (7).
8. HIGH PRESSURE STEAM MANIFOLD AND STEAM SUPPLY TUBES

INSTALLATION. See figure 1.
a. Lubricate threads of 12 bolts (26) with antiseize compound.
b. Install two turnbuckle brackets (17) onto the forward side of rear compressor case aft
flange at hole locations (36, 37, 38) and (81, 82, 83) and secure with bolts (26) and nuts (27).
Install two turnbuckle brackets (18) onto the forward side of rear compressor case aft flange at
hole locations (12, 13, 14) and (60, 61, 62) and secure with bolts (26) and nuts (27). Tighten nuts
to 100-130 lb in. (11.3-14.7 N·m) of torque.
WARNING
NOTE
A hydraulic jack or overhead hoist shall be used to support steam
manifold halves during installation.
c. Position manifold halves (2 and 3) around engine at approximately forward compressor

case aft flange position. Ensure that manifold is concentric with engine casing and that interface
flange is level in all directions.
d. Coat threads of bolts (19) with antiseize compound.

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VOLUME II
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e. Install gasket (22, Detail A) between flanges of manifold halves (2 and 3) and connect
flanges with bolts (19), nuts (20), and washers (21). Tighten bolts (19) to obtain a gap of
approximately 0.020 inch (0.51 mm) between flange and gasket. Do not torque at this time.
f. Coat threads of bolts (8, Detail B) and rod end (11) with antiseize compound.
g. Adjust rod ends (11 and 12) to nominal bolthole center-to-center length of 3.00 inches
(76.2 mm). Install rod ends at 6:00 o’clock position and secure with two bolts (8), nuts (9), and
washers (10). Tighten bolts to 190-230 lb in. (21.4-26 N·m) of torque.
h. Tighten steam manifold flange bolts (19) to 100-130 lb in. (11.3-14.7 N·m) of torque.
i. Apply grease to threads of all fuel nozzle threaded connectors.
j. Lubricate all tube connector threads of steam manifold halves (2 and 3) with grease.
NOTE
The 30 steam supply tubes (4) are of two types PN L34755 and
L34751. There are four steam supply tubes, PN L34755, located at
fuel nozzles positions 6, 8, 19, and 20 aft looking forward. There
are 26 steam supply tubes, PN L34751, located at the remaining
positions.
k. Connect steam supply tubes (4) onto steam manifold halves (2 and 3) at locations 1, 9, 15,
16, 23, and 30. Tighten coupling nuts (5) finger-tight.
l. Connect steam supply tubes (4) to fuel nozzles (7) at locations 1, 9, 15, 16, 23, and 30.
Tighten coupling nuts (6) finger-tight.
CAUTION
MINIMUM CLEARANCE OF 0.125 INCH (93.18 MM) SHALL
BE MAINTAINED BETWEEN STEAM SUPPLY TUBES (4) OD
AND ADJACENT PARTS. A SLIGHT BENDING OF TUBE (4)
IS PERMITTED TO MAINTAIN CLEARANCE.
m. Connect steam supply tubes (4) to steam manifold halves (2 and 3) at locations 6, 8, 19,
and 20. Tighten coupling nuts (6) finger-tight.
n. Connect steam supply tube (4) to fuel nozzles (7) at locations 6, 8, 19, and 20. Tighten
coupling nuts (6) finger-tight.
o. Connect 20 remaining steam supply tubes (4) to steam manifold halves (2 and 3). Tighten
coupling nuts (6) finger-tight.

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VOLUME II
SWP 104 08
p. Connect 20 remaining steam supply tubes (4) to fuel nozzles (7). Tighten coupling
nuts (6) finger-tight.
q. Ensure interface flange of steam manifold (3), located at the 6:00 or 12:00 o’clock
position, is level.
r. Adjust normal bolthole center-to-center length of four turnbuckles (16) to 13.25 inches
(336.6 mm).
s. Coat threads of four bolts (23) and four bolts (13) with antiseize compound.
t. Install four turnbuckles (16) onto brackets (17 and 18) and secure with bolts (23),
nuts (24), and washers (25). Tighten nuts to 190-230 lb in. (21.5-26 N·m) of torque.
u. Secure four turnbuckles (16) to steam manifold halves (2 and 3) with bolts (13), nuts (14),
and washers (15). Adjust length of turnbuckles as necessary to install bolts (13). Tighten nuts to
190-230 lb in. (21.5-26.0 N·m) of torque.
v. Remove hydraulic jack or overhead hoists.
CAUTION
THE USE OF COUNTER-TORQUE WHILE TIGHTENING
STEAM SUPPLY TUBES IS CRITICAL TO PART LIFE.
w. Using tool, 1C8204, in a criss-cross pattern, tighten coupling nuts (5 and 6) to 75-91 lb ft
x. Tighten four jamnut (38) and jamnut (39) to 100-130 lb in. (11.3-14.7 N·m) of torque.
y. Install insulation blanket (1) onto steam manifold halves (2 and 3) and secure with safety
wire on insulation blanket capstans.
9. COMPRESSOR DISCHARGE PORT (CDP) STEAM MANIFOLDS INSTALLATION

(PE-MDA MODEL). See figure 2.
a. Coat threads of bolts (1) with antiseize compound.
b. Install gasket seals (7), CDP steam manifold assemblies (4), and angle brackets (6) onto
CDP ports (5) and secure with bolts (1), nuts (2), and washers (3). Tighten nuts to 100-130 lb in.
(11.3-14.7 N·m) of torque.

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VOLUME II
SWP 104 08
10. GAS FUEL MANIFOLD AND GAS FUEL FEEDER TUBES ALIGNMENT.
CAUTION
INCLUDED.
NOTE
generator.

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GEK 97310
VOLUME II
SWP 104 08
(5) Tighten all fuel nozzle flange bolts to 55-70 lb in. (6.2-7.9 N·m) of torque and
safety-wire.
(7) Using same sequence as step (3) above, tighten all gas fuel feeder tube B-nuts
connected to fuel nozzles to 75-91 lb ft (101.7-123.4 N·m) of torque.
(8) Using same sequence as step (4) above, tighten all gas fuel feeder tube B-nuts
connected to gas fuel manifold nipples to 75-91 lb ft (101.7-123.4 N·m) of torque.
l. Using 6 bolts, connect gas fuel manifold to customer interface flexible hose. Tighten bolts
per packager’s manual.
75-91 lb ft (101.7-123.4 N·m) of torque.

12
GEK 97310
VOLUME II
SWP 104 09
REPLACEMENT OF FUEL NOZZLES

(DUAL FUEL WITH STEAM INJECTION)
EFFECTIVITY: LM2500 - PE-MDS & PE-MDA MODELS

1-4.......... 0
ALPHABETICAL INDEX
Subject Page
Fuel Nozzle Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Fuel Nozzle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
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SWP 104 09
the fuel nozzle. Prior to performing the tasks described herein, remove all external tubing and
electrical leads, as required to gain access to the fuel nozzles, per WP 117 00.
2. SUPPORT EQUIPMENT REQUIRED.

2C6081G05 Wrench Set

MIL-G-23827 Grease
736L680G01 Safety Cable
R297P04 (Alt.) Safety Wire
4. FUEL NOZZLE REMOVAL. See figure 1.
CAUTION
REMOVE FUEL NOZZLES WITH CARE. ANY FORCE CAN
DAMAGE NOZZLE TIPS.
NOTE
required per WP 117 00.
lent wrench to perform the task specified.
z Mark location of fuel and steam supply tubes before removal to
ensure proper location during installation.
a. Disconnect fuel supply tube (1) by loosening coupling nut (2) on fuel nozzle (3).
b. Disconnect steam supply tube (4) by loosening coupling nut (5) on fuel nozzle (3).
c. Using wrench set, 2C6081, disconnect secondary and primary fuel feeder tubes (6 and 7)
connectors (8 and 9) from fuel nozzle (3).

2
GEK 97310
VOLUME II
SWP 104 09
Figure 1. Fuel Nozzles

3
GEK 97310
VOLUME II
SWP 104 09
d. Remove safety wire and three bolts (10) from fuel nozzle (3) and remove fuel nozzle.
Remove and discard seal ring (11).
e. Cap or plug all openings with plastic caps or locally manufactured protectors.
f. Repeat steps a through e, as required, to remove remaining fuel nozzles (3).
5. FUEL NOZZLE INSTALLATION. See figure 1.
NOTE
z After installation of the fuel nozzles, reinstall any external pip-
ing, clamps, and electrical leads previously removed per
WP 117 00.
lent wrench to perform the task specified.
a. Remove all protective covers, plug, and caps as required to install fuel nozzle (3).
b. Coat threads of bolts (10) with antiseize compound.
CAUTION
INSERT NOZZLES INTO FRAME WITH CARE. USE OF
FORCE COULD DAMAGE NOZZLE TIPS.
c. Install seal ring (11) and fuel nozzle (3) at each nozzle location and secure with three
bolts (10). Tighten bolts to 55-70 lb in. (6.2-7.9 N·m) of torque and safety-wire.
d. Lubricate fuel feeder tube connectors (8 and 9), coupling nut (5), and coupling nut (2)
with grease.
e. Connect secondary and primary fuel feeder tubes (6 and 7) connectors (8 and 9) to fuel
nozzle (3). Tighten tube connectors (8 and 9) to 160-180 lb in. (18.08-20.34 N·m) of torque.
f. Connect steam supply tube (4) to fuel nozzle (3). Tighten coupling nut (5) to 75-91 lb ft
g. Connect fuel supply tube (1) to fuel nozzle (3). Tighten coupling nut (2) to 75-91 lb ft
h. Repeat steps a through g, as required, to install remaining nozzles (3).

4
GEK 97310
VOLUME II
WP 105 00
WORK PACKAGE
REPLACEMENT OF LUBE AND SCAVENGE PUMP
EFFECTIVITY: LM2500 GAS GENERATOR MODELS - ALL (Except GA101)

1-6.......... 0
ALPHABETICAL INDEX
Subject Page
Installation of Lube and Scavenge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Removal of Lube and Scavenge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
WP 105 00
the lube and scavenge pump. The V-band clamp used to mount the pump must be installed per
Chapter 5 of Volume I. After installation, the pump must be purged of air and leak-checked per
Chapter 4 of Volume I.
NOTE
None

MIL-L-23699 Oil, Lubricating
Safety Wire
4. REMOVAL OF LUBE AND SCAVENGE PUMP. See figure 1.
NOTE
Pump, tubes, and hoses may contain oil at time of removal. Provide
suitable container to catch oil as lines are disconnected.
a. Disconnect electrical leads from scavenge line resistance temperature detectors (24).
b. Disconnect the 4 scavenge oil hoses and the forward scavenge oil tube from the pump.
c. Disconnect the oil supply in and out hoses and the scavenge oil discharge tube from the
pump.
d. Disconnect spline lube tube from bottom forward end of pump. Disconnect drain tube
from bottom aft end of pump.
e. Loosen clamps on forward scavenge tube, spline lube tube, drain tube, and scavenge dis-
charge tube to allow them to be moved slightly.

2
GEK 97310
VOLUME II
WP 105 00

3
GEK 97310
VOLUME II
WP 105 00
CAUTION
BE SURE PUMP IS SUPPORTED DURING REMOVAL OF
V-BAND CLAMP.
f. Loosen V-band clamp and carefully remove pump from gearbox.
g. Remove the 8 flange tubes from the pump. Remove the 3 flange gaskets from top of
pump.
h. Remove drain nipple and spline lube nipple from bottom of pump. Remove and discard
nipple O-rings.
i. Cover or cap all openings of pump to prevent entry of foreign material.
5. INSTALLATION OF LUBE AND SCAVENGE PUMP.
a. Lubricate gaskets and O-rings with gas turbine lube oil.
b. Place new flange gasket (16, figure 1) on pump.
c. Install C-sump scavenge line (19), B-sump scavenge line (18), and A-sump (transfer gear-
box) scavenge line (17). Secure each with 3 bolts (15) and washers. Install bolts from bottom
with washers under boltheads. Finger-tighten the bolts.
d. Place new flange gasket (3) on pump.
e. Install scavenge line (1) and accessory gearbox scavenge line (2). Install bolt and washer
in forward bolthole of each tube flange and finger-tighten.
f. Install bracket (4) to aft boltholes in flange of speed sensor-sump scavenge line if not
installed. Secure with 2 bolts, nuts, and washers (washers under boltheads) and finger-tighten.
g. Install bracket (9) to aft boltholes, in flange of accessory gearbox scavenge line (2), if not
installed. Secure with 2 bolts, nuts, and washers (washers under boltheads) and finger-tighten.
h. Place new flange gasket (12) on pump.
i. Install scavenge discharge line (6), lube oil discharge line (8), and lube inlet line (10).
Secure each with 3 bolts and washers. Install bolts from bottom with washers under boltheads.
Finger-tighten.

4
GEK 97310
VOLUME II
WP 105 00
j. Install clamp (5) to scavenge discharge line (6), if not installed, loop aft. Attach clamp to
bracket (4) using bolt, nut, and washer. Finger-tighten.
k. Install clamp (7) to lube discharge line (8), if not installed, loop up. Attach clamp to
bracket (9) using bolt, nut, and washer. Finger-tighten.
l. Install new O-ring (21) on spline lube union (20). Install union and torque to 40-60 lb in.
(4.5-6.8 N·m).
m. Install new O-ring (13) on seal drain union (14). Install union and torque to 40-60 lb in.
(4.5-6.8 N·m).
n. Spread V-band clamp (23) and slip it over gearbox mounting flange. Position clamp with
bolt at bottom and nut to left (viewed aft looking forward).
o. Lubricate pump gasket (22) with engine oil and place on pump flange. Hang gasket over
the locating dowel pin at 12 o’clock position on pump flange.
p. Lubricate pump drive splines with gas generator lube oil. Align pump drive splines and
place pump into mounted position. Ensure that locating dowel pin enters hole in gearbox flange.
q. Position V-band clamp over pump and gearbox flanges. Tighten per Chapter 5, Volume I,
to 100-130 1b in. (11.3-14.7 N·m) final torque and safety-wire.
r. Install clamps securing spline supply line to transfer gearbox scavenge line.
s. Align pump tubing and flex lines. Connect lines and hand-tighten couplings.
t. Torque all clamp nuts to 24-27 lb in. (2.7-3 N·m).
u. Torque flange bolts/nuts securing tubes to pump to 55-70 lb in. (6.2-7.9 N·m).
v. Torque connections between flexible lines and pump tubes to the following values:
A-Sump (Transfer Gearbox) Scavenge (17) 54-65 lb ft

(73.2-88 N·m)
Lube Inlet (10) 158-183 lb ft

(214-248 N·m)
Lube Discharge (8) 158-183 lb ft

(214-248 N·m)

5
GEK 97310
VOLUME II
WP 105 00
Scavenge Discharge (6) 133-150 lb ft
(180.3-203.4 N·m)
Accessory Transfer Gearbox Scavenge (2) 54-65 lb ft

(73.2-88 N·m)
Speed Sensor - Sump Scavenge 54-65 lb ft

(73.2-88 N·m)
B-Sump Scavenge (18) 58-70 lb ft

(78.6-95 N·m)
C-Sump Scavenge (19) 58-70 lb ft

(78.6-95 N·m)
Seal Drain 135-150 lb in.

(15.3-16.9 N·m)
Spline Lube Supply 135-150 lb in.

(15.3-16.9 N·m)
w. Open lube oil supply between lube oil storage and conditioning assembly and gas
generator.
x. Loosen the LUBE IN screen a few turns and hold until a steady stream of oil flows
between the threads. Do not completely unscrew the screen.
y. After the oil flows continuously, tighten the oil screen. Torque to 55-70 lb in.
(6.2-7.9 N·m) and safety-wire.
z. Be sure electrical leads are correctly located. Attach electrical leads to resistance temper-
ature detectors (24), hand-tighten, and safety-wire. Remove tags.
aa. Dry motor the gas generator for 2 minutes to purge lube system of air and check for leaks
per Chapter 4, Volume I.
ab. Check lube oil level after coastdown and refill lube oil storage tank if necessary.

6
GEK 97310
VOLUME II
SWP 105 01
REPLACEMENT OF LUBE AND SCAVENGE PUMP

AND FORWARD SCAVENGE PUMP

1-6.......... 0
ALPHABETICAL INDEX
Subject Page
Installation of Forward Scavenge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Removal of Forward Scavenge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1
GEK 97310
VOLUME II
SWP 105 01
installation of the lube and scavenge pump and forward scavenge pump. The V-band clamp used
to mount the pump must be installed per Chapter 5 of Volume I. After installation the pump must
be purged of air and leak checked per Chapter 4 of Volume I.
NOTE
None

MIL-L-23699 Lubricating Oil (Gas Generator)
Safety wire
NOTE
The pump and tubes may have oil in them at time of removal.
Drain oil into suitable container.
a. Disconnect flexible couplings from B- and C-sump, inlet tubes.
b. Remove nut and bolt from the clamp securing check valve to bracket.
c. Disconnect scavenge discharge tube from check valve.
d. Disconnect coupling from lube inlet and outlet tubes.
e. Disconnect forward scavenge inlet tube by removing 4 bolts and washers.

2
GEK 97310
VOLUME II
SWP 105 01

3
GEK 97310
VOLUME II
SWP 105 01
CAUTION
V-BAND CLAMP.
f. Loosen V-band clamp and carefully remove pump from gearbox.
g. Remove bolts and washers from flanged tubes.
h. Remove flanged tubes and seals from pump.
5. INSTALLATION OF LUBE AND SCAVENGE PUMP.
a. Install flanged tubes and new gaskets on new pump using bolts and washers.
b. Install new gasket on gearbox mounting pad.
c. Align pump drive spline and position locating pin into hole in gearbox flange.
d. Position V-band clamp over pump and gearbox flanges. Tap rim of clamp, using a mallet,
to enable clamp to seat properly, while tightening bolt. Torque and lockwire.
e. Install forward scavenge inlet tube and new gasket on pump, using bolts and washer.
Torque and lockwire.
f. Connect scavenge discharge tube to check valve.
g. Install clamp on check valve and secure to bracket.
h. Install the B- and C-sump tubes, with flexible coupling and O-rings, at each end, on the
pump. Torque and lockwire.
i. Connect couplings to lube pump inlet and outlet tubes. Torque and lockwire.
6. REMOVAL OF FORWARD SCAVENGE PUMP. See figure 2.
NOTE
The pump and tube may have oil in them at time of removal. Drain
oil into suitable container.
a. Loosen clamps securing scavenge outlet tube to gearbox.
b. Disconnect scavenge inlet and outlet tubes, and gaskets by removing bolts and washers.

4
GEK 97310
VOLUME II
SWP 105 01
Figure 2. Forward Scavenge Pump

5
GEK 97310
VOLUME II
SWP 105 01
CAUTION
MOUNTING BOLTS.
c. Remove the 6 mounting bolts and washers.
d. Remove pump and gasket; disengage drive gear carefully.
e. Remove nut and washer, using spanner wrench, and the gear, using a puller. Remove key.
7. INSTALLATION OF FORWARD SCAVENGE PUMP.
a. Install key on shaft of replacement pump and hold in place.
CAUTION
THE PUMP DRIVE GEAR MUST BE HEATED IN AN OVEN
BEFORE INSTALLATION OF THE GEAR. HEAT TO
250° ± 5°F (121° ± 3°C) FOR APPROXIMATELY 20 MINUTES.
NOTE
The gear must be installed with longer hub toward the pump.
b. Install drive gear.
c. Install washer and nut on shaft. Tighten nut, using spanner wrench. Torque nut
480-570 lb in. (54.2-64.4 N·m).
d. When gear cools to room temperature, loosen nut 1/2 turn and retorque.
e. Position gasket on pump mounting flange, align pump with gearbox mounting pad, mak-
ing sure gear engages mating gear in gearbox; install pump.
f. Install 6 mounting bolts and washers. Torque and lockwire.
g. Connect scavenge inlet and outlet tubes with gaskets to pump. Secure each tube with
4 bolts and washers. Torque and lockwire.
h. Tighten clamps securing scavenge outlet tube to gearbox.

6
GEK 97310
VOLUME II
SWP 105 02
REMOVAL/INSTALLATION OF SIX SCAVENGE

ELEMENT LUBE AND SCAVENGE PUMP
EFFECTIVITY: LM2500 GAS TURBINE - P SERIES MODELS

1-7.......... 0 8 Blank . . . . . . . 0
ALPHABETICAL INDEX
Subject Page


1
GEK 97310
VOLUME II
SWP 105 02
the modified lube and scavenge pump (the pump was modified to also scavenge oil directly from
the air-oil separator). The V-band clamp used to mount the pump must be installed per
Chapter 5 of Volume I. After installation the pump must be purged of air and leak-checked per
Chapter 4 of Volume I.
NOTE
None

MIL-L-23699 Lubricating Oil (Gas Generator)
R297P04 Safety Wire
NOTE
Pump, tubes, and hoses may contain oil at time of removal. Provide
suitable container to catch oil as lines are disconnected.
a. Disconnect electrical leads from scavenge line resistance temperature detectors (24).
b. Disconnect the four scavenge oil hoses and the forward scavenge oil tube at the tube
connectors.
c. Disconnect the oil supply in and out hoses and the scavenge oil discharge tube at the tube
connectors.
d. Disconnect spline lube tube from bottom forward end of pump. Disconnect drain tube
from bottom aft end of pump.

2
GEK 97310
VOLUME II
SWP 105 02
Figure 1. Lube and Scavenge Pump (Sheet 1 of 2)

3
GEK 97310
VOLUME II
SWP 105 02
Figure 1. Lube and Scavenge Pump (Sheet 2 of 2)
e. Remove bolts from both flanges of the air-oil separator scavenge oil line (at both the
scavenge pump and the air-oil separator), and remove the clamp holding this scavenge oil line at
the bracket on the transfer gearbox. Remove the air-oil separator oil scavenge line and the gas-
kets at both flanges. Discard the gaskets.
f. Loosen clamps on forward scavenge tube, spline lube tube, drain tube, and scavenge
discharge tube to allow them to be moved slightly.
CAUTION
MAKE SURE PUMP IS SUPPORTED DURING REMOVAL OF
V-BAND CLAMP.
g. Loosen V-band clamp and carefully remove pump from gearbox.
h. Remove the eight flange tubes and the air-oil separator scavenge discharge line from the
pump. Disconnect (or loosen) the air-oil separator scavenge discharge tube (31) at the main scav-
enge discharge line (6). Remove the three flange gaskets from top of pump and the gasket (30)
from the air-oil separator scavenge discharge port.

4
GEK 97310
VOLUME II
SWP 105 02
i. Remove drain nipple and spline lube nipple from bottom of pump. Remove and discard
nipple O-rings.
j. Cover or cap all openings of pump to prevent entry of foreign material.
5. INSTALLATION OF LUBE AND SCAVENGE PUMP. See figure 1.
a. Lubricate gaskets and O-rings with gas turbine lube oil.

b. Place new flange gasket (16) on pump.
c. Install C-sump scavenge line (19), B-sump scavenge line (18), and A-sump (transfer
gearbox) scavenge line (17). Secure each with three bolts (15) and washers. Install bolts from
bottom with washers under boltheads. Tighten bolts fingertight.
d. Place new flange gasket (3) on pump.
e. Install D-sump scavenge line (1) and accessory gearbox scavenge line (2). Install bolt and
washer in forward bolthole of each tube flange and tighten fingertight.
f. Install bracket (4) to aft boltholes in flange of speed sensor sump scavenge line if not
installed. Secure with two bolts, nuts and washers (washers under boltheads) and tighten
finger-tight.
g. Install bracket (9) to aft boltholes in flange of accessory gearbox scavenge line (2) if not
installed. Secure with two bolts, nuts, and washers (washers under boltheads) and tighten
fingertight.
h. Place new flange gasket (12) on pump.
i. Install scavenge discharge line (6), lubeoil discharge line (8) and lubeoil inlet line (10).
Secure each with three bolts and washers. Install bolts from bottom with washers under bolth-
eads. Tighten fingertight.
j. Install clamp (5) to scavenge discharge line (6), if not installed, loop aft. Attach clamp to
bracket (4) using bolt, nut and washer. Tighten fingertight.
k. Install clamp (7) to lube oil discharge line (8), if not installed, loop up. Attach clamp to
bracket (9) using bolt, nut, and washer. Tighten fingertight.
l. Install new flange gasket (30) on air-oil separator scavenge discharge port of pump.
Assemble air-oil separator discharge line (31) to pump using four bolts and washers (washers
under boltheads). Tighten bolts to 33-37 lb in. (3.7-4.2 N·m) of torque. Assemble air-oil separa-
tor discharge line (31) to nipple on scavenge discharge line (6). Tighten to 54-65 lb ft
m. Install new O-ring (21) on spline lube union (20). Install union and tighten to 40-60 lb in.
(4.5-6.8 N·m) of torque.
n. Install new O-ring (13) on seal drain union (14). Install union and tighten to 55-70 lb in.

5
GEK 97310
VOLUME II
SWP 105 02
o. Spread V-band clamp (23) and slip it over gearbox mounting flange. Position clamp with
bolt at bottom and nut to left (viewed aft looking forward).
p. Lubricate pump gasket (22) with engine oil and place on pump flange. Hang gasket over
the locating dowel pin at 12 o’clock position on pump flange.
q. Lubricate pump drive splines with gas generator lube oil. Align pump drive splines and
place pump into mounted position. Ensure that locating dowel pin enters hole in gearbox flange.
r. Assemble new gaskets (28 and 29) to either end of air-oil separator scavenge tube (26) and
assemble to scavenge pump and to air-oil separator using four bolts at each flange. Tighten bolts
s. Assemble clamp (27) to air-oil scavenge tube (26) at transfer gearbox bracket using bolt,
washer, and nut. Tighten fingertight.
t. Position V-band clamp over pump and gearbox flanges. Tighten per Chapter 5, Volume I
to 100-130 1b in. (11.3-14.7 N·m) final torque and safety-wire.
u. Install clamps securing spline supply line to transfer gearbox scavenge line.
v. Align pump tubing and flex lines. Connect lines and hand-tighten couplings.
w. Tighten all clamp nuts to 33-37 lb in. (3.7-4.2 N·m) of torque.
x. Tighten flange bolts/nuts securing tubes to pump to 55-70 lb in. (6.2-7.9 N·m) of torque,
except air-oil separator scavenge tube (26) and discharge tube (31). Tighten these bolts to
33-37 lb in. (3.7-4.2 N·m) of torque.
y. Tighten connections between flexible lines and pump tubes to the following torque values:
A-Sump (Transfer Gearbox) Scavenge (17) 112-128 lb ft
(152-174 N·m)
Lube Inlet (10) 158-183 lb ft
(214-248 N·m)
Lube Discharge (8) 112-128 lb ft
(152-174 N·m)
Scavenge Discharge (6) 133-150 lb ft
(180-203 N·m)
Accessory Gearbox Scavenge (2) 54-65 lb ft
(73-88 N·m)
Speed Sensor - Sump Scavenge 54-65 lb ft
(73-88 N·m)
B-Sump Scavenge (18) 112-128 lb ft
(152-174 N·m)
C-Sump Scavenge (19) 112-128 lb ft
(152-174 N·m)

6
GEK 97310
VOLUME II
SWP 105 02
D-Sump Scavenge (1) 54-65 lb ft
(73-88 N·m)
Air-oil Separator Scavenge Discharge Tube (31) to 54-65 lb ft
Scavenge Discharge Line (6) (73-88 N·m)
Seal Drain 135-150 lb in.
(15.3-17.0 N·m)
Spline Lube Supply 135-150 lb in.
(15.3-17.0 N·m)
z. Open lube oil supply between lube oil storage and conditioning assembly and gas
generator.
aa. Loosen the LUBE IN screen a few turns and hold until a steady stream of oil flows
between the threads. Do not completely unscrew the screen.
ab. After the oil flows continuously, tighten the oil screen. Tighten to 55-70 lb in.
ac. Ensure that electrical leads are correctly located. Attach electrical leads to resistance
temperature detectors (24), hand-tighten and safety-wire. Remove tags.
ad. Dry motor the gas generator for 2 minutes to purge lube system of air and check for leaks
per Chapter 4, Volume I.
ae. Check lube oil level after coast down and refill lube oil storage tank, if necessary.

7/(8 Blank)
GEK 97310
VOLUME II
WP 106 00
WORK PACKAGE
REPLACEMENT OF SPARK IGNITERS
EFFECTIVITY: LM2500 ENGINE MODELS - ALL MODELS EXCEPT GA101

1-9.......... 0 10 Blank . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Installation of Spark Igniter and Ignition Lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Removal of Spark Igniter and Ignition Lead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1
GEK 97310
VOLUME II
WP 106 00
1. INTRODUCTION. This work package contains instructions for removing and installing
spark igniters and/or ignition leads. Following installation of either spark igniters and/or ignition
leads, a check-out per the appropriate addendum contained in Volume I must be accomplished.
NOTE

1C6096 Depth Gage

R297P04 Safety Wire

2
GEK 97310
VOLUME II
WP 106 00
4. REMOVAL OF SPARK IGNITER AND IGNITION LEAD. See figures 1, 2, 3 and 4.
WARNING
BEFORE YOU DISCONNECT THE IGNITION LEADS, MAKE
SURE THE IGNITION SYSTEM WAS OFF FOR MORE THAN
TWO MINUTES. THE IGNITION SYSTEM COULD BE
CHARGED WITH HIGH VOLTAGE THAT CAN CAUSE
DEATH.
CAUTION
THE LEAD COUPLING NUT RETAINS THE SPARK IGNITER
IN THE ADAPTER. DO NOT LET IGNITER DROP FROM
ADAPTER AFTER LEAD IS REMOVED TO PREVENT DAM-
AGE TO THE IGNITER.
NOTE
There are 2 spark igniters. Removal procedure is the same for each.
a. Disconnect input leads (1, figure 1) from ignition exciters (2).
b. Disconnect coupling nut of ignition lead (6, figure 2) from adapter boss (2).
NOTE
There are metal spacers between igniter plug and adapter gasket.
Quantity may vary from one to 8.
c. Remove spark igniter (3).
d. Disconnect ignition lead (3, figure 1) from ignition exciter. Remove lead.

3
GEK 97310
VOLUME II
WP 106 00
Figure 1. Removal of Ignition Leads From Ignition Exciters

4
GEK 97310
VOLUME II
WP 106 00
Figure 2. Spark Igniter and Ignition Leads

5
GEK 97310
VOLUME II
WP 106 00
Figure 3. Gas Generator Ignition Leads (Sheet 1 of 2) (Early Configuration)

6
GEK 97310
VOLUME II
WP 106 00
Figure 3. Gas Generator Ignition Leads (Sheet 2 of 2) (Later Configuration)

7
GEK 97310
VOLUME II
WP 106 00
Figure 4. Routing of Ignition Leads
5. INSTALLATION OF SPARK IGNITER AND IGNITION LEAD.

See figures 1, 2, 3 and 4.
NOTE
If same igniter and gaskets are being installed, disregard step a. If
different igniter is being installed, immersion depth must be
established per step a.
a. Establish spark igniter immersion depth as follows:
(1) Remove all loose gaskets from spark igniter (3).
(2) Measure dimension Y from tip of spark igniter (3) to face of integral gasket. See
figure 2, detail A.
(3) Using spark igniter immersion depth gage, 1C6096, measure dimension X from
adapter face to combustor igniter ferrule of combustor dome. See figure 2, detail C.

8
GEK 97310
VOLUME II
WP 106 00
NOTE
Individual gasket thickness is 0.030-0.034 inch (0.76-0.86 mm).
(4) Add loose gaskets (zero to eight each) to spark igniter such that required total gasket
thickness equals dimension Y minus dimension X plus [0.030-0.070 inch (0.76-1.78 mm)]. See
figure 2, detail B.
b. Insert igniter (3) into adapter boss (2). Attach ignition lead (6) coupling nut to boss.
Torque coupling nut to 23-27 lb ft (31-37 N·m) and safety-wire.
c. Attach ignition leads (3, figure 1) to ignition exciters (2). Tighten coupling nuts to 130-
150 lb in. (14.7-16.9 N·m) of torque.
d. Inspect preformed packings (4) for damage. Replace packings, if damaged.
e. Attach input leads to ignition exciters (2). Hand-tighten the couplings and safety-wire.
f. Perform checkout per Chapter 4 of Volume I.
g. If required, replace adapter boss (2, figure 2) as follows:
(1) Remove two bolts and washers that secure adapter to frame. Remove and retain
metal ring seal (1).
(2) Place seal (1) on adapter boss (2) and insert adapter boss into boss on CRF.
(3) Make sure that seal (1) seats in counterbore of boss on CRF. Secure each adapter
with two bolts and washers. Tighten bolts to 55-75 lb in. (6.2-8.5 N·m) of torque.

9/(10 Blank)
GEK 97310
VOLUME II
SWP 106 01
REPLACEMENT OF SPARK IGNITERS

1-4.......... 0
ALPHABETICAL INDEX
Subject Page
Installation of Spark Igniter and Ignition Lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Removal of Spark Igniter and Ignition Lead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
SWP 106 01
installing spark igniters and/or ignition leads. Following installation of either spark igniters
and/or ignition leads, a check-out per the appropriate addendum contained in Volume I must be
accomplished.
NOTE
None

Safety Wire
4. REMOVAL OF SPARK IGNITER AND IGNITION LEAD. See figure 1.
WARNING
DEATH.
a. Remove all bolts and nuts securing ignition leads to gas generator.
b. Disconnect ignition lead from ignition exciter.
c. Disconnect and remove ignition lead from adapter boss.
d. Remove igniter and metal seal from ignition lead.

2
GEK 97310
VOLUME II
SWP 106 01
Figure 1. Spark Igniter Installation

3
GEK 97310
VOLUME II
SWP 106 01
5. INSTALLATION OF SPARK IGNITER AND IGNITION LEAD.
a. Measure distance from inner surface of combustion swirl cup to outer surface of igniter
adapter boss.
b. Measure distance from tip of igniter to inside surface of igniter flange.
NOTE
The dimension recorded in step (b) must be equal to or greater than
the dimension recorded in step (a) by 0-0.100 inch (0-2.54 mm).
See figure 1.
c. The dimension recorded in step (b) may be decreased by adding gaskets between adapter
boss and igniter.
d. Install igniter into adapter.
e. Install ignition lead into igniter and adapter.
CAUTION
USE A FLARE-NUT WRENCH ONLY WHEN TORQUING
THE LEAD COUPLING NUT TO AVOID DISTORTING THE
NUT.
f. Torque lead coupling nut 23-27 lb ft (31-36.6 N·m) and lockwire.
g. Install ignition lead to ignition exciter; torque 20-30 lb ft (27-41 N·m) and lockwire.
h. Install bolt and nuts to secure ignition lead to gas generator. Torque bolt to 24-27 lb in.
(2.7-3.1 N·m).

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WP 107 00
WORK PACKAGE
REPLACEMENT OF IGNITION EXCITER

1-3.......... 0 4 Blank . . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Ignition Exciter Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Ignition Exciter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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1. INTRODUCTION. This work package contains general safety precautions to be observed
during replacement of an ignition exciter. For detailed instructions for removal and installation of
an ignition exciter, refer to the purchaser’s manual.
WARNING
DEATH.
None
None
NOTE
The following procedure applies to LM2500GA101 gas generators.
For LM2500GB series gas generators, the ignition exciters are
off-gas generator mounted, and off-gas generator mounted equip-
ment replacement is performed per the packager’s manual.
4. IGNITION EXCITER REMOVAL. See figure 1.
a. Disconnect or loosen clamps as required to allow disconnecting of electrical cables.
WARNING
DEATH.
b. Disconnect electric supply cable and ignition leads from ignition exciter.
c. Remove 6 bolts securing ignition exciter to mounting bracket, and remove exciter.

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Figure 1. Ignition Exciter Installation (GA101 Only)
5. IGNITION EXCITER INSTALLATION. See figure 1.
a. Install replacement exciter on mounting bracket and secure with 6 bolts and washers.
Torque bolts to 55-70 lb in. (6.2-7.9 N·m).
b. Connect ignition leads to exciter connections. Torque to 130-150 lb in. (14.7-16.9 N·m)
and lockwire.
c. Connect electric supply cable to exciter connection., tighten fingertight, and lockwire.
d. Connect and secure all clamps removed or loosened in step 4a. Torque nuts to 33-37 lb in.
(3.7-4.2 N·m).

3/(4 Blank)
GEK 97310
VOLUME II
WP 108 00
WORK PACKAGE
REPLACEMENT OF GAS GENERATOR SPEED

PICKUP

1-4.......... 0
ALPHABETICAL INDEX
Subject Page
Installation of Gas Generator Speed Pickup.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Removal of Gas Generator Speed Pickup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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the gas generator speed pickup.
NOTE
None

RTV-106 (Red) Adhesive, Silicone Rubber
Safety Wire
4. REMOVAL OF GAS GENERATOR SPEED PICKUP. See figure 1.
a. Disconnect electrical lead from speed pickup.
b. Loosen jamnut (2) on speed pickup. Remove speed pickup.
5. INSTALLATION OF GAS GENERATOR SPEED PICKUP. See figure 1.
a. Remove cover (4) and gasket (3) from access opening on gearbox. Retain cover, gasket,
and attaching bolts.
b. Install jamnut (2) on pickup. Install pickup in gearbox boss by hand carefully until tip of
pickup just touches a tooth crown of gear (5), see view A.
c. Back pickup out until clearance between gear tooth and pickup tip is 0.010-0.015 inch
(0.25-0.38 mm) by use of feeler gage.
d. Apply a thin bead of RTV-106 red silicone rubber adhesive (approximately 0.06 inch
[1.5 mm] diameter) around pickup at gearbox. Remove excess RTV from threads and gearbox.

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WP 108 00
Figure 1. Gas Generator Speed Pickup

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NOTE
Jamnut shall be tightened while RTV is still wet.
e. Hold pickup and tighten jamnut (2) against gearbox boss. Torque jamnut to 90-110 lb in.
(10.2-12.4 N·m).
f. Check the clearance between the pickup tip and gear tooth to make sure that it is within
limits by using a feeler gage.
g. Install gasket (3) and cover plate (4) over gearbox access opening. Torque bolts to
40-60 lb in. (4.5-6.8 N·m).
h. Safety-wire jamnut (2) to top left bolt of cover (4) and then continue safety-wire to lower
left bolt. Safety-wire bolts on right side of cover together.
i. Make sure that seal is in the electrical lead (1) connector and is serviceable. Replace seal
if necessary. Connect electrical lead to pickup. Hand-tighten and safety-wire the connector.

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GEK 97310
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SWP 108 01
REPLACEMENT OF GAS GENERATOR SPEED

PICKUP

1-4.......... 0
ALPHABETICAL INDEX
Subject Page
Installation of Gas Generator Speed Pickup.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Removal of Gas Generator Speed Pickup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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GEK 97310
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SWP 108 01
installation of the gas generator speed pickup.
NOTE
None

RTV-106 (Red) Adhesive, Silicone Rubber
Safety Wire
4. REMOVAL OF GAS GENERATOR SPEED PICKUP. See figure 1.
a. Disconnect electrical lead from speed pickup.
b. Remove 8 bolts securing cover to gearbox pad. Remove cover, brackets, and gasket.
Retain all parts for reassembly.
c. Loosen jamnut securing speed pickup to gearbox pad, and remove pickup.
5. INSTALLATION OF GAS GENERATOR SPEED PICKUP. See figure 1.
a. Install jamnut on pickup. Install pickup in gearbox pad by hand carefully until tip of
pickup just touches a tooth crown of gear.
b. Back pickup out until clearance between gear tooth and pickup tip is 0.013-0.003 inch
(0.33-0.08 mm) by use of feeler gage.
c. Apply a thin bead of RTV-106 red silicone rubber adhesive (approximately 0.06 inch
[1.5 mm] diameter) around pickup at gearbox pad. Remove excessive RTV from threads and
gearbox.

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SWP 108 01
Figure 1. Gas Generator Speed Pickups

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SWP 108 01
NOTE
Jamnut shall be tightened while RTV is still wet.
d. Hold pickup and tighten jamnut against gearbox pad. Torque jamnut 90-110 lb in.
(10.2-12.4 N·m).
e. Check clearance between pickup tip and gear teeth to ensure proper clearance by using a
feeler gage.
f. Install gasket, cover, and brackets on gearbox pad. Install 8 bolts and torque 40-60 lb in.
(4.5-6.8 N·m). Safety-wire bolts and jamnut.
g. Make sure that seal is in the electrical lead connector and is serviceable. Replace seal if
necessary. Connect electrical lead to pickup. Hand-tighten and safety-wire the connector.

4
GEK 97310
VOLUME II
WP 109 00
WORK PACKAGE
REPLACEMENT OF POWER TURBINE SPEED PICKUP

LEADS

1-5.......... 0 6 Blank . . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Installation of Power Turbine Speed Pickup Lead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Removal of Power Turbine Speed Lead.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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GEK 97310
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WP 109 00
the power turbine speed pickup leads.
NOTE
None
None
4. REMOVAL OF POWER TURBINE SPEED LEAD. See figure 1.
a. Loosen, but do not disconnect, connectors at each end of lead.
b. Remove clamps securing lead to gas turbine.
CAUTION
CARE MUST BE TAKEN SO THAT RIGID LEAD IS NOT
DAMAGED DURING REMOVAL AND THAT CONNECTOR
ON PICKUP IS NOT DAMAGED.
c. Disconnect electrical connectors at each end of lead and carefully remove lead.
5. INSTALLATION OF POWER TURBINE SPEED PICKUP LEAD. See figure 1.
CAUTION
CARE MUST BE TAKEN SO THAT RIGID LEAD IS NOT
DAMAGED DURING REMOVAL AND THAT CONNECTOR
ON PICKUP IS NOT DAMAGED.
a. Make sure that seals are inside electrical connectors on each end of lead and are
serviceable. Replace seals if necessary.

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WP 109 00
Figure 1. Power Turbine Speed Pickup Leads (Sheet 1 of 2) (Early Configuration)

3
GEK 97310
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WP 109 00
Figure 1. Power Turbine Speed Pickup Leads (Sheet 2 of 2) (Later Configuration)

4
GEK 97310
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WP 109 00
CAUTION
IF NEW LEAD IS BEING INSTALLED IT MUST BE HAND
FORMED TO FIT. USE EXTREME CARE TO PREVENT
SHARP BENDS, OR INSULATION WILL BE DAMAGED.
INSULATION RESISTANCE AND CONTINUITY MUST BE
CHECKED AFTER INSTALLATION.
b. Carefully position lead to align electrical end connectors and hand-tighten connectors. If
required, carefully form lead to provide 0.75 inch (19.1 mm) clearance over fuel tubes.
c. Attach lead clamps (right lead, 10 clamps; left lead, 11 clamps), except the aft clamp at the
power turbine speed pickup. Torque clamp bolts to 24-27 lb in. (2.7-3.1 N·m).
d. Torque aft connector nut to 70-80 lb in. (7.9-9.0 N·m). Torque forward connector to
30-50 lb in. (3.4-5.6 N·m).
e. Remove the clamps bracket at the pickup retainer.
f. Place aft clamp around lead and attach bracket to clamp. Tighten clamp bolt, leaving it
loose enough to permit rotation on the lead.
g. Attach bracket to probe retainer flange with bolt and nut, and torque to
24-27 lb in. (2.7-3.1 N·m).
h. If rigid lead has been hand formed, test as follows:
(1) Test insulation resistance from forward connector shell to either of its connector pins.
Resistance shall be a minimum of 15 megohms at 500 VDC.
(2) Measure continuity from pin to pin in the forward connector. Resistance shall be
166 ± 10 ohms at 72°F (22°C).

5/(6 Blank)
GEK 97310
VOLUME II
WP 110 00
WORK PACKAGE
REPLACEMENT OF POWER TURBINE SPEED

TRANSDUCER
EFFECTIVITY: LM2500 GAS TURBINE MODELS - ALL

1 - 11 . . . . . . . . . 0 12 Blank . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Installation of Power Turbine Speed Transducer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Power Turbine Speed Transducer Tip Clearance Measurement. . . . . . . . . . . . . . . . . . . . . . 6
Removal of Power Turbine Speed Transducer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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GEK 97310
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WP 110 00
the power turbine speed pickup leads.
NOTE

1C6345G01/G02 Gage, Clearance - Overspeed Transducer

MIL-L-23699 or Oil, Lubricating
MIL-L-7808
4. EXPENDABLE MATERIAL. Reference GEK 50336, Illustrated Parts Breakdown (IPB).
Nomenclature IPB Figure No./Item

Preformed Packing 35/3
Shim Pack (Used only 35/2
on Transducer,
PN L21656)

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GEK 97310
VOLUME II
WP 110 00
5. REMOVAL OF POWER TURBINE SPEED TRANSDUCER.
a. Remove electrical lead from speed transducer per WP 109 00.

CAUTION
THE TRANSDUCER SPRING IS RETAINED UNDER
COMPRESSION BY THE RETAINER. RETAINER BOLTS
MUST BE LOOSENED IN SMALL, EQUAL AMOUNTS TO
PREVENT BINDING.
NOTE
There are two speed transducers located in the turbine rear frame.
One is in strut No. 3 and one is in strut No. 7. This procedure
applies to both. Tool set, 1C6345, is required to remove, adjust, and
install the transducers. Items contained in the tool set are shown in
figures 1 and 2.
b. Loosen each of three spring retainer bolts two turns at a time until bolts are removed.
Remove angle bracket, spring retainer, and spring.
c. Slide flanged plug (2, figure 1) over end of transducer. Screw knurled nut (3) onto trans-
ducer and against flanged plug. Finger-tighten nut (3).
d. Install three jackscrews (1) in tapped holes of flanged plug (2).
e. Tighten jackscrews (1) in small, equal amounts to disengage transducer from inside the
frame strut.
f. Remove knurled nut (3) and flanged plug (2) from transducer.
g. Slide transducer assembly out of frame strut until both sets of wrenching flats are exposed.
NOTE
It is not necessary to remove outer support tube if there is sufficient
space to remove transducer without bending tube.
h. Hold inner wrenching flat and unscrew outer support tube from transducer.
i. Carefully slide transducer back into strut until there is at least a 12.0-inch
(305 mm) clearance between end of transducer and enclosure wall (if applicable).
j. Carefully remove outer support tube from transducer.
k. Slide transducer out of frame strut to expose flexible section.

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WP 110 00
Figure 1. Power Turbine Speed Transducer Installation and Removal

4
GEK 97310
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WP 110 00
Figure 2. Power Turbine Speed Transducer Tip Clearance Gaging Using 1C6345

5
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WP 110 00
CAUTION
DO NOT EXCEED A 90 DEGREE BEND OF THE FLEXIBLE
SECTION OF TRANSDUCER. USE CARE TO PREVENT
DAMAGE TO POLE PIECE AT INNER END OF
TRANSDUCER.
l. Carefully bend flexible section of transducer as required, to maximum of 90 degrees, and

slide rest of transducer from strut.
m. Install outer support tube onto transducer and hand-tighten connection.
6. POWER TURBINE SPEED TRANSDUCER TIP CLEARANCE MEASUREMENT.
CAUTION
IF SHIMS HAVE BEEN DISTURBED OR IF TRANSDUCER IS
NEW TO THIS FRAME STRUT, TIP CLEARANCE SHALL BE
DETERMINED BEFORE TRANSDUCER IS INSTALLED.
DAMAGE TO TRANSDUCER CAN RESULT FROM
IMPROPER TIP CLEARANCE.
NOTE
There is no requirement to measure or adjust tip clearance for
transducer, PN L44780P01.
a. Insert sleeve (1, figure 2), with wrench flats on outer end, into frame strut and leave
wrench flats exposed. Connect flanged sleeve (2) to sleeve (1) and tighten until firmly seated.
b. Slide sleeve assembly into frame until it bottoms on strut inner seating surface. Sleeve
flange should be approximately 0.25 inch (6.4 mm) from strut flange.
c. Secure sleeve assembly (1 and 2) to strut flange with three bolts (6) and nuts (5). Tighten
to
10-15 lb in. (1.1-1.7 N·m) of torque.
d. Pivot shaft assembly (4) at center joint, only as far as necessary and not more than
90 degrees, and insert end of shaft into sleeve assembly (1 and 2). Straighten shaft and align
setscrew (7) with slot in sleeve (2). Carefully insert shaft until shaft threads touch sleeve threads.
e. Screw shaft (4) into sleeve assembly by hand until tip of shaft touches spur gear teeth.
Hand-tighten shaft.

6
GEK 97310
VOLUME II
WP 110 00
f. Rotate split nut (3) until it contacts flanged sleeve (2). Insert spanner wrench or short,
0.19-inch (4.8 mm) diameter rod in split nut to serve as a wrench, and tighten nut.
g. Lock split nut (3) in place by tightening socket capscrew (8) hand-tight.
CAUTION
DO NOT LOOSEN THE SPLIT NUT ONCE IT IS TIGHTENED
IN PLACE OR IMPROPER TIP CLEARANCE MAY RESULT.
TRANSDUCER TIP MAY BE DAMAGED IF INSERTED TOO
FAR INTO THE FRAME.
h. Unscrew shaft (4) from sleeve assembly (1 and 2). Do not loosen split nut (3). Pull shaft
outward, pivot it 90 degrees at center joint, and remove it from sleeve assembly.
i. Remove bolts (6) and nuts (5) holding sleeve assembly (1 and 2) in frame strut. Slide
sleeve assembly out to expose wrenching flats. Separate sleeve (2) from sleeve (1) and remove
both sleeves from frame.
j. Connect sleeve (2) to sleeve (1) and tighten until firmly seated.
k. Insert shaft (4) into sleeve assembly (1 and 2). Screw shaft into sleeve assembly until split
nut (3) seats against sleeve flange.
l. Retract micrometer (10) and insert shaft/sleeve assembly into gage fixture. Secure assem-
bly with three bolts (6) and nuts (5). Tighten to 10-15 lb in. (1.1-1.7 N·m) of torque.
m. Extend spindle of micrometer (10) until it touches shaft tip. Record micrometer setting.
n. Retract micrometer (10) spindle and remove bolts (6) and nuts (5). Remove
shaft/sleeve assembly from gage fixture.
NOTE
Install nut with capscrew wrench holes towards shim pack.
o. Install new shim pack and serviceable nut on new transducer. Hand-tighten nut while
holding shim pack in place.

7
GEK 97310
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WP 110 00
CAUTION
MAKE SURE THAT CAPSCREWS (11) ENTER HOLES IN NUT
TO PREVENT DAMAGE TO NUT.
p. Insert transducer into gage fixture. Tighten capscrews (11). Using crowfoot wrench on
transducer end wrenching flat, tighten nut to 200-240 lb in. (22.6-27.1 N·m) of torque. Loosen
capscrews (11).
q. Place spring and spring retainer on transducer. Secure spring retainer to gage fixture with
three bolts (6) and nuts (5). Tighten to 10-15 lb in. (1.1-1.7 N·m) of torque.
r. Extend spindle of micrometer (10) until it touches tip of transducer. Record micrometer
reading.
s. Determine required shim pack size as follows:
(1) Subtract reading recorded in step m. from reading recorded in step r. and record
difference.
(2) If the difference recorded equals 0.032-0.044 inch (0.81-1.12 mm), proceed with
installation of transducer.
Example: 0.596 inch (15.14 mm) from step r.

0.556 inch (14.12 mm) from step m.
0.040 inch (1.02 mm)
(3) If the difference is less than 0.032 inch (0.81 mm) or more than 0.044 inch
(1.12 mm), determine the number of shims to be removed or added to shim pack. Each shim has
a thickness of 0.001-0.003 inch (0.03-0.08 mm).
Example: 0.596 inch (15.14 mm) from step r.

0.536 inch (13.61 mm) from step m.
0.060 inch (1.52 mm)
For the above example, peel seven shims from shim pack (0.003 inch [0.08 mm] each or
0.021 inch [0.53 mm] total) and repeat steps o. through s. (3).
t. Remove three retaining bolts (6) and nuts (5) slowly and in equal amounts. Remove
spring retainer and spring.
u. Retract micrometer (10) spindle and carefully remove transducer from gage fixture.
v. Remove nut and shim pack from transducer. Peel shims from shim pack as determined in
step s.

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GEK 97310
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WP 110 00
w. Install corrected shim pack and nut on transducer. Hand-tighten nut while holding shim
pack in place.
x. Repeat steps p. through r.
y. Subtract reading recorded in step m. from new reading recorded in step x. If this value
equals 0.032-0.044 inch (0.81-1.12 mm), proceed with installation of transducer. If this value is
less than 0.032 inch (0.81 mm) or greater than 0.044 inch (1.12 mm), repeat steps t. through y. Do
not repeat steps t. through y. more than once without repeating all of paragraph 5.
Example: 0.058 inch (1.47 mm) from step x.

0.020 inch (0.51mm) from step m.
0.038 inch (0.97 mm)
7. INSTALLATION OF POWER TURBINE SPEED TRANSDUCER.
CAUTION
IF SHIMS HAVE BEEN DISTURBED OR IF TRANSDUCER IS
NEW TO THIS FRAME STRUT, PARAGRAPH 6 MUST BE
ACCOMPLISHED BEFORE INSTALLING THE
TRANSDUCER. DAMAGE TO TRANSDUCER CAN RESULT
FROM IMPROPER CLEARANCE.
NOTE
It is not necessary to remove outer support tube from transducer if
sufficient space exists to install transducer without bending tube.
a. Remove outer support tube from transducer. Do not apply any torque to flexible
portion of transducer.
WARNING
LUBRICATING OIL, MIL-PRF-23699F (C/I): COMBUSTIBLE.
DO NOT INHALE, INGEST, OR LET THIS MATERIAL
TOUCH YOU. IRRITANT. PERSONAL PROTECTIVE
EQUIPMENT REQUIRED. USE MECHANICAL EXHAUST
VENTILATION - IF NOT AVAILABLE, USE AN APPROVED
RESPIRATOR.
b. Install two lubricated O-rings using lubricating oil, MIL-L-23699, on tip of transducer
(figure 3).

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WP 110 00
Figure 3. Speed Transducer – Pickup End, PN L21656

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GEK 97310
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WP 110 00
CAUTION
DO NOT EXCEED A 90 DEGREE BEND OF THE
TRANSDUCER. USE CARE TO PREVENT DAMAGE TO
POLE PIECE AT INNER END OF TRANSDUCER.
c. Carefully bend transducer as required, but not more than 90 degrees, and insert it into
frame strut. Straighten transducer and slide it in until outer support can be slipped over the end.
d. Screw outer support into transducer and tighten to 200-240 lb in. (22.6-27.1 N·m) of
torque. Use only provided wrenching flats for tightening the support.
e. Place flanged plug (2, figure 1) on transducer.
f. Insert set plug (4) in transducer connector so that slot in set plug engages index key in
connector. Rotate transducer until arrow on set plug is pointing to 12 o’clock position.
g. Remove set plug (4). Do not rotate transducer once it has been indexed.
h. Carefully push the transducer/flanged plug assembly inward. Install bolts (6) and nuts (5)
to hold flanged plug (2) to strut flange. Tighten bolts evenly until transducer is seated.
i. Insert set plug (4) into transducer connector and engage slot of set plug with index key in
connector. Check to make sure that position of arrow has not changed.
j. Remove set plug (4) and flanged plug (2) from transducer.
k. Place spring and spring retainer over end of transducer. Position angle bracket on spring
retainer. Install three bolts and nuts to secure bracket and retainer to strut flange. Draw bolts
down alternately in small, equal amounts. Tighten to 55-70 lb in. (6.2-7.9 N·m) of torque.
l. Install power turbine speed pickup leads per WP 109 00.

11/(12 Blank)
GEK 97310
VOLUME II
WP 111 00
WORK PACKAGE
REPLACEMENT OF TERMOCOUPLE LEADS AND

HARNESS

1 - 12 . . . . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Installation of Thermocouple Lead and Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Removal of Thermocouple Lead and Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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WP 111 00
thermocouple leads and harnesses on LM2500 gas turbine models.
NOTE
None

4. REMOVAL OF THERMOCOUPLE LEAD AND HARNESS. See figure 1.
a. Forward rigid lead.
CAUTION
DO NOT BEND LEAD DURING REMOVAL.
NOTE
Only certain LM2500 PC series gas turbines are configured with
the rigid forward thermocouple lead. Consult GEK 50336
Illustrated Parts Breakdown for the correct gas turbine
configuration.
(1) Remove 7 clamps securing the leads to the gas turbine brackets.
(2) Disconnect the lead from the thermocouple aft rigid lead.
(3) Carefully remove lead. Discard metal gasket from aft lead connector.

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WP 111 00
Figure 1. Thermocouple Harnesses and Leads - Early Configuration (Sheet 1 of 3)

3
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WP 111 00
Figure 1. Thermocouple Harnesses and Leads - Early Configuration - Continued (Sheet 2 of 3)

4
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WP 111 00
Figure 1. Thermocouple Harnesses and Leads - Early Configuration - Continued (Sheet 3 of 3)

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GEK 97310
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WP 111 00
b. Aft rigid lead.
CAUTION
(1) Remove the 6 clamps securing the aft lead to the gas turbine bracket.
(2) Loosen, but do not remove, the retaining straps on each thermocouple harness
adjacent to the lead connectors.
(3) Disconnect the 4 harnesses from the lead connectors.
(4) Remove and discard the metal gaskets (1) from the lead connectors.
(5) Disconnect the Pt5.4 manifold retaining straps at 3 brackets.
(6) Remove the 2 nuts and bolts that secure the lead end-brackets to the flange of the
turbine mid frame.
(7) Remove 2 nuts and bolts securing the lead center-bracket (4) to the flange of the
turbine mid frame.
c. Thermocouple harnesses.
CAUTION
DO NOT BEND THERMOCOUPLE HARNESS OR DAMAGE
PROBES.
(1) If top right harness is to be removed, remove turbine rear frame (TRF) cooling tube
and disconnect D-sump vent tubes as follows (see figure 2):
(a) Remove retaining strap from turbine rear frame (TRF) cooling tube at aft flange
of the turbine mid frame (TMF). Loosen retaining straps on forward section of tube.
(b) Remove tube section, seal retainers, and gaskets. Discard gaskets.
(c) Disconnect aft section of D-sump vent tube at the 6 o’clock position at TRF and
2 o’clock position at TMF.
(d) Remove the 3 sets of retaining straps.
(e) Position tube to allow removal of thermocouple harness. Remove seal retainers
and discard metal gaskets.

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WP 111 00
Figure 2. Power Turbine Piping - Right Side

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WP 111 00
(2) If top left harness is to be removed, disconnect ejector D-sump pressurizing tube as
follows (see figures 2 and 3):
(a) Disconnect aft section of D-sump pressurizing tube at forward and aft tube
flanges.
(b) Remove tube retaining straps.
(c) Remove tube section, seal retainers, and gaskets. Discard gaskets.
(3) Disengage thermocouple probe nuts from turbine mid frame bosses.
(4) Loosen harness retaining straps sufficiently to permit removal of harness, but do not
remove straps.
(5) Carefully remove harness and probes from turbine mid frame.
(6) If not previously removed, remove and discard connector metal O-ring (1) from
thermocouple aft (rigid) lead.
5. INSTALLATION OF THERMOCOUPLE LEAD AND HARNESS. See figure 1.
a. Thermocouple harnesses.
(1) Lightly coat threads of probe bosses on TMF with antiseize compound, A50TF201.
CAUTION
DO NOT BEND HARNESS OR DAMAGE PROBES.
(2) Position harness on TMF so that probes (7) are inserted in frame bosses (5). Finger-
tighten probe nuts (6).
(3) If the thermocouple aft lead is already in place, coat connector threads lightly with
antiseize compound, A50TF201, install new metal O-rings (1), and tighten the connectors to
18-20 lb ft (24.4-27.1 N·m) of torque.
(4) Attach harness retaining straps. Tighten bolts to 24-27 lb in. (2.7-3.1 N·m) of torque.
(5) Tighten probe nuts to 18-20 lb ft (24.4-27.1 N·m) of torque.
(6) Install TRF cooling tube and D-sump vent tubes as follows. See figure 2.

8
GEK 97310
VOLUME II
WP 111 00
Figure 3. Power Turbine Piping - Left Side

9
GEK 97310
VOLUME II
WP 111 00
(a) Position TRF cooling tube. Install seal retainer and new metal gasket at each
end of tube.
(b) Install tube flange bolts with boltheads forward and washers under nuts. Secure
with nuts and tighten but do not torque the bolts.
(c) Install retaining straps on tube and on bracket on TMF aft flange with bolts and
nuts. Tighten to 24-27 lb in. (2.7-3.1 N·m) of torque.
(d) Tighten tube aft flange bolts to 100-130 lb in. (11.3-14.7 N·m) of torque.
Tighten tube forward flange bolts to 55-70 lb in. (6.22-7.91 N·m) of torque.
(e) Position D-sump vent tube. Install seal retainer and new metal gasket at each
end of tube.
(f) Install tube flange bolts with boltheads forward and washers under the nuts.
Secure forward flange with nuts. Tighten but do not torque the bolts.
(g) Install the three sets of retaining straps to tube. Secure straps to brackets with
bolts and nuts. Tighten to 24-27 lb in. (2.7-3.1 N·m) of torque.
(h) Tighten tube flange bolts to 55-70 lb in. (6.22-7.91 N·m) of torque.
(7) Install ejector D-sump pressurizing tube as follows. See figures 2 and 3.
(a) Position tube and install seal retainers and new gasket at each end of tube.
(b) Install tube flange bolts with boltheads forward and washers under nuts. Secure
with nuts and tighten but do not torque the bolts.
(c) Install strap retainers on the tube and bracket with bolts and nuts. Tighten to
24-27 lb in. (2.7-3.1 N·m) of torque.
(d) Tighten tube aft flange bolts to 100-130 lb in. (11.3-14.7 N·m) of torque.
Tighten tube forward flange bolts to 55-70 lb in. (6.22-7.91 Nm) of torque.
b. Aft rigid lead.
CAUTION
DO NOT BEND LEAD DURING INSTALLATION.
(1) Position aft lead around bottom of TMF with double connector at 9 o’clock position
and triple connector at 3 o’clock position.

10
GEK 97310
VOLUME II
WP 111 00
(2) Lightly coat connector threads with antiseize compound, A50TF201.
(3) Install new metal O-rings (1) at connectors.
(4) Connect thermocouple harness (and forward lead (3), if in place) to aft lead
connectors fingertight.
(5) Install the six aft lead retaining straps. Tighten bolts to 24-27 lb in. (2.7-3.1 N·m) of
torque.
(6) If harness retaining straps have not been previously tightened, attach clamps to
harnesses and tighten bolts to 24-27 lb in. (2.7-3.1 N·m) of torque. If probe nuts (6) have not been
previously tightened, tighten them to 18-20 lb ft (24.4-27.1 N·m) of torque.
(7) Attach aft lead end brackets (2) and center bracket (4) to TMF aft flange with bolts
(heads forward) and nuts. Torque bolts to 55-70 lb in. (6.22-7.91 N·m).
(8) Torque lead connectors 18-20 lb ft (24.4-27.1 N·m).
(9) Attach Pt5.4 manifold clamps to end and center brackets (2 and 4). Torque to
24-27 lb in. (2.7-3.1 N·m).
c. Forward rigid lead.
CAUTION
DO NOT MAKE ANY SHARP BENDS IN LEAD DURING
INSTALLATION OR INTERNAL INSULATION WILL BE
DAMAGED.
NOTE
Only certain LM2500 PC series gas turbines are configured with
the rigid forward thermocouple lead. Consult GEK 50336
Illustrated Parts Breakdown for the correct gas turbine
configuration.
(1) Position forward lead (3) on gas turbine.
(2) Lightly lubricate aft connector threads with antiseize compound, MIL-T-5544.
Install new metal O-ring (1) at aft connector. Finger-tighten connector.
(3) If flexible forward lead is already installed, be sure that O-ring and metal O-ring are
in place at connection of forward lead and flexible lead. Hand-tighten forward connector to
flexible lead.

11
GEK 97310
VOLUME II
WP 111 00
(4) Very carefully hand form lead as required to provide 0.75 inch (19.1 mm) clearance
between lead and gas manifold and tubes. Do not make any sharp bends in lead or internal
insulation will be damaged.
(5) Install the 7 lead clamps. Secure clamps to brackets with bolts and nuts. Torque
bolts to 24-27 lb in. (2.7-3.1 N·m).
(6) Torque aft connector to 18-20 lb ft (24.4-27.1 N·m).
NOTE
If thermocouple aft lead is not installed, install harness and lead
retaining straps after lead has been connected fingertight to harness,
and then torque thermocouple probe nuts.

12
GEK 97310
VOLUME II
SWP 111 01
REPLACEMENT OF THERMOCOUPLE LEADS AND

HARNESSES

1-6.......... 0
ALPHABETICAL INDEX
Subject Page
Installation of Thermocouple Leads and Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Removal of Thermocouple Leads and Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
SWP 111 01
installation of thermocouple harnesses on LM2500 gas generators.
NOTE
None

R297P04 Safety Wire
4. REMOVAL OF THERMOCOUPLE LEADS AND HARNESSES.

See figures 1 through 3.
CAUTION
THE THERMOCOUPLE HARNESS IS EASILY BENT. USE
CARE IN REMOVAL AND DO NOT DAMAGE THE PROBES.
DO NOT FORCE THE THERMOCOUPLES.
a. Remove two clamps securing the electrical connectors at the 6 o’clock position.
b. Disconnect right and left thermocouple harness electrical connections from thermocouple
lead at the 6 o’clock position.
c. Remove bolts and nuts from nine brackets securing thermocouple harness to turbine
frame.
d. Disconnect thermocouple probe nuts from mounting bosses.
e. Carefully withdraw probes from turbine frame, beginning with probes located at 6 o’clock
and moving in order around to probes located at 12 o’clock. Remove guide sleeves if necessary.

2
GEK 97310
VOLUME II
SWP 111 01
Figure 1. Thermocouple Harnesses and Lead Assembly

3
GEK 97310
VOLUME II
SWP 111 01
Figure 2. Thermocouple Harnesses and Lead - Early Configuration

4
GEK 97310
VOLUME II
SWP 111 01
Figure 3. Thermocouple Harnesses and Lead - Latest Configuration

5
GEK 97310
VOLUME II
SWP 111 01
f. Remove two halves of thermocouple harness, and remove eight brackets and 33 clamps
from harness.
5. INSTALLATION OF THERMOCOUPLE LEADS AND HARNESSES.

CAUTION
DO NOT SUBSTITUTE ANY ANTISEIZE COMPOUND FOR
A50TF201. USE OF UNAUTHORIZED LUBRICANT ON
BOLT/NUT THREADS CAN CAUSE SULFIDATION ATTACK
AND PREMATURE FAILURES.
a. Lightly coat turbine frame bosses and thermocouple probe nuts with antiseize compound
A50TF201.
b. Install thermocouple probe guide sleeve in frame bosses, if sleeves were removed in
step 4.e.
NOTE
When installing thermocouple probes, insert the 12 o’clock probe
first, then remaining probes in order around the gas generator to the
6 o’clock probes.
c. Install the 11 thermocouple probes carefully; tighten probe nuts to 70-80 lb in.
d. Connect thermocouple harness electrical connectors to thermocouple lead at the 6 o’clock

position. Tighten to 30-40 lb in. (3.4-4.5 N·m) of torque and safety-wire.
e. Install 33 clamps to thermocouple harness and secure clamps to brackets attached to tur-
bine frame. Tighten clamp bolts to 24-27 lb in. (2.7-3.1 N·m) of torque.

6
GEK 97310
VOLUME II
SWP 111 02
REPLACEMENT OF THERMOCOUPLE HARNESSES

1-3.......... 0 4 Blank . . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Installation of Thermocouple Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Removal of Thermocouple Harnesses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
SWP 111 02
installation of thermocouple harnesses on LM2500 GA101 model gas generators.
NOTE
checks, rigging, adjustments, runouts, etc.
None

R297P04 Safety Wire
4. REMOVAL OF THERMOCOUPLE HARNESSES.
CAUTION
THE THERMOCOUPLE HARNESS IS EASILY BENT. USE
CARE IN REMOVAL AND DO NOT DAMAGE THE PROBES.
DO NOT FORCE THE THERMOCOUPLES.
a. Remove two clamps securing the electrical connectors at the 6 o’clock position.
b. Disconnect right and left thermocouple harness electrical connections from thermocouple
lead at the 6 o’clock position.
c. Remove bolts and nuts from nine brackets securing thermocouple harness to turbine
frame.
d. Disconnect thermocouple probe nuts from mounting bosses.
e. Carefully withdraw probes from turbine frame, beginning with probes located at 6 o’clock
and moving in order around to probes located at 12 o’clock. Remove guide sleeves if necessary.

2
GEK 97310
VOLUME II
SWP 111 02
f. Remove two halves of thermocouple harness, and remove eight brackets and 33 clamps
from harness.
5. INSTALLATION OF THERMOCOUPLE HARNESSES.
CAUTION
DO NOT SUBSTITUTE ANY ANTISEIZE COMPOUND FOR
a. Lightly coat turbine frame bosses and thermocouple probe nuts with antiseize compound,
A50TF201.
b. Install thermocouple probe guide sleeves in frame bosses, if sleeves were removed in
step 4.e.
NOTE
When installing thermocouple probes, insert the 12 o’clock probe
first, then remaining probes in order around the gas generator to the
6 o’clock probes.
c. Install the 11 thermocouple probes carefully; tighten probe nuts to 70-80 lb in.
d. Connect thermocouple harness electrical connectors to thermocouple lead at the 6 o’clock

e. Install 33 clamps to thermocouple harness and secure clamps to brackets attached to tur-
bine frame. Tighten clamp bolts to 24-27 lb in. (2.7-3.1 N·m) of torque.

3/(4 Blank)
GEK 97310
VOLUME II
WP 112 00
WORK PACKAGE
REPLACEMENT OF COMPRESSOR INLET

TEMPERATURE (CIT) SENSOR
EFFECTIVITY: LM2500 ENGINE MODELS - ALL (Except GA101)

1-2.......... 0
ALPHABETICAL INDEX
Subject Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
WP 112 00
1. INTRODUCTION. For removal and installation of the compressor inlet temperature (CIT)
sensor, see packager’s manual.

2
GEK 97310
VOLUME II
SWP 112 01
REPLACEMENT OF COMPRESSOR INLET

TEMPERATURE (CIT) SENSOR

1-3.......... 0 4 Blank . . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Installation of Compressor Inlet Temperature (CIT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . 2

Removal of Compressor Inlet Temperature (CIT) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
SWP 112 01
1. INTRODUCTION. This subordinate work package contains the instructions for removing
and installing the compressor inlet temperature (CIT) sensor.
None
None
4. REMOVAL OF COMPRESSOR INLET TEMPERATURE (CIT) SENSOR.

See figure 1.
CAUTION
THE SENSOR AND HOSES MAY HAVE OIL IN THEM AT
TIME OF REMOVAL. DRAIN OIL INTO SUITABLE
CONTAINER.
a. Disconnect compressor discharge pressure hose from sensor.
b. Disconnect sensor oil supply hose from orifice on side of sensor.
c. Disconnect sensor signal pressure hose and drain hose from sensor.
d. Remove 4 bolts and washers securing sensor to front frame. Remove sensor and gasket
from front frame.
5. INSTALLATION OF COMPRESSOR INLET TEMPERATURE (CIT) SENSOR.

See figure 1.
a. Install gasket on replacement sensor and install sensor into front frame. Secure sensor,
using 4 bolts and washers; torque to 24-27 lb in. (2.7-3 N·m).
b. Connect signal pressure, drain, and supply hoses to sensor. Tighten hoses.
c. Connect compressor discharge pressure hose to sensor. Torque hoses to standard values.

2
GEK 97310
VOLUME II
SWP 112 01
Figure 1. Compressor Inlet Temperature (CIT) Sensor

3/(4 Blank)
GEK 97310
VOLUME II
WP 113 00
WORK PACKAGE
REPLACEMENT OF LUBE SYSTEM

TEMPERATURE SENSORS

1-4.......... 0
ALPHABETICAL INDEX
Subject Page
Installation of Lube System Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Removal of Lube System Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
WP 113 00
1. INTRODUCTION. This work package contains the instructions for removing and installing
the lube system temperature sensors. Either resistance temperature detectors (RTD) or thermo-
couples may be used.
None

R297P04 Safety Wire
4. REMOVAL OF LUBE SYSTEM TEMPERATURE SENSOR. See figure 1.
NOTE
z There are 5 sensors located in the scavenge oil system lines.
They sense oil temperature for the A-, B-, C-, and D-sumps and
for the transfer gearbox. Procedure for replacement is the same
for each. (Some gas generators utilize fewer sensors.)
z There is one sensor in the lube oil supply line, located just
above the lube and scavenge pump. It is identical to the scav-
enge oil sensors.
a. Disconnect and remove electrical lead (1).
NOTE
Lube system temperatures are monitored by 6 temperature sen-
sors. The Buyer has the option of using thermocouples or resis-
tance temperature detectors.
b. Remove sensor. Remove and discard O-ring.

2
GEK 97310
VOLUME II
WP 113 00
Figure 1. Lube System Temperature Sensors (Typical)

3
GEK 97310
VOLUME II
WP 113 00
5. INSTALLATION OF LUBE SYSTEM TEMPERATURE SENSOR. See figure 1.
CAUTION
CARE SHOULD BE TAKEN NOT TO DAMAGE TIP OF
SENSOR .
a. Lubricate O-ring (2) and install on sensor.
b. Install sensor in tube boss. Torque to 10-12 lb ft (14-16 N·m).
c. Check to ensure seal is in electrical connector and is serviceable. Replace seal if required.
Attach electrical lead (1). Hand-tighten and safety-wire the electrical connector.

4
GEK 97310
VOLUME II
WP 114 00
WORK PACKAGE
REPLACEMENT OF POWER TURBINE VIBRATION

TRANSDUCER LEAD

1-4.......... 0
ALPHABETICAL INDEX
Subject Page
Installation of Power Turbine Vibration Transducer Lead . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Removal of Power Turbine Vibration Transducer Lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
WP 114 00
1. INTRODUCTION. This work package contains instructions for the removal and installation
of power turbine vibration transducer leads.
None

R297P04 Safety Wire
4. REMOVAL OF POWER TURBINE VIBRATION TRANSDUCER LEAD.

CAUTION
a. Disconnect lead at forward connector.
b. Remove clamps that secure lead to gas turbine.
c. Disconnect lead aft connector and remove lead.
5. INSTALLATION OF POWER TURBINE VIBRATION TRANSDUCER LEAD.

CAUTION
DO NOT BEND LEAD DURING INSTALLATION.
a. Position the lead carefully along the bottom of the gas turbine to avoid any excessive
bending.
b. Check to make sure seal ring is inside electrical connector of flexible lead located at
6 o’clock.
c. Connect forward connector of rigid lead to flexible lead at compressor rear frame forward
flange (6 o’clock position). Hand-tighten and safety-wire the connector.
d. Connect aft electrical connector to vibration sensor on turbine rear frame forward flange.
Hand-tighten and safety-wire the connector.
e. Install the 6 clamps to the lead to brackets along bottom of gas turbine. Secure each with
nut and bolt and torque to 24-27 lb in. (2.7-3.1 N·m).

2
GEK 97310
VOLUME II
WP 114 00
Figure 1. Vibration Transducer and Electrical Lead (Early Configuration)

3
GEK 97310
VOLUME II
WP 114 00
Figure 2. Vibration Transducers and Electrical Leads (Earlier Configuration)
Figure 3. Vibration Transducers and Electrical Leads (Later Configuration)

4
GEK 97310
VOLUME II
WP 115 00
WORK PACKAGE
REPLACEMENT OF VIBRATION TRANSDUCERS

1-3.......... 0 4 Blank . . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Installation of Vibration Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Removal of Vibration Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
WP 115 00
1. INTRODUCTION. This work package contains the instructions for the removal and instal-
lation of vibration transducers. Transducer leads shall be removed and installed per WP 114 00.
None

R297P04 Safety Wire
4. REMOVAL OF VIBRATION TRANSDUCERS. See figures 1 and 2.
NOTE
There are two vibration transducers; one on the gas generator and
the other on the power turbine.
a. Disconnect electrical lead from transducer.
b. Remove 3 bolts and nuts that secure transducer to bracket.
5. INSTALLATION OF VIBRATION TRANSDUCERS. See figures 1 and 2.
a. Position transducer on bracket with electrical connector facing forward.
b. Secure transducer to bracket with 3 bolts and nuts. Torque to 24-27 lb in. (3.2-3.5 N·m).
c. Make sure seal is in lead connector and is serviceable. Replace seal if necessary. Connect
electrical lead to transducer hand-tight and safety-wire.

2
GEK 97310
VOLUME II
WP 115 00
Figure 1. Vibration Transducers, Top Mounted (Early Configuration)
Figure 2. Vibration Transducers, Bottom Mounted (Later Configuration)

3/(4 Blank)
GEK 97310
VOLUME II
SWP 115 01
REPLACEMENT OF ACCELEROMETER

1-4.......... 0
ALPHABETICAL INDEX
Subject Page
Installation of Accelerometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal of Accelerometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
SWP 115 01
1. INTRODUCTION. This subordinate work package contains the instructions for the removal
and installation of the accelerometer.
NOTE
None

R297P04 Safety Wire
Local Purchase Tags
Local Purchase Bags
4. REMOVAL OF ACCELEROMETER. See figure 1.
WARNING
CHAPTER 1.
NOTE
There are two accelerometers: one on the gas generator and the
other on the power turbine. Removal procedures are the same for
both.
a. Remove safety wire and disconnect electrical lead from accelerometer. Loosen nearby
clamps if necessary.
b. Remove bolts, nuts, washers, and the accelerometer from the bracket. Tag and bag the
accelerometer and attaching hardware as necessary.

2
GEK 97310
VOLUME II
SWP 115 01
Figure 1. Replacement of Accelerometer

3
GEK 97310
VOLUME II
SWP 115 01
5. INSTALLATION OF ACCELEROMETER. See figure 1.
NOTE
There are two accelerometers: one on the gas generator and the
other on the power turbine. Installation procedures are the same for
both.
a. Visually check the electrical connector to determine if it is serviceable.
b. Visually inspect accelerometer bracket for cracks and/or loose and missing mount bolts.
Tighten or replace as necessary.
c. Position accelerometer on bracket with electrical connector facing forward and secure
with bolts, nuts, and washers. Torque bolts to 24-27 lb in. (2.7-3.1 N·m) for 3 bolthole configura-
tion and 55-70 lb in. (6.2-7.9 N·m) for 4 bolthole configuration.
d. Attach electrical lead to the accelerometer connector and turn 5 to 20 degrees beyond
hand-tight and safety-wire.
e. Attach the lead chain of the instruction plate with cable tie to accelerometer within
1.5 inches of electrical connector threads.
f. Secure any clamps which may have been loosened.

4
GEK 97310
VOLUME II
SWP 115 02
REPLACEMENT OF VIBRATION TRANSDUCER

1-3.......... 0 4 Blank . . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Installation of Vibration Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Removal of Vibration Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
SWP 115 02
and installation of vibration transducers. Transducer leads shall be removed and installed per
WP 114 00.
None

R297P04 Safety Wire
4. REMOVAL OF VIBRATION TRANSDUCER. See figure 1.
NOTE
There is one vibration transducer on the gas generator.
5. INSTALLATION OF VIBRATION TRANSDUCER. See figure 1.
a. Position transducer on bracket with electrical connector facing aft.

2
GEK 97310
VOLUME II
SWP 115 02
Figure 1. Vibration Transducer

3/(4 Blank)
GEK 97310
VOLUME II
SWP 115 03
REPLACEMENT OF VIBRATION TRANSDUCERS

1-3.......... 0 4 Blank . . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Installation of Vibration Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Removal of Vibration Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
SWP 115 03
and installation of vibration transducers. Transducer leads shall be removed and installed per
WP 114 00.
None

R297P04 Safety Wire
4. REMOVAL OF VIBRATION TRANSDUCER. See figure 1.
NOTE
There is one vibration transducer on the gas generator.
5. INSTALLATION OF VIBRATION TRANSDUCER. See figure 1.
a. Position transducer on bracket with electrical connector facing aft.

2
GEK 97310
VOLUME II
SWP 115 03
Figure 1. Vibration Transducer

3/(4 Blank)
GEK 97310
VOLUME II
SWP 115 04
REPLACEMENT OF ACCELEROMETER

1-3.......... 0 4 Blank . . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Installation of Accelerometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal of Accelerometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
SWP 115 04
and installation of accelerometer.
NOTE
None

R297P04 Safety Wire
Local Purchase Tags
Local Purchase Bags
4. REMOVAL OF ACCELEROMETER. See figure 1.
WARNING
CHAPTER 1.
NOTE
There are two types of accelerometers: one with 3 boltholes and
one with 4 boltholes. Removal procedures are the same for both.
a. Remove safety wire and disconnect electrical lead from accelerometer. Loosen nearby
clamps if necessary.
b. Remove bolts, nuts, washers, and the accelerometer from the bracket. Tag and bag the
accelerometer and attaching hardware as necessary.

2
GEK 97310
VOLUME II
SWP 115 04
Figure 1. Replacement of Accelerometer
5. INSTALLATION OF ACCELEROMETER. See figure 1.
NOTE
There are two types of accelerometers: one with 3 boltholes and
one with 4 boltholes. Installation procedures are the same for both.
a. Visually check the electrical connector to determine if it is serviceable.
b. Visually inspect accelerometer bracket for cracks and/or loose and missing mount bolts.
Tighten or replace as necessary.
c. Position accelerometer on bracket with electrical connector facing forward and secure
with bolts, nuts, and washers. Torque bolts to 24-27 lb in. (2.7-3.1 N·m) for 3 bolthole configura-
tion and 55-70 lb in. (6.2-7.9 N·m) for 4 bolthole configuration.
d. Attach electrical lead to the accelerometer connector and turn 5 to 20 degrees beyond
hand-tight and safety-wire.
e. Attach the lead chain of the instruction plate with cable tie to accelerometer within
1.5 inches of electrical connector threads.
f. Secure any clamps which may have been loosened.

3/(4 Blank)
GEK 97310
VOLUME II
WP 116 00
WORK PACKAGE
REPLACEMENT OF PRESSURE PROBES - GAS
GENERATOR INLET AND POWER TURBINE INLET
(Pt2 AND Pt5.4)
EFFECTIVITY: LM2500 ENGINE MODELS - ALL (Except GA101)

1-6.......... 0
ALPHABETICAL INDEX
Subject Page
Installation of Pressure Probes - Gas Generator Inlet and Power Turbine Inlet . . . . . . . . . . 3
Removal of Pressure Probes - Gas Generator Inlet and Power Turbine Inlet . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
WP 116 00
of total pressure (Pt5.4) probes on LM2500 gas generators (except GA101).
NOTE
None

R297P04 Safety Wire
4. REMOVAL OF PRESSURE PROBES - GAS GENERATOR INLET AND POWER

TURBINE INLET.
a. Removal of compressor inlet pressure (Pt2) probe. See figure 1.
(1) Disconnect tube from probe.
(2) Remove the four bolts that secure probe assembly to compressor front frame.
(3) Remove the two bolts that secure probe to plate. Remove plate and probe from com-
pressor front frame.

2
GEK 97310
VOLUME II
WP 116 00
b. Removal of power turbine inlet pressure probes (Pt5.4) and manifold. See figure 2.
NOTE
Probes, manifolds, and tubes may be replaced independently. Cer-
tain LM2500 PC series gas turbines are provided with only one
Pt5.4 pressure probe and no manifold. Consult GEK 50336 Illus-
trated Parts Breakdown for correct configuration.
(1) Remove manifolds as follows:
(a) Remove nuts, bolts, and retaining straps (4) that secure manifold
sections (2 and 7) to turbine mid frame flange brackets.
(b) Disconnect tube assemblies (6) at manifold connections and loosen connector at
the probe to allow tube to swing out of the way.
(c) Disconnect manifold sections at T-fitting (1) and coupling (5).
(d) Remove manifold.
(2) Remove tube assemblies (6) by disconnecting tube from probe (3).
(3) Remove pressure probe (3) by removing probe nut (10).
5. INSTALLATION OF PRESSURE PROBES - GAS GENERATOR INLET AND

POWER TURBINE INLET.
a. Installation of compressor inlet pressure (Pt2) probe. See figure 1.
(1) Attach probe to plate by inserting two bolts through plate. Install the longest bolt
through the plate boss. Tighten both bolts to 55-70 lb in. (6.2-7.9 N·m) of torque.
(2) Insert the probe into the front frame with probe opening facing forward.
(3) Install four bolts to secure probe assembly to frame. Tighten the bolts to 55-70 lb in.
(6.2-7.9 N·m) of torque. Safety-wire all six bolts.
(4) Connect air tube to the probe. Tighten tube fitting to 270-300 lb in. (30.5-33.9 N·m)
of torque.
b. Installation of power turbine inlet pressure probes (Pt5.4) and manifold. See figure 2.

3
GEK 97310
VOLUME II
WP 116 00
Figure 1. Compressor Inlet Pressure Probe
NOTE
Probes, manifolds and tubes may be replaced independently.
(1) Install pressure probe (3) as follows:
CAUTION
EACH PROBE MUST BE INSTALLED WITH THE THREE
TABS ON THE PROBE FLANGE INSERTED INTO THE
THREE SLOTS IN THE MOUNTING BOSS (8). THIS WILL
ENSURE CORRECT POSITIONING OF PROBE WITH HOLES
IN PROBE FACING FORWARD. IMPROPER INSTALLATION
WILL RESULT IN LOW PRESSURE INDICATIONS.
NOTE
Later configurations have only one probe and no manifold. Install
the probe as indicated and connect the tube assembly.
(a) Lightly coat the turbine mid frame boss (8) and probe nut (10) threads with anti-
seize compound, A50TF201.

4
GEK 97310
VOLUME II
WP 116 00
Figure 2. Total Pressure Probes (Pt5.4) and Manifolds

5
GEK 97310
VOLUME II
WP 116 00
(b) Carefully install probe into TMF boss. Make sure that alignment tabs (9) are
seated in boss slots.
(c) Hold probe firmly in place, install probe nut (10), and tighten nut to 70-80 lb in.
(6.22-9.01 N·m) of torque.
(d) Make sure that alignment flat (11) on probe faces forward and then safety-wire.
(2) Attach tube assembly (6) to probe fingertight.
(3) Position manifold sections (2 and 7) on turbine mid frame with T-fitting (1) just
below 9 o’clock position. Connect manifold sections at T-fitting (1) and coupling (5) fingertight.
(4) Connect tube assemblies (6) to manifolds fingertight.
(5) Install retaining straps (4) to manifold and secure to turbine mid frame flange bracket
with bolt and nut. Tighten nut to 24-27 lb in. (2.7-3.1 N·m) of torque.
(6) Tighten all tube connections to 135-150 lb in. (15.3-17.0 N·m) of torque.

6
GEK 97310
VOLUME II
SWP 116 01
REPLACEMENT OF GAS GENERATOR POWER

TURBINE INLET PRESSURE PROBES (PT5.4)

1-3.......... 0 4 Blank . . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Installation of Pressure Probes - Gas Generator Pt5.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Removal of Pressure Probes - Gas Generator Pt5.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
SWP 116 01
and installation of power turbine inlet total pressure (Pt5.4) probes on LM2500 Model GA101 gas
generators.
NOTE
None

R297P04 Safety Wire
4. REMOVAL OF PRESSURE PROBES - GAS GENERATOR Pt5.4.
CAUTION
EXERCISE CARE DURING REMOVAL OF PRESSURE
PROBES AND MANIFOLD. LOW PRESSURE READINGS
WILL RESULT FROM BENT OR DAMAGED PROBES.
a. Remove clamps securing tubes to turbine frame.
b. Remove five tubes connecting probes to manifold by disconnecting five nuts at the probes
and five nuts at the manifold. Remove tubes.
c. Disconnect probe retaining nuts and remove probes.
d. Disconnect eight clamps securing manifold to turbine frame.
e. Disconnect three fittings connecting manifold sections; remove manifold.

2
GEK 97310
VOLUME II
SWP 116 01
5. INSTALLATION OF PRESSURE PROBES - GAS GENERATOR Pt5.4.
CAUTION
DO NOT SUBSTITUTE ANY THREAD LUBRICANT FOR
a. Lightly coat the mounting boss with A50TF201 antiseize compound.
CAUTION
PRESSURE PROBES MUST BE INSTALLED WITH THREE
TANGS ON PROBE FLANGE INSERTED INTO THREE SLOTS
IN MOUNTING BOSS. HOLES IN PROBE SHAFT MUST
FACE FORWARD.
b. Carefully insert probes into mounting bosses and align tabs with slots. Secure probes to
bosses, using retaining nuts. Tighten to 78-80 lb in. (8.9-9.0 N·m) of torque and safety-wire.
c. Install three manifold sections; connect three fittings. Position the connector at 12 o’clock
d. Install eight clamps to secure manifold to brackets; tighten to 24-27 lb in. (2.7-3.0 N·m) of
torque and safety-wire.
e. Install five tubes connecting probes to manifold. Connect coupling at each end of tubes.
Tighten to 24-27 lb in. (2.7-3.0 N·m) of torque.
f. Secure tubes to brackets on turbine frame, using a clamp at tubes. Tighten to 24-27 lb in.

3/(4 Blank)
GEK 97310
VOLUME II
WP 117 00
WORK PACKAGE
REPLACEMENT OF OUTSIDE PIPING AND WIRING
EFFECTIVITY: LM2500 GAS TURBINE MODELS

1 - 38 . . . . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Installation of Outside Piping and Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Removal of Outside Piping and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1
GEK 97310
VOLUME II
WP 117 00
1. INTRODUCTION. This work package contains the instructions for the removing and
installing of gas turbine outside piping and wiring.
CAUTION
OBSERVE THE MAINTENANCE PRACTICES OF VOLUME I,
CHAPTER 5.
The following wiring shall be removed and installed per the appropriate work package:
Ignition Leads WP 106 00

Power Turbine Speed Pickup Leads WP 109 00
Power Turbine Vibration Transducer Lead WP 114 00
Thermocouple WP 111 00
NOTE

1C6344 Wrench Set, Air Tube Coupling

Safety Wire

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GEK 97310
VOLUME II
WP 117 00
4. REMOVAL OF OUTSIDE PIPING AND WIRING. Use 1C6344 air tube coupling
wrench set.
CAUTION
OBSERVE MAINTENANCE PRACTICES OF VOLUME I,
CHAPTER 5.
a. Left side piping. See figure 1.
NOTE
There is no special sequence for removing outside piping. Adhere
to maintenance practices of Volume I, Chapter 5.
b. Right side piping. See figure 2.
NOTE
c. Transfer gearbox piping. See figure 3.
NOTE
d. Gas turbine wiring.
(1) Refer to applicable paragraph for detailed instructions for removal of electrical lead
being removed.
(2) Adhere to maintenance practices of Volume I, Chapter 5.
(3) Refer to work packages:
Ignition Leads 106 00

Power Turbine Speed Pickup Leads 109 00
Thermocouple Lead 111 00
Power Turbine Vibration Transducer Lead 114 00

3
GEK 97310
VOLUME II
WP 117 00
Figure 1. Gas Turbine Piping - Left Side (Sheet 1 of 3)

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VOLUME II
WP 117 00

5
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WP 117 00

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WP 117 00
Figure 2. Gas Turbine Piping - Right Side (Sheet 1 of 3)

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WP 117 00

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WP 117 00

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WP 117 00
Figure 3. Transfer Gearbox Piping (Sheet 1 of 2)

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WP 117 00

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VOLUME II
WP 117 00
5. INSTALLATION OF OUTSIDE PIPING AND WIRING.
CAUTION
CHAPTER 5.
(1) Table 1 lists items in normal sequence of installation.
(2) The number following the listed item refers to its location in the illustration.
(3) To determine the torque required for installing any item, first locate the item number
in the illustration, and then locate the item number in the table.
(4) Use 1C6344 air tube coupling wrench set.
CAUTION
CHAPTER 5.
(2) The number following the listed items refer to its location in the illustration.
(3) To determine the torque required for installing any item, first locate the item in the
illustration and then locate the item number in the table.
CAUTION
CHAPTER 5.
(1) There is no special sequence for installing the transfer gearbox piping.
(2) Table 3 has items in normal sequence of installation and gives required torque
values.
in the illustration and then locate the item number in the table.

12
Table 1. GAS TURBINE LEFT SIDE PIPING
Item No. To With Torque Note
O-ring 18 Adapter 19 Lubricate

Adapter 19 VSV Actuator 135-150 lb in (15-17 N·m) Safety-wire
O-ring 17 Adapter Drain 16 Lubricate
Adapter Drain 16 VSV Actuator Hand Tight
Tube, Head End 11 VSV Actuator 135-150 lb in (15-17 N·m)
Tube, Head End 3 Tube 11 135-150 lb in (15-17 N·m)
Tube, Rod End 14 VSV Actuator 135-150 lb in (15-17 N·m)
Tube, Drain 13 Adapter Drain 16 135-150 lb in (15-17 N·m)
Tube, Drain 4 Tube 13 135-150 lb in (15-17 N·m)
Clamps 10 Tubes 11, l3,14 Bolt, nut, spacer 24-27 lb in (2.71-3.05 N·m) To bracket
Clamps 9 Tubes 11,13,14 Bolt, spacer 24-27 lb in (2.71-3.05 N·m) To bracket
Tube 1 Tube 14 135-150 lb in (15-17 N·m)
Clamps 2 Tubes 1, 3, 4 Bolt, spacer 24-27 lb in (2.71-3.05 N·m) To bracket
Clamps 12 Tubes 11,14 Bolt, nut 24-27 lb in (2.71-3.05 N·m)
Clamps 15 Tubes 11,14 Bolt, nut 24-27 lb in (2.71-3.05 N·m)
Nipple 8 CFF 440 lb in (50 N·m)
Hose 7 Nipple 8 440 lb in (50 N·m)

13
WP 117 00
GEK 97310
VOLUME II
Table 1. GAS TURBINE LEFT SIDE PIPING - Continued
14
WP 117 00
VOLUME II
Bracket, Clamp 6 Hose 7 Bolt, nut 24-27 lb in (2.71-3.05 N·m)

GEK 97310
Bracket, Clamp 5 Tubes 1, 3, 4 Bolt, spacer 24-27 lb in (2.71-3.05 N·m) To gearbox mount
Tube, B 65 CRF 4 bolts, nut, washers 55-70 lb in (6-8 N·m) Gasket at CRF
Scavenge
Clamp 72 Tube 66 Bolt, nut, washer 24-27 lb in (2.71-3.05 N·m) Spacer between
clamp & bracket
Tube, Bracket & 64 CRF 4 bolts, nuts, washer 125 lb in (14 N·m) Gasket, retainer
Spray Shield 2 bolts 24-27 lb in (2.71-30.5 N·m)
Tube 47 Tube 64 4 bolts, nuts, washers 55-70 lb in (6-8 N·m) Gasket, retainer
TMF clamp 36-44 lb in (4-5 N·m)
Straps 62 2 bolts, nuts, washers 24-27 lb in (2.71-3.05 N·m)
Straps 52 2 bolts, nuts, washers 24-27 lb in (2.71-3.05 N·m)
Cover, Gasket 32 CRF 3 bolts, nuts 125 lb in (14 N·m)
Bracket 33 Cover 32 3 bolts, nuts 125 lb in (14 N·m)
Tube, LPT 34 9th Stg Comp Clamp 36-44 lb in (4-5 N·m)
Clamp 31 Tube 34 2 bolts, nuts 55-70 lb in (6-8 N·m)
Tube, LPT 35 Tube 34 2 bolts, nuts, washers 55-70 lb in (6-8 N·m) Seal retainer
Straps 25 Tube 35 2 bolts, nuts, washers 24-27 lb in (2.71-3.05 N·m)
Clamps 36 Tube 35 2 bolts, nuts 24-27 lb in (2.71-3.05 N·m)


Tube 27 TMF 4 bolts, nuts, washers 55-70 lb in (6-8 N·m) Gasket
Tube 35 Coupling 24-26 lb ft (32.5-35.3 N·m) Saftey-wire
Tube 35 Coupling 24-26 lb ft (32.5-35.3 N·m) Safety-wire
Tube 35 Coupling 24-26 lb ft (32.5-35.3 N·m) Safety-wire
Tube 22 Tube 34 4 bolts, nuts, washers 55-70 lb in (6-8 N·m) Seal, retainer
Strap 24 Tube 22 2 bolts, nuts, washers 24-27 lb in (2.71-3.05 N·m)
Strap 29 Tube 22 2 bolts, nuts, washers 24-27 lb in (2.71-3.05 N·m)
Cover, Gasket 80 CRF 3 bolts, nuts 125 lb in (14 N·m)
Tube 78 13th Stg Comp Clamp 41-49 lb in (5-6 N·m)
Clamp 79 Bracket 81 2 bolts, nuts 55-70 lb in (6-8 N·m)
Strap 83 Tube 78 2 bolts, nuts 24-27 lb in (2.71-3.05 N·m)
Tube 40 CRF 4 bolts, washers 55-70 lb in (6-8 N·m) Gasket,
Safety-wire
Tube 42 Tubes 40, 78 Couplings 74-76 lb ft (100-103 N·m) Safety-wire
Tube 57 CRF 4 bolts, washers 55-70 lb in (6-8 N·m) Gasket,

Safety-wire
GEK 97310
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WP 117 00
VOLUME II
16
WP 117 00
VOLUME II
Tube 49 Tubes 57, 78 Couplings 74-76 lb ft (100-103 N·m) Safety-wire

GEK 97310

Clamp 39 Tube 38 Bolt, nut, washer 24-27 lb in (2.71-3.05 N·m)
Tube (Ref. right 75
side piping)
Clamp 74 Tube 75 Bolt, nut, washer, 24-27 lb in (2.71-3.05 N·m) Spacer between
spacer clamp
Tube 82 TMF 4 bolts, nuts, washers 24-27 lb in (2.71-3.05 N·m) Gasket
Tube 75 connector 50 lb ft (68 N·m)
Clamp 85 Tube 82 Bolt, nut, guide 24-27 lb in (2.71-3.05 N·m)
shoulder, washer
Tube (Ref. right 70
side piping )
O-ring 69 Reducer 69
Reducer 69 Check Valve 69 325 lb in (37 N·m)

Check Valve 69 Tube 70 50 lb ft (68 N·m)

Tube 63 Reducer 69 440 lb in (50 N·m)
Clamp 67 Tube 63 Bolt, nut, washer, 24-27 lb in (2.71-3.05 N·m)
spacer
Clamp 60 Tube 63 Bolt, nut, guide, 24-27 lb in (2.71-3.05 N·m)
shoulder washer
Spray Shield 68 Check Valve 69 2 clamps, bolts, nuts 24-27 lb in (2.71-3.05 N·m)
Tube 48 Tube 63, TMF 450-550 lb in (51-62 N·m)
Clamp 87 Tubes 82, 48 Bolt, nut 24-27 lb in (2.71-3.05 N·m)
Clamp 46 Tube 48 Bolt, nut 24-27 lb in (2.71-3.05 N·m)
Spray Shields 41, Tube 45 Nut, bolt, clamp 24-27 lb in (2.71-3.05 N·m)
86
Tube (Ref. right 76
side piping)
Clamp 73 Tube 76 Bolt, nut, washer 24-27 lb in (2.71-3.05 N·m) Spacer between
spacer clamps
Tube 59 Tube 76 450-550 lb in (51-62 N·m)

GEK 97310
17
WP 117 00
VOLUME II
18
WP 117 00
VOLUME II
Clamp 60 Tube 59 Bolt, nut, guide 24-27 lb in (2.71-3.05 N·m)

GEK 97310
shoulder washer
Tube & Spacer 20 CRF 4 bolts, nuts, washers 55-70 lb in (6-8 N·m)
Tube & Spacer 65 CRF 4 bolts, nuts, washers 55-70 lb in (6-8 N·m)
Tube 54 TMF 270 lb in (31 N·m)
Tube 56 CRF, tube 54 270 lb in (31 N·m)
Ejector, 89 TRF Strut 4 bolts, nuts, washers 55-70 lb in (6-8 N·m) Seal, retainer
D-sump Pres. Tubes 22, 38 (each) (each)
Strap 88 Ejector 89 2 bolts, nuts 24-27 1b in (2.71-3.05 N·m)
Tube 93 Tube 63, TRF 450-550 lb in (2.71-3.05 N·m)
shoulder washer
Cap 97 Tube 93 450-550 lb in (51-62 N·m)
Spray Shield 90 Tube 93 Clamp, bolt, nut 24-27 lb in (2.71-3.05 N·m)

Spray Shield 99 Tube 93 Clamp, bolt, nut 24-27 lb in (2.71-3.05 N·m)
Nipple, O-ring 100 TRF Sump 650-770 lb in (73-87 N·m) Lubricate

Manifold
Tube 92 Tube 59, 50 lb ft (68 N·m)
Nipple 100
shoulder washer
Cap 98 Tube 92 650-770 lb in (73-87 N·m)
Table 2. GAS TURBINE RIGHT SIDE PIPING
Tube 37 TMF V-clamp 35-44 lb in (4-5 N·m)

Strap Retainers 34 Tube 37 2 bolts, nuts 24-27 lb in (2.71-3.05 N·m)
Clamp 40 Tube 37 2 bolts, nuts 24-27 lb in (2.71-3.05 N·m)
Tube 43 CRF, Tube 37 4 bolts, nuts, washers 55-70 lb in (6-8 N·m)
Tube, Gasket 21 CRF 3 bolts, nuts 125 lb in (14 N·m)

Tube 18 9th Stg. Comp Clamp 35-44 lb in (4-5 N·m)
GEK 97310
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WP 117 00
VOLUME II
Table 2. GAS TURBINE RIGHT SIDE PIPING - Continued
20
WP 117 00
VOLUME II
Strap 19 Tube 18, 2 bolts, nuts 55-70 lb in (6-8 N·m)

GEK 97310
Bracket 20
Strap 10 Tube 14, Bracket 2 bolts, nuts 24-27 lb in (2.71-3.05 N·m)
Strap 25 Tube 24, Bracket 4 bolts, nuts, washers 24-27 lb in (2.71-3.05 N·m)
Tube 2 Tube 24, TMF 4 bolts, nuts, washers 55-70 lb in (6-8 N·m) Seal, retainer
coupling 24-27 lb in (2.71-3.05 N·m) Wrench, 1C6344
Safety-wire
Tube 36 Tube 24, TMF 4 bolts, nuts, washers 55-70 lb in (6-8,N·m) Seal, retainer
Wrench, 1C6344
Safety-wire
Cover, Gasket 21 CRF 3 bolts, nuts, washers 125 lb in (14 N·m)
Bracket 20 Cover 21 3 bolts, nuts, washers 125 lb in (14 N·m)
Tube 16 13th Stg. Comp. Clamp 41-49 lb in (5-6 N·m)


Bracket 20
Tube 7 CRF 4 bolts, washers 55-70 lb in (6-8 N·m) Gasket, Safety-wire
Tube 35 CRF 4 bolts, washers 55-70 lb in (6-8 N·m) Gasket, Safety-wire
Tube 27 Tubes 7, 16 2 couplings 60 lb ft (81 N·m) Wrench, 1C6344
Tube 26 Tubes 35, 16 2 couplings 60 lb ft (81 N·m) Wrench, 1C6344
Tube 2 Ejector 97, 4 bolts, nuts, washers 55-70 lb in (6-8 N·m) Seal, retainer
Tube 16
Clamp 29 Tube 2, Bracket 2 bolts, nuts 24-27 lb in (2.71-3.05 N·m)
Adapter 63 8th Stg. Clamp 90-100 lb in (10-11 N·m)
Manifold
Tube 64 Adapter 63, 4 bolts, nuts, washers 55-70 lb in (6-8 N·m) Gasket, retainer
Ejector 60
Clamp 65 Tube 64, Bracket Bolt, nut 24-27 lb in (2.71-3.05 N·m)
Ejector 60 Tube 86, 64 4 bolts, nuts, washers 55-70 lb in (6-8 N·m) Gasket, retainer

GEK 97310
21
WP 117 00
VOLUME II
22
WP 117 00
VOLUME II
Strap 61 Ejector 60, 2 bolts, nuts 24-27 lb in (2.71-3.05 N·m)

GEK 97310
Bracket
Clamp 78 Ejector 60, 2 bolts, nuts 24-27 lb in (2.71-3.05 N·m)
G/B Support
Tube 86 CFF 4 bolts, nuts 55-70 lb in (6-8 N·m) Gasket, retainer
Screen 62 Ejector 60 Clamp 36-44 lb in (4-5 N·m)
Clamp 66 Tube Bolt, nut 24-27 lb in (2.71-3.05 N·m)
Clamp 70 Tube Bolt, nut 24-27 lb in (2.71-3.05 N·m)
Clamp 67 Tube Bolt, nut, washer, 24-27 lb in (2.71-3.05 N·m) Spacer between
spacer clamp and bracket
Clamps 68 Tubes 69 Bolt, nut, washer 24-27 lb in (2.71-3.05 N·m) Spacer between
clamp and bracket
Hose 71 Tube 550 lb in (62 N·m)
Hose 72 Tube 70 lb ft (95 N·m)
Hose 75 Tube 70 lb ft (95 N·m)
Clamp 74 Hoses 72,75 Bolt, nut 24-27 lb in (2.71-3.05 N·m)
Tube 76 Hose 87 440 lb in (50 N·m)
Clamp 73 Bracket, Stg 6 2 bolts, nuts 24-27 lb in (2.71-3.05 N·m) Bracket tab aft
Boss

Clamp 78 G/B Mount Bolt 24-27 lb in (2.71-3.05 N·m)

Plug & O-ring 80 Tube 76 110 lb in (12 N·m) Luricate
Cap 81 Tube 76 250 lb in (28 N·m)
Hose 87 Tube 76 440 lb in (50 N·m)
Clamp, Bracket 88 Hose 87 Bolt, nut 24-27 lb in (2.71-3.05 N·m)
Tube 45 CRF & Tube 250 lb in (28 N·m)
Bracket, Clamp 44A Tube 45 Bolt, nut 24-27 lb in (2.71-3.05 N·m)
Clamp 47 Tube 45, Bracket Bolt, nut 24-27 lb in (2.71-3.05 N·m)
Tube 42 Adapter 63 4 bolts, washers 55-70 lb in (6-8 N·m) Gasket and retainer
Clamp 42A Tube 42 Bolt, nut, washers 24-27 lb in (2.71-3.05 N·m)

Adapter, Tube 93 VSV Actuator 135-150 lb in (15-17 N·m)
O-ring 91 VSV Actuator Lubricate
GEK 97310
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WP 117 00
VOLUME II
24
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VOLUME II

GEK 97310
Tube, Rod End 89 VSV Actuator & 110 lb in (12 N·m)

Tube 82
Tube, Head 94 VSV Actuator & 110 lb in (12 N·m)
End Tube 84
Tube, Drain 95 VSV Actuator 110 lb in (12 N·m)
Shroud
Clamp 58 G/B Mount Bolt, spacer 24-27 lb in (2.71-3.05 N·m)
Bracket, Clamp 83 Tubes 82, 84, 94 Bolt, spacer 24-27 lb in (2.71-3.05 N·m)
Tube 54 CFF 4 bolts, washers 55-70 lb in (6-8 N·m) Seal, retainer
Clamp 53 Tube 54, Bolt, nut 24-27 lb in (2.71-3.05 N·m)
Stator Bracket
Stator Bracket
O-ring 59 Tube 18 Lubricate
Tube 57 Tube 54 Hand tight
Clamp 77 Tube 57, 2 bolts, nuts 24-27 lb in (2.71-3.05 N·m)
Stator Bracket


Tube 14 Tube 51, 4 bolts, nuts, washers 55-70 lb in (6-8 N·m) Seal, retainer
CRF 6 bolts, nuts washers 55-70 lb in (6-8 N·m)
Clamp 49 Tube 14, 2 bolts, nuts 24-27 lb in (2.71-3.05 N·m)
CRF Bracket
Strap 48 Tube 51, 2 bolts, nuts 24-27 lb in (2.71-3.05 N·m)
Stator Bracket
O-ring 15 Tube Lubricate
Tube 1 Tube 12, 4 bolts, nuts, washers 55-70 lb in (6-8 N·m) Seal, retainer
TMF Strut 4 bolts, nuts, washers 55-70 lb in (6-8 N·m) Seal, retainers
Screen 31 TMF Strut Clamp 36-44 lb in (4-5 N·m)
Screen 32 TMF Strut Clamp 36-44 lb in (4-5 N·m)
Cover Plate 50 8th Stg. Comp Clamp 90-100 lb in (10-11 N·m)
Ejector 97 Tubes 2, 6 4 bolts, nuts, washers 55-70 lb in (6-8 N·m) Seal, retainer
D-sump TRF (each) (each)
Press.

GEK 97310
25
WP 117 00
VOLUME II
26
WP 117 00
VOLUME II
Strap 101 Ejector 97 2 bolts, nuts 24-27 lb in (2.71-3.05 N·m)

GEK 97310
Tube 98 Tube 1, D-sump 4 bolts, nuts, washers 55-70 lb in (6-8 N·m) Seal, retainer
Manifold 4 bolts, washers 55-70 lb in (6-8 N·m) Seal, retainer,
Safety-wire
Ejector 103 Tube 42, 4 bolts, nuts, washers 55-70 lb in (6-8 N·m) Seal, retainer
TRF Strut (each)
Strap 104 Ejector 103 2 bolts, nuts 24-27 lb in (2.71-3.05 N·m)

Screen 105 Clamp 36-44 lb in (4 -5 N·m)
Spray Shield 44A Bolt, nut 24-27 lb in (2.71-3.05 N·m) Clamp
Table 3. TRANSFER GEARBOX PIPING
Nipple & O-ring 42 Gearbox 135-150 lb in (15-17 N·m) Lubricate

Tube 52 TBG Scav, 112-128 lb ft (152-174 N·m)
Lube Pump
Table 3. TRANSFER GEARBOX PIPING - Continued
Hose 45 Gearbox 4 bolts 24-27 lb in (2.71-3.05 N·m) Gasket

Tube 52 112-128 lb ft (152-174 N·m)
Clamp 44 Hose 45, Bolt, nut 24-27 lb in (2.71-3.05 N·m)
A/O Separator
Bracket
Tube, Lube- 54 Lube Pump 135-150 lb in (15-17 N·m)
Spline
Clamps 51 Tubes 54, 52 Bolt 24-27 lb in (2.71-3.05 N·m)
Cap 55 Tube 54 135-150 lb in (15-17 N·m)
Nipple & O-ring 21 A/O Sep Cover 180-200 lb in (20-33 N·m) Lubricate
Reducers & 62 Gearbox 155-175 lb in (18-20 N·m) Lubricate
O-rings
Tube 64 Reducer 62, Oil 135-150 lb in (15-17 N·m)
Supply Tube
Hose 63 Reducer 62, 135-150 lb in (15-17 N·m)
Tube 64
Cap 78 Tube (A/O Sep) 135-150 lb in (15-17 N·m)
Hose/Tube 26 Gearbox, 4 bolts 24-27 lb in (2.71-3.05 N·m)
Lube Pump 75-91 lb ft (102-123 N·m)
Bracket 33 Gearbox 2 bolts 24-27 lb in (2.71-3.05 N·m)

Clamp 27 Gearbox Bolt 24-27 lb in (2.71-3.05 N·m)
GEK 97310
27
WP 117 00
VOLUME II
28
WP 117 00
VOLUME II
Cap 28 Hose/Tube 26 75-91 lb ft (102-123 N·m)

GEK 97310
Brackets 48 Gearbox 2 bolts, washers 55-70 lb in (6-8 N·m) Safety-wire

Check Valve & 47 Tube 43 75-91 lb ft (102-123 N·m) Lubricate
O-ring
Tube & O-ring 43 Check Valve 47 75-91 lb ft (102-123 N·m) Lubricate
Lube Pump 112-128 lb ft (152-174 N·m)
Support & 46 Bracket 48, 2 nuts, washers 24-27 lb in (2.71-3.05 N·m)
U-bolt Check Valve 47
Check Valve & 50 Tube 53 75-91 lb ft (102-123 N·m) Lubricate
O-ring
Tube & O-ring 53 Check Valve 50, 75-91 lb ft (102-123 N·m) Lubricate
Lube Pump 112-128 lb ft (152-174 N·m)
Support & 49 Bracket 48, 2 nuts, washers 24-27 lb in (2.71-3.05 N·m)
U-Bolt Check Valve 50
Bracket 4 Gearbox 2 bolts, nuts 55-70 lb in (6-8 N·m)
Bracket 36 Gearbox Bolt 160-210 lb in (18-28 N·m)
Bracket 10 Gearbox (side) Bolt, washer 160-210 lb in (18-28 N·m) Safety-wire
Gearbox (bottom) Bolt, washer 24-27 lb in (2.71-3.05 N·m) Safety-wire
Bracket 12 Gearbox Bolt, washer 160-210 lb in (18-28 N·m) Safety-wire
(fwd side)

Bracket 10 2 bolts, nuts, 55-70 lb in (6-8 N·m)
4 washers
Nipples & 38 Gearbox Pads 135-150 lb in (15-17 N·m) Lubricate

O-rings
Tubes & O-ring 34 Gearbox Pads 135-150 lb in (15-17 N·m) Lubricate
Manifold, Drain 35 Nipple 38 135-150 lb in (15-17 N·m)
Hose 25 Nipple 38, 135-150 lb in (15-17 N·m)
Manifold 35
Clamp 37 Manifold 35, Bolt, nut 24-27 lb in (15-17 N·m)
Bracket 36
Clamp 32 Manifold 35, Bolt, nut 24-27 lb in (2.71-3.05 N·m)
Bracket 33
Tee 31 Manifold 35 135-150 lb in (15-17 N·m)
Hose 30 Tee 31, Lube 135-150 lb in (15-17 N·m)
Pump
Clamps 29 Tube 26, Hose 30 Bolt, nut 24-27 lb in (2.71-3.05 N·m)
Nipple & O-ring 17 Speed Sensor 180-200 lb in (20-23 N·m) Lubricate
Brackets 60 Gearbox Cover 2 nuts, washers 55-70 lb in (6-8 N·m)
Clamps 61 Brackets 60, 2 bolts, nuts 24-27 lb in (2.71-3.05 N·m)

CIT Lead
GEK 97310
29
WP 117 00
VOLUME II
30
WP 117 00
VOLUME II
Nipple & O-ring 16 Servo Valve 180-200 lb in (20-23 N·m) Lubricate

GEK 97310

Hose 9 Nipples 16, 176 270-300 lb in (31-34 N·m)
Bracket 12
Hose 7 Nipple 13 450-550 lb in (51-62 N·m)
Clamp 5 Hose 7, Bracket 4 Bolt, nut 24-27 lb in (2.71-3.05 N·m)
Clamp 3 Hose 6, Bracket 4 Bolt, nut, washer 24-27 lb in (2.71-3.05 N·m)
Clamps 8 Hoses 6, 7 Bolt, nut 24-27 lb in (2.71-3.05 N·m)
Hose 23 Nipple 15, Lube 450-500 lb in (51-62 N·m)
Supply Tube
Hose 24 Nipple 19, Lube 450-500 lb in (51-62 N·m)
Supply Tube
Clamp 59 Hose 23, Bracket Bolt, nut 24-27 lb in (2.71-3.05 N·m)
Clamps 58 Hoses 23, 24 2 bolts, nuts 24-27 lb in (2.71-3.05 N·m)
Bracket


Check Valve 41 Hose 20 270-300 lb in (31-34 N·m)
Reducer & 40 Check Valve 41 180-200 lb in (20-23 N·m) Lubricate
O-ring
Lube Pump
Hose 20 Check Valve 41, 270-300 lb in (31-34 N·m)
Nipple 18
Clamp 65 Hose 23, CIT lead Bolt, nut 24-27 lb in (2.71-3.05 N·m)
Bracket 70 Sump Vent Tube Bolt, nut, washer 55-70 lb in (6-8 N·m)
Coupling, 66 Lube Pump 75-91 lb ft (102-123 N·m)
D-Scav
C-Scav
B-Scav
Clamp 69 Hose 39, Sump Bolt, nut 24-27 lb in (2.71-3.05 N·m)
Vent Tube

GEK 97310
31
WP 117 00
VOLUME II
32
WP 117 00
VOLUME II
Clamp 71 Check Valve 41, Bolt, nut 24-27 lb in (2.71-3.05 N·m)

GEK 97310
Sump Vent Tube,

Flange Bracket 70
Coupling 72 Tube 42, Lube 450-500 lb in (51-62 N·m)
Supply Tube
Clamp 73 Hose 20, Sump Bolt, nut 24-27 lb in (2.71-3.05 N·m)
Vent Tube
Tube 77 Nipple 21, Sump 135-150 lb in (15-17 N·m)
Vent Tube
Tube 76 Vent Tube, Hand tight
A/O Separator 6 bolts, washers 55-70 lb in (6-8 N·m) Saftey-wire
Sensor, CIT 57 CFF 4 screws 24-27 lb in (2.71-3.05 N·m)
Bracket 83 Gearbox Pad Nut
Hose 84 Tee 31, VSV 135-150 lb in (15-17 N·m)
Drain Manifold
Clamp 82 Bracket 80,
Hose 81
Bracket 80 Gearbox Bolt 90-110 lb in (10-11 N·m) Safety-wire

Clamp 80 Bracket 80 Bolt, nut, washer 24-27 lb in (2.71-3.05 N·m)
Coupling 81 Oil Supply 55-65 lb ft (75-88 N·m)

Manifold
Coupling 79 Oil Supply 135-150 lb in (15-17 N·m)
Manifold

GEK 97310
33
WP 117 00
VOLUME II
GEK 97310
VOLUME II
WP 117 00
d. Optional continuous lube starter piping (non-shrouded and shrouded).
(See figures 4 and 5 and table 4.)
e. Gas turbine wiring.
(1) Refer to applicable work package for detailed installation instructions for electrical
lead being installed.
Ignition Leads 106 00

Power Turbine Speed Pickup Lead 109 00
Thermocouple Lead 111 00
Power Turbine Vibration Transducer Lead 114 00

34
GEK 97310
VOLUME II
WP 117 00
Figure 4. Continuous Lube Starter Piping (Non-Shrouded)

35
GEK 97310
VOLUME II
WP 117 00
Figure 5. Continuous Lube Starter Piping (Shrouded)

36
Table 4. Continuous Lube Starter Piping (Non-Shrouded & Shrouded)
(See figures 4 & 5)
Item No. To No. With No. Torque Note
Plug & O-Ring 13, 14 Starter 15 135-150 lb in (15-17 N·m)

Elbow & O-Ring 30, 28 Starter Air 15 Jam Nut 29 180-200 lb in (20-23 N·m)
Supply Port
Elbow & O-Ring 32, 27 Starter Lube 15 Jam Nut 31 135-150 lb in (15-17 N·m)
Supply Port
Nipple & O-Ring 22, 21 Starter Lube 15 270-300 lb in (31-34 N·m)
Scavenge
Port
Starter & Gasket 15, 11 Gearbox 35 Self 12 190-230 lb in (22-30 N·m)
Locking Nuts
Nipple & O-Ring 5, 6 A-Sump 180-200 lb in (20-23 N·m)
Tube
Hose Assembly 10 Nipple & 5, 30 Coupling 270-300 lb in (31-34 N·m)
Elbow Nuts
Screen Assy & 34, 33 Gearbox 35 270-300 lb in (31-34 N·m)
O-Ring
Oil Scavenge Tube 18 Union 34, 21 Coupling Nut 450-550 lb in (57-62 N·m)
Assy (Screen Assy)
Oil Supply Tube 23 Elbow 32 Coupling Nut 135-150 lb in (15-17 N·m)
Assy
Bracket 17 Starter 15 Self Locking 12 190-230 lb in (22-30 N·m)
Nuts

Loop Clamp 20 Bracket 17 Bolt, Nut 19, 16 24-27 lb in (2.71-3.05 N·m)
GEK 97310
37
WP 117 00
VOLUME II
Table 4. Continuous Lube Starter Piping (Non-Shrouded & Shrouded) - Continued
38
(See figures 4 & 5)

WP 117 00
VOLUME II
GEK 97310
Loop Clamp 26 Gearbox 35 Bolt, Washer 24, 25 24-27 lb in (2.71-3.05 N·m)

Oil Drain Plug 1, 2 Starter Oil 15 135-150 lb in (15-17 N·m) Safety-wire
& Gasket Drain Port
Plug & O-Ring 13, 14 Starter 15 135-150 lb in (15-17 N·m) Safety-wire

GEK 97310
VOLUME II
SWP 117 01

1 - 32 . . . . . . . . . 0
ALPHABETICAL INDEX
Subject Page


1
GEK 97310
VOLUME II
SWP 117 01
and installing gas generator outside piping and wiring.
CAUTION
OBSERVE THE MAINTENANCE PRACTICE OF VOLUME I,
CHAPTER V.

Thermocouple SWP 111 01
NOTE


Safety Wire
wrench set.
CAUTION
CHAPTER V.

2
GEK 97310
VOLUME II
SWP 117 01
Figure 1. Gas Generator Left Side Piping (Sheet 1 of 2)

3
GEK 97310
VOLUME II
SWP 117 01

4
GEK 97310
VOLUME II
SWP 117 01
NOTE
to maintenance practices of Volume I, Chapter V.
NOTE
NOTE
d. Gas generator wiring.
being removed.
(2) Adhere to maintenance practices of Volume I, Chapter V.

Thermocouple Lead SWP 111 01
CAUTION
CHAPTER V.

5
GEK 97310
VOLUME II
SWP 117 01
Figure 2. Gas Generator Right Side Piping (Sheet 1 of 2)

6
GEK 97310
VOLUME II
SWP 117 01

7
GEK 97310
VOLUME II
SWP 117 01

8
GEK 97310
VOLUME II
SWP 117 01

9
Table 1. GAS GENERATOR LEFT SIDE PIPING. See Figure 1.
10
Index Index
Attach Item No. To Item No. Secure With Torque Note
VOLUME II
GEK 97310
SWP 117 01

Adapter 71 VSV Actuator 135-150 lb in Safety-wire
(15.26-16.95 N·m)
O-ring 72 Adapter Drain 70 Lubricate
CIT Sensor Hose 16 CIT Sensor 270-300 lb in
(31.0-33.9 N·m)
Tube, Head End 6 VSV Actuator 135-150 lb in
(15.26-16.95 N·m)
Tube, Head End 12 Tube 6 270-300 lb in
(30.5-33.9 N·m)
Tube, Rod End 9 VSV Actuator 270-300 lb in
(30.5-33.9 N·m)
Tube, Drain 8 Adapter, Drain 70 135-150 lb in
(15.26-16.95 N·m)
Tube, Drain 11 Tube 8 135-150 lb in
(15.26-16.95 N·m)
Clamps 5 Tubes 6, 8, 9 Nut, bolt, spacer 24-27 lb in To bracket
(2.7-3.1 N·m)
Clamps 4 Tubes 6, 8, 9 Bolt, spacer 24-27 lb in

(2.7-3.1 N·m)
Table 1. GAS GENERATOR LEFT SIDE PIPING. See Figure 1. - Continued
Index Index
Tube 14 Tube 9 270-300 lb in

(30.5-33.9 N·m)
Clamps 13 Tubes 11, 12, Bolt, spacer 24-27 lb in To bracket
14 (2.7-3.1 N·m)
Clamps 7 Tubes 6, 9 Bolt, nut 24-27 lb in
(2.7-3.1 N·m)
(2.7-3.1 N·m)
Bracket, Clamps 15 Hose, Tube 16, 9 2 bolts, 2 nuts 24-27 lb in
(2.7-3.1 N·m)
Nipple 3 Front Frame 440 lb in
(49.72 N·m)
Hose 2 Nipple 3 440 lb in
(49.72 N·m)
Bracket, Clamp 1 Hose 2 Bolt, nut 24-27 lb in
(2.7-3.1 N·m)
CDP Tube 50 CRF, CIT 16 270-300 lb in
Hose (31.0-34.0 N·m)
Clamp 17 CDP Tube 50 Bolt, nut, washer 24-27 lb in To bracket
(2.7-3.1 N·m)

Tube, 53 CRF 4 bolts, nuts, 55-70 lb in Gasket at CRF,
B Scavenge washers (6.22-7.91 N·m) Route to other side
of gas generator
GEK 97310
11
SWP 117 01
VOLUME II
12
Index Index
VOLUME II
GEK 97310
SWP 117 01
Clamps 47 Tube 53 2 bolts, nuts, 24-27 lb in To brackets

washers, spacers (2.7-3.1 N·m)
(2.7-3.1 N·m)
Cap 46 Tube 50 135-150 lb in
(15.26-16.95 N·m)
Tube, Lube Supply 54 Route to other side
of gas generator
Clamp 51 Tube 51 Bolt, nut, washer 24-27 lb in To bracket
(2.7-3.1 N·m)
Clamp 48 Tube 54 Bolt, nut, washer, 24-27 lb in To bracket
spacer (2.7-3.1 N·m)
Tube, Lube Supply 56 TMF, Tube 54 Tube End 450-500 lb in
Connector (50.9-56.5 N·m)
(2.7-3.1 N·m)
guide (2.7-3.1 N·m)
(2.7-3.1 N·m)

guide (2.7-3.1 N·m)
Index Index
Cover & Gasket 26 CRF 4 bolts, nuts 70-110 lb in

(8.0-12.4 N·m)
Bracket 27 Cover, CRF 2 bolts, nuts 70-110 lb in
(8.0-12.4 N·m)
Tube, LPT 28 Comp, Coupling clamp, 18 36-44 lb in
Manifold Stage 9 (4-5 N·m)
Forward Tube, LPT 29 Tube 28 4 bolts, nuts 55-70 lb in Seal retainer, Gasket
Cooling (6.2-7.9 N·m)
Clamps 21, 30, 29 Bolt, nuts (each) 24-27 lb in To brackets
40 (2.7-3.1 N·m)
Strap Retainers 25 Tube 28 2 bolts, nuts 55-70 lb in To bracket
(6.2-8.0 N·m)
Tube, LPT Cooling 22 TMF 4 bolts, nuts 55-70 lb in Gasket 25 at TMF
(6.2-8.0 N·m)
Tube, LPT Cooling Tube 28 Coupling 74-76 lb ft Wrench, 1C6345
(100.0-103.1 N·m)
Tube, LPT Cooling 23 TMF 4 bolts, nuts, 55-70 lb in Gasket 69 at TMF
washers (6.2-8.0 N·m)
Tube, LPT Cooling Tube 28 Coupling 74-76 lb ft Wrench, 1C6345
(100.0-103.1 N·m)

GEK 97310
13
SWP 117 01
VOLUME II
14
Index Index
VOLUME II
GEK 97310
SWP 117 01
Tube, LPT Cooling 43 TMF 4 bolts, nuts 55-70 lb in Gasket 65 at TMF

(6.2-8.0 N·m)
Tube 28 Coupling 74-76 lb ft Wrench, 1C6345
(100-103.1 N·m)
Tube, HPT Cooling 32 Comp, Coupling clamp 41-49 lb in
Stage 13 (4.6-5.5 N·m)
Cover, Gasket 36 CRF 5 bolts, nuts 70-110 lb in
(8.0-12.4 N·m)
Manifold, HPT 42 Tube 32 Coupling clamp 36-44 lb in
Cooling (4-5 N·m)
Clamps 44, 64 Tube 42 Bolt, nut, washer 24-27 lb in To bracket
(2.7-3.1 N·m)
Strap Retainers 41 Tube 42 2 bolts, nut 24-27 lb in To bracket
(2.7-3.1 N·m)
Bracket, Clamp 37 Tube 42 Bolt, nut 125 lb in To cover
(14.1 N·m)
Adapters 67, 57 CRF 4 bolts, washers 74-76 lb ft Orifice, Gasket,
(100.0-103.1 N·m) safety-wire
Tubes 68, 58 Tubes/ 42, 57, Couplings 74-76 lb ft Wrench, 1C6345,
Adapters 67 (100.0-103.1 N·m) safety-wire

Tube 34 Route to other side
of gas generator
Index Index

(2.7-3.1 N·m)
(2.7-3.1 N·m)
Tube 38 TMF 4 bolts, nuts, 55-70 lb in Gasket 64 at TMF
Tube 34 Coupling 75-91 lb ft Wrench, 1C5345,
guide (2.7-3.1 N·m)
Screens 19 CRF 4 bolts, nuts, 55-70 lb in Struts No. 5, 6, 7, 10
washers (each) (6.2-8.0 N·m)
Screen 59 TMF Coupling clamp 36-44 lb in
(4-5 N·m)

GEK 97310
15
SWP 117 01
VOLUME II
GEK 97310
VOLUME II
SWP 117 01
CAUTION
CHAPTER V.
CAUTION
CHAPTER V.
(2) Table 3 has items in normal sequence of installation and gives required torque values.
in the illustration and then locate the item number in the table.
d. Optional continuous lube starter piping (nonshrouded and shrouded). See figures 4 and 5.
e. Gas generator wiring.
(2) Adhere to maintenance practices of Volume I, Chapter V.


16
Table 2. GAS GENERATOR RIGHT SIDE PIPING. See Figure 2.
Index Index
Clamps 44, 45 Tube Bolt, nut, washer, 24-27 lb in To bracket

spacer (2.7-3.1 N·m)
Clamps 46, 48 Tube Bolt, nut, washer 24-27 lb in To bracket
(2.7-3.1 N·m)
Adapter, Tube 72 VSV Actuator 135-150 lb in
(15-17 N·m)
O-ring 70 VSV Actuator Lubricate
Tube, Rod End 68 Adapter & 72, 56 135-150 lb in
Tube (15-17 N·m)
Tube, Head End 65 VSV Actuator 58 135-150 lb in
& Tube (15-17 N·m)
Tube, Drain 67 Adapter & 72, 58 135-150 lb in
Tube (15-17 N·m)
Clamps 66 Tubes, Rod & 65, 67 Bolt, nut 24-27 lb in
Drain (2.7-3.1 N·m)
Clamps 64 Tubes 65, 67, Bolt, spacer 24-27 lb in To gearbox mount
68 (2.7-3.1 N·m)

Clamp 57 Tubes 56, 58, Bolt, spacer 24-27 lb in To gearbox mount
59 (2.7-3.1 N·m)
17
SWP 117 01
GEK 97310
VOLUME II
Table 2. GAS GENERATOR RIGHT SIDE PIPING. See Figure 2. - Continued
18
Index Index
VOLUME II
GEK 97310
SWP 117 01
Clamps 61 Hose 62 24-27 lb in To brackets

(2.7-3.1 N·m)
Tube, Lube Supply 51 Tube 450-500 lb in
(50.9-56.5 N·m)
Hose 62 Tube 51 Coupling 450-500 lb in
(50.9-56.5 N·m)
Clamps 49 Tube 51 Bolt, nut, washer 24-27 lb in To bracket
(2.7-3.1 N·m)
Clamps 54 Tube 51 Bolt 24-27 lb in To gearbox mount
(2.7-3.1 N·m)
Tube 41 CRF & Tube Coupling 450-500 lb in
(50.9-56.5 N·m)
Clamp 42 Tube 41 Bolt, nut, washer 24-27 lb in
(2.7-3.1 N·m)
Tube 63 CFF 4 bolts, nuts, 55-70 lb in Gasket, retainer
Clamps 60 Hose/Tube 62, 63 Bolt, nut 24-27 lb in
(2.7-3.1 N·m)
Tube, Nozzle 50 Tube 63 4 bolts, nuts, 55-70 lb in Gasket, retainer

Clamp 52 Tube 50 2 bolts, nuts, 24-27 lb in To bracket
Index Index
Straps 47 Tube 50 Bolt, nut, washer 24-27 lb in To bracket

(2.7-3.1 N·m)
Adapter 35 8th Stage Coupling clamp 90-100 lb in Gasket
Comp (10.8-11.3 N·m)
Tube 34 Adapter 35 4 bolts, washers 55-70 lb in Gasket, retainer
(6.2-8.0 N·m)
Tube 50 4 bolts, nuts, 55-70 lb in Gasket, retainer
Clamp 32 Tube 34 Bolt, nut 24-27 lb in To bracket
(2.7-3.1 N·m)
Cover Plate 36 Adapter 35 4 bolts, washers 55-70 lb in Gasket, retainer
(6.2-8.0 N·m)
Cover Plate 11 8th Stage Coupling clamp 90-100 lb in Gasket
Comp (10.9-11.3 N·m)
Cover, Bracket 30, 31 CRF 6 bolts, nuts 70-110 lb in Gasket, bolt heads
(8.0-12.4 N·m) toward CRF
Tube, LPT Cooling 25 9th Stage Coupling clamp 36-44 lb in
Comp (4.1-5.0 N·m)
Strap 29 Tube 25 2 bolts, nuts 24-27 lb in
(2.7-3.1 N·m)

Tube, LPT Cooling 21 Tube 25 4 bolts, nuts, 55-70 lb in Gasket, retainer
GEK 97310
19
SWP 117 01
VOLUME II
20
Index Index
VOLUME II
GEK 97310
SWP 117 01
Tube 2 TMF 4 bolts, nuts, 55-70 lb in Gasket

(32.5-35.3 N·m)
Tube 39 TMF 4 bolts, nuts, 55-70 lb in Gasket
(32.5-35.3 N·m)
Clamp 3, 24 Tube 21 Bolt, nut 24-27 lb in To bracket
(2.7-3.1 N·m)
Clamp 40 Tube 21 2 bolts, nuts 24-27 lb in
(2.7-3.1 N·m)
Screen 18 TMF Coupling clamp 36-44 lb in
(4.1-5.0 N·m)
Cover, Bracket 26, 27 CRF 6 bolts, nuts 70-110 lb in Gasket, bolt heads
(8.0-12.4 N·m) toward CRF
Tube, HPT Cooling 33 13th Stage Coupling clamp 41-49 lb in
Comp (4.6-5.5 N·m)
Tube, HPT Cooling 19 Tube 33 Coupling clamp 41-49 lb in
(4.6-5.5 N·m)

Clamp 28 Tube 19 Bolt, nut 24-27 lb in To bracket
(2.7-3.1 N·m)
Index Index
Strap 23 Tube 19 2 bolts, nuts 24-27 lb in To bracket

(2.7-3.1 N·m)
Straps 20 Tube 19 2 bolts, nuts, 24-27 lb in To bracket
washers (each) (2.7-3.1 N·m)
Orifice 1 CRF 4 bolts, washers 55-70 lb in Gasket, safety-wire
(6.2-8.0 N·m)
Orifice 38 CRF 4 bolts, washers 55-70 lb in Gasket, safety-wire
(6.2-8.0 N·m)
Tube 37 Tube 19 Couplings 74-76 lb ft
(each end) (100.0-103.1 N·m)
Tube, A Sump Vent 15 CFF 4 bolts, washers 55-70 lb in Gasket, retainer,
Clamp 14 Tube 15 2 bolts, nuts 55-70 lb in To bracket
(6.2-8.0 N·m)
Straps 17 Tube 15 2 bolts, nuts 55-70 lb in To bracket
(6.2-8.0 N·m)
O-rings (2) 16 Tube 15 Lubricate
Tube, Vent 55 Tube 15 Hand Tight
Clamp 53 Tube 55 2 bolts, nuts 24-27 lb in To bracket
(2.7-3.1 N·m)

GEK 97310
21
SWP 117 01
VOLUME II
22
Index Index
VOLUME II
GEK 97310
SWP 117 01
O-rings (4) 13 Tube 12 Lubricate

Manifold, Sump 12 Tube 15 Hand Tight
Vent
Tube, B Sump Vent 6 CRF 6 bolts, nuts, 55-70 lb in Gasket, retainer
Tube 12 4 bolts, nuts, 55-70 lb in Gasket, retainer
(2.7-3.1 N·m)
(2.7-3.1 N·m)
Tube 5 Tube 12 Hand Tight
TMF 4 bolts, nuts, 55-70 lb in Gasket, retainer
Strap 7 Tube 5 2 bolts, nuts 24-27 lb in To bracket
(2.7-3.1 N·m)
Straps (2) 4 Tube 5 2 bolts, nuts 24-27 lb in To bracket
(2.7-3.1 N·m)

Table 3. TRANSFER GEARBOX PIPING. See Figure 4.

Nipple & O-ring 42 Gearbox 135-150 lb in (15-17 N·m) Lubricate
Tube 52 TGB Scav, Lube Pump 112-128 lb ft (152-173.6 N·m)
Hose 45 Gearbox 4 bolts 24-27 lb in (2.71-3.05 N·m) Gasket
Tube 52 112-128 lb ft (152-173.6 N·m)
Clamp 44 Hose 45, A/O Bolt, nut 24-27 lb in (2.71-3.05 N·m)
Separator Bracket
Tube, Lube-Spline 54 Lube Pump 135-150 lb in (15-17 N·m)
Clamps 51 Tubes 54, 52 Bolt 24-27 lb in (2.71-3.05 N·m)
Cap 55 Tube 54 135-150 lb in (15-17 N·m)
Nipple & O-ring 21 A/O Sep. Cover 180-200 lb in (20-23 N·m) Lubricate
Reducers & O-rings 62 Gearbox 155-175 lb in (18-20 N·m) Lubricate
Tube 64 Reducer 62, 135-150 lb in (15-17 N·m) Lubricate
Oil Supply Tube
Hose 63 Reducer 62, Tube 64 135-150 lb in (15-17 N·m)
Cap 78 Tube (A/O Sep) 135-150 lb in (15-17 N·m)
Hose/Tube 26 Gearbox 4 bolts 24-27 lb in (2.71-3.05 N·m)
Lube Pump 75-91 lb ft (101.7-123.4 N·m)
Bracket 33 Gearbox 2 bolts 24-27 lb in (2.71-3.05 N·m)
Clamp 27 Gearbox Bolt 24-27 lb in (2.71-3.05 N·m)

GEK 97310
23
SWP 117 01
VOLUME II
Table 3. TRANSFER GEARBOX PIPING. See Figure 4. - Continued
24
Cap 28 Hose/Tube 26 75-91 lb ft (101.9-123.4 N·m)
VOLUME II
GEK 97310
SWP 117 01
Brackets 48 Gearbox 2 bolts, washers 55-70 lb in (6-8 N·m) Safety-wire

Check Valve & 47 Tube 43 75-91 lb ft (101.9-123.4 N·m) Lubricate
O-ring
Tube & O-ring 43 Check Valve 47 75-91 lb ft (101.9-123.4 N·m) Lubricate
Lube Pump 112-128 lb ft (151.9-173.6 N·m)
Support & U-Bolt 46 Bracket 48, 2 nuts, washers 24-27 lb in (2.71-3.05 N·m)
Check Valve 47
Check Valve & 50 Tube 53 75-91 lb ft (101.9-123.4 N·m) Lubricate
O-ring
Tube & O-ring 53 Check Valve 50 75-91 lb ft (101.9-123.4 N·m) Lubricate
Lube Pump 112-128 lb ft (151.9-173.6 N·m)
Support & U-Bolt 49 Bracket 48, 2 nuts, washers 24-27 lb in (2.71-3.05 N·m)
Check Valve 50
Bracket 4 Gearbox 2 bolts, nuts 55-70 lb in (6-8 N·m)
Bracket 36 Gearbox Bolt 160-210 lb in (18-23.7 N·m)
Bracket 10 Gearbox (side) Bolt, washer 160-210 lb in (18-23.7 N·m) Safety-wire
Gearbox (bottom) Bolt, washer 24-27 lb in (2.71-3.05 N·m) Safety-wire
Bracket 12 Gearbox (fwd side) Bolt, washer 160-210 lb in (18-23.7 N·m) Safety-wire
Bracket 10 2 bolts, nuts, 55-70 lb in (6-8 N·m)
4 washers

Nipples & O-rings 38 Gearbox Pads 135-150 lb in (15-17 N·m) Lubricate

Tubes & O-ring 34 Gearbox Pads 135-150 lb in (15-17 N·m) Lubricate
Manifold, Drain 35 Nipple 38 135-150 lb in (15-17 N·m)
Hose 25 Nipple 38, 135-150 lb in (15-17 N·m)
Manifold 35
Bracket 36
Bracket 33
Tee 31 Manifold 35 135-150 lb in (15-17 N·m)
Hose 30 Tee 31, Lube Pump 135-150 lb in (15-17 N·m)
Clamps 29 Tube 26, Hose 30 Bolt, nut 24-27 lb in (2.71-3.05 N·m)
Brackets 60 Gearbox Cover 2 nuts, washers 55-70 lb in (6-8 N·m)
Clamps 61 Brackets 60, 2 bolts, nuts 24-27 lb in (2.71-3.05 N·m)
CIT Lead

GEK 97310
25
SWP 117 01
VOLUME II
26
VOLUME II
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SWP 117 01
Hose 9 Nipples 16, 17 270-300 lb in (31-34 N·m)

Hose 7 Nipple 13 450-550 lb in (50.8-62 N·m)
Clamp 3 Hose 6, Bracket 4 Bolt, nut, washer 24-27 lb in (2.71-3.05 N·m)
Hose 23 Nipple 15, 450-500 lb in (50.8-56.5 N·m)
Lube Supply Tube
Hose 24 Nipple 19, 450-500 lb in (50.8-56.5 N·m)
Lube Supply Tube
Clamp 59 Hose 23, Bracket Bolt, nut 24-27 lb in (2.71-3.05 N·m)
Bracket
Check Valve 41 Hose 20 270-300 lb in (31-34 N·m)
Reducer & O-ring 40 Check Valve 41 180-200 lb in (20-23 N·m) Lubricate

Lube Pump

Hose 20 Check Valve 41 270-300 lb in (31-34 N·m)
Nipple 18
Clamp 65 Hose 23, CIT lead Bolt, nut 24-27 lb in (2.71-3.05 N·m)
Bracket 70 Sump Vent Tube Bolt, nut, washer 55-70 lb in (6-8 N·m)
Coupling, D-Scav 66 Lube Pump 75-91 lb ft (102-123 N·m)
Coupling, C-Scav 67 Lube Pump 112-128 lb ft (152-174 N·m)
Coupling, B-Scav 68 Lube Pump 112-128 lb ft (152-174 N·m)
Sump Vent Tube
Clamp 71 Check Valve 41, Bolt, nut 24-27 lb in (2.71-3.05 N·m)
Sump Vent Tube
Flange Bracket 70
Coupling 72 Tube 43, 450-500 lb in (51-56.5 N·m)
Lube Supply Tube
Sump Vent Tube
Tube 77 Nipple 21, 135-150 lb in (15-17 N·m)
Sump Vent Tube

GEK 97310
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SWP 117 01
VOLUME II
28
Tube 76 Vent Tube Hand Tight
VOLUME II
GEK 97310
SWP 117 01
A/O Separator 6 bolts, washers 55-70 lb in (6-8 N·m) Safety-wire

Sensor, CIT 57 CFF 4 screws 24-27 lb in (2.71-3.05 N·m)
Bracket 83 Gearbox Pad Nut
Hose 84 Tee 31, 135-150 lb in (15-17 N·m)
VSV Drain Manifold
Clamp 82 Bracket 80,
Hose 81
Bracket 80 Gearbox Bolt 90-110 lb in (10-12.4 N·m) Safety-wire
Clamp 80 Bracket 80 Bolt, nut, washer 24-27 lb in (2.71-3.05 N·m)
Coupling 81 Oil Supply 55-65 lb ft (75-88 N·m)
Manifold
Coupling 79 Oil Supply 135-150 lb in (15-17 N·m)
Manifold

GEK 97310
VOLUME II
SWP 117 01
Figure 4. Continuous Lube Starter Piping (Non-Shrouded)

29
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SWP 117 01
Figure 5. Continuous Lube Starter Piping (Shrouded)

30
Table 4. CONTINUOUS LUBE STARTER PIPING (NON-SHROUDED AND SHROUDED). See Figures 4 and 5.
Plug & O-ring 13, 14 Starter 15 135-150 lb in

(15-17 N·m)
Elbow & O-ring 30, 28 Starter Air 15 Jamnut 29 180-200 lb in
Supply Port (20-23 N·m)
Elbow & O-ring 32, 27 Starter Lube 15 Jamnut 31 135-150 lb in
Nipple & O-ring 22, 19 Starter Lube 15 270-300 lb in
Scavenge Port (31-33.9 N·m)
Starter & Gasket 15, 11 Gearbox 35 Self-locking nuts 12 190-230 lb in
(22-26 N·m)
Nipple & O-ring 5, 6 A-Sump Tube 180-200 lb in
(20-23 N·m)
Hose Assembly 10 Nipple & 5, 30 Coupling nuts 270-300 lb in
Elbow (31-33.9 N·m)
Screen Assy & 34, 33 Gearbox 35 270-300 lb in
O-ring (31-33.9 N·m)
Oil Scavenge Tube 18 Union 34, 21 Coupling nut 450-550 lb in
Assy (Screen Assy) (50.8-62 N·m)
Oil Supply Tube 23 Elbow 32 Coupling nut 135-150 lb in
Assy (15-17 N·m)

Bracket 17 Starter 15 Self-locking nuts 12 190-230 lb in
(22-26 N·m)
GEK 97310
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SWP 117 01
VOLUME II
Table 4. CONTINUOUS LUBE STARTER PIPING (NON-SHROUDED AND SHROUDED). See Figures 4 and 5. - Continued
32
Loop Clamp 20 Bracket 17 Bolt, nut 19, 16 24-27 lb in

VOLUME II
GEK 97310
SWP 117 01
(2.7-3.1 N·m)
Loop Clamp 26 Gearbox 35 Bolt, washer 24, 25 24-27 lb in
(2.7-3.1 N·m)
Oil Drain Plug & 1, 2 Starter Oil 135-150 lb in Safety-wire
Gasket Drain Port (15-17 N·m)
Plug & O-ring 13, 14 Starter 15 135-150 lb in Safety-wire
(15-17 N·m)

GEK 97310
VOLUME II
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1 - 19 . . . . . . . . . 0 20 Blank . . . . . . 0
ALPHABETICAL INDEX
Subject Page


1
GEK 97310
VOLUME II
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1. INTRODUCTION. This subordinate work package contains the instructions for the
removing and installing of gas generator outside piping and wiring.
CAUTION
OBSERVE THE MAINTENANCE PRACTICE OF VOLUME I,
CHAPTER 5.
Ignition Leads SWP 106 01

Thermocouple SWP 111 02
NOTE


Safety Wire
wrench set.
CAUTION
CHAPTER 5.

2
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SWP 117 02

3
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4
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NOTE
NOTE
NOTE
There is no special sequence for removing gearbox piping. Adhere
being removed.

CAUTION
CHAPTER 5.

5
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SWP 117 02

6
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7
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Figure 3. Transfer Gearbox Piping and Clamping (Sheet 1 of 2)

8
GEK 97310
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SWP 117 02
Figure 3. Transfer Gearbox Piping and Clamping (Sheet 2 of 2)

9
Table 1. LEFT SIDE PIPING (See figure 1.)
10
Index Index
VOLUME II
GEK 97310
SWP 117 02
Tube 27 4 bolts, nuts, 125 lb in Seal, retainer

washers (14 N·m)
Strap Clamps 24 Tube 27 2 bolts, nuts 55-70 lb in To bracket CRF mid
(6-8 N·m) flange
Tube 19 Tube 27 Coupling 60 lb ft Wrench, 1C6344,
(81 N·m) Safety wire
TMF Coupling clamp 45 lb in
(5.1 N·m)
Clamps 18 Tube 19 Bolt, nut (each) 24-27 lb in To bracket TFF
(2.7-3.1 N·m) forward
Tube B Sump Lube 2 CRF Coupling nut 450-550 lb in Safety wire
(50.9-62.2 N·m)
Clamp 2 Tube 3 Bolt, nut 24-27 lb in To bracket CRF front
(2.7-3.1 N·m) flange
Tube, LPT Cooling 49 9th Stage Comp Coupling clamp 45 lb in Plastiseal F,
(5.1 N·m) safety wire
Manifold, LPT 5 Tube 49 Coupling clamp 45 lb in Plastiseal F,
Cooling (5.1 N·m) safety wire
Strap Clams 8 Manifold 5 3 bolts, nuts 24-27 lb in To bracket, CRF mid

Clamp, Bushing (2) 9 Manifold 5 2 bolts, nuts 24-27 lb in To brackets, CRF
(each) (2.7-3.1 N·m) mid flange
Table 1. LEFT SIDE PIPING (See figure 1.) - Continued
Index Index
Tube, LPT Cooling (4) 10 Manifold & TMF 5 Couplings (8) 20 lb ft Wrench, 1C6344,
Clamps, Bushings (4) 11 Tubes, LPT 10 6 bolts, nuts 24-27 lb in To bracket, TMF
Cooling (2.7-3.1 N·m) flange
Tube, Lube Supply 15 TMF Coupling nut 450-550 lb in Safety wire
(50.9-62.2 N·m)
Cap 14 Tube 15 245 lb in Safety wire
(27.7 N·m)
Tube, Lube Supply 26 Tube 15 Coupling nut 450-550 lb in Safety wire
(50.9-62.2 N·m)
Clamp 21 Tube 26 Bolt, nut 24-27 lb in To bracket, CRF mid
(2.72-3.05 N·m) flange
Manifold, Lube Supply 38 Tube 26 Coupling nut (2) 450-550 lb in
(50.9-62.2 N·m)
Tube, C Scavenge 20 TMF 4 bolts, nuts, 24-27 lb in Gasket
Tube 28 Tube 20 4 bolts, nuts, 24-27 lb in Gasket
Clamp 22 Tube 28 Bolt, nut, spacer, 24-27 lb in To bracket, CRF mid
guide (2.7-3.1 N·m) flange

Clamp 34 Tube 28 Bolt, nut, spacer, 24-27 lb in To bracket, Comp
guide (2.7-3.1 N·m) mid flange
GEK 97310
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VOLUME II
12
Index Index
VOLUME II
GEK 97310
SWP 117 02
Adapters (2) 13 CRF 4 bolts (each) 55-70 lb in 2 gaskets, 1 spacer

(6.22-7.91 N·m) Plastiseal F both
sides each gasket,
safety wire
Tubes, HPT Cooling (2) 12 Adapters 13 Couplings 60 lb ft Wrench, 1C6344,
(81 N·m) safety wire
Tube, HPT Cooling 6 Tubes 12 Couplings 60 lb ft Wrench, 1C6344,
Strap & Clamps (2) 17 Tube 6 2 bolts, nuts 24-27 lb in 2 washers under
(each) (2.7-3.1 N·m) forward bolt head
Clamps (2) 16 Tube 15
Tube, HPT Cooling 1 13th Stage Comp Coupling clamp 45 lb in Plastiseal F
(5.1 N·m)
Tube 6 Coupling clamp 45 lb in Plastiseal F
(5.1 N·m)
Strap Clamps 7 Tube 6 2 bolts, nuts 55-70 lb in To bracket, CRF mid
(6.22-7.91 N·m) flange
Strap Clamps 4 Tube 1 2 bolts, nuts 55-70 lb in To bracket, CRF for-
(6.22-7.91 N·m) ward flange
Tube 23 TMF Coupling nut 270-300 lb in Safety wire
(30.5-33.9 N·m)

Clamp 25 Tube 23 Bolt, nut 24-27 lb in
(2.7-3.1 N·m)
Index Index
Tube 30 CRF/Tube 23 2 coupling nuts 270-300 lb in Safety wire

(30.5-33.9 N·m)
Tube 29 CRF 4 bolts, nuts, 55-70 lb in Gasket
washers (6.22-7.91 N·m)
Clamps 33, 34 Tube 29 Bolt, nut, spacer, 24-27 lb in To bracket, comp
guide (2.7-3.1 N·m) mid flange
Tube, Hose, CIT 41 CRF, CIT Sensor Coupling nut 270-300 lb in Safety wire
Sensor (30.5-33.9 N·m)
Cap 32 Tube 41 135-150 lb in Safety wire
(15.3-17.0 N·m)
Clamps 33 Tube/Tube 41, 29 Bolt, nut 24-27 lb in
(2.7-3.1 N·m)
Clamp 39 Tube 38 2 bolts, nuts 24-27 lb in To bracket, 5th Stage
(2.7-3.1 N·m) comp
Install Servo Valve
Manifold Head End 43 VSV Actuator Coupling nut 135-150 lb in Safety wire
(15.3-17.0 N·m)
Tube VSV Drain 44 VSV Actuator Coupling nut 135-150 lb in Safety wire
(15.3-17.0 N·m)
Manifold Rod End 42 VSV Actuator Coupling nut 270-300 lb in Safety wire

(30.5-33.9 N·m)
GEK 97310
13
SWP 117 02
VOLUME II
14
Index Index
VOLUME II
GEK 97310
SWP 117 02
Clamps 47 Manifolds 42, 43 Bolt, nut 24-27 lb in To bracket, CFF aft

Clamps 40 Manifolds 42, 43 2 bolts, nuts 24-27 lb in To bracket, 6th Stage
(2.7-3.1 N·m) comp
Clamps 48 Tube Manifold 42, 44 Bolt, nut 24-27 lb in
(2.7-3.1 N·m)
Clamps 46 Tube Manifold 42, 44 Bolt, nut 24-27 lb in To bracket, CFF aft
(2.7-3.1 N·m)
Hose, Rod End 37 Tube 42 Coupling nut Safety wire
Servo Valve Coupling nut Safety wire
Hose, Head End 36 Tube 43 Coupling nut Safety wire
Servo Valve Coupling nut Safety wire
Bracket 31 2 bolts, nuts, To bracket, CRF
washers forward flange
Install Feedback Cable

GEK 97310
VOLUME II
SWP 117 02
CAUTION
CHAPTER 5.
CAUTION
CHAPTER 5.
(2) Refer to legend in figure 3, sheet 2 for gearbox piping. Items not listed in the legend
are brackets and clamps.


15
Table 2. RIGHT SIDE PIPING - GA (See figure 3.)
16
Index Index
VOLUME II
GEK 97310
SWP 117 02
Tube, LPT Cooling 38 9th Stage Comp Coupling clamp 45 lb in Plastiseal F at

(5.1 N·m) forward end
Manifold, LPT 40 Tube 38 Coupling clamp 45 lb in Plastiseal F at
Cooling (5.1 N·m) forward end
Clamps 41 Manifold 40 3 bolts, nuts
Bushing, Clamp (2) 43, 53 Manifold 40 Bolt, nut (each) 24-27 lb in To brackets
(2.7-3.1 N·m)
Tubes, LPT Cooling (4) 50, 51 Manifold & TMF 40 20 lb ft Wrench, 1C6344,
Bushings, Clamps (4) 45, 49 Tubes, LPT 50, 57 6 bolts, nuts 24-27 lb in To brackets
56 Cooling (2.7-3.1 N·m)
Tube, CDP Recoup 39 CRF 4 bolts, nuts, 55-70 lb in Seal, retainer
washers (6-8 N·m)
Strap Clamps 42 Tube 39 2 bolts, nuts 24-27 lb in To bracket, CRF
(2.7-3.1 N·m)
Tube 44 Tube 39 Coupling 60 lb ft Wrench, 1C6344,
TMF Elbow Coupling clamp 45 lb in
(5.1 N·m)
Clamp 46 Tube 44 Bolt, nut, washer 24-27 lb in To bracket, TMF

(2.7-3.1 N·m)
Table 2. RIGHT SIDE PIPING - GA (See figure 3.) - Continued
Index Index
Tube, C Vent* 58 TMF 4 bolts, nuts, 55-70 lb in Gasket at TMF

washers (6-8 N·m)
Strap Clamp 3 Tube 58 2 bolts, nuts 24-27 lb in To bracket
(2.7-3.1 N·m)
Manifold, Vent 8 Tube 58 Misalignment 45 lb ft Wrench, 1C6344
Fitting (61 N·m) safety wire
Strap Clamp 6 Tube 8 2 bolts, nuts 24-27 lb in To bracket, CRF
(2.7-3.1 N·m)
Manifold, B Vent 7 CRF 6 bolts, nuts, 55-70 lb in Gasket
washers (6-8 N·m)
Tube B Vent 5 Manifold 7 Misalignment 35 lb ft Wrench, 1C6344,
Fitting (47.5 N·m) safety wire
Manifold 8 Misalignment 35 lb ft Wrench, 1C6344,
Fitting (47.5 N·m) safety wire
Tube, Head End 36 VSV Actuator Coupling nut 105 lb in Safety wire
(11.9 N·m)
Tube, Rod End 35 VSV Actuator Coupling nut 105 lb in Safety wire
(11.9 N·m)
(2.7-3.1 N·m)

*0.125 in. min clearance between vent tubes and fuel nozzle tubes. Adjust fuel manifold-slotted-brackets as required for
clearance.
GEK 97310
17
SWP 117 02
VOLUME II
18
Index Index
VOLUME II
GEK 97310
SWP 117 02
Tube, Drain 34 VSV Actuator Coupling nut 245 lb in Safety wire

(27.7 N·m)
Clamp 32 Tube 34 Bolt, nut 24-27 lb in To bracket, CFF
(2.7-3.1 N·m)
Bracket 20 Bracket 2 bolts, nuts, 24-27 lb in To bracket, Comp
washers (2.7-3.1 N·m) Stage 8
Bracket 13 Bracket 2 bolts, nuts, 24-27 lb in To bracket, CRF
washers (2.7-3.1 N·m) forward flange
Tube, Seal Pressure 31 CFF Coupling clamp 45 lb in
(5.1 N·m)
Straps 30 Tube 31 2 bolts, nuts 24-27 lb in To bracket, CFF
(2.7-3.1 N·m)
Clamps 28 Tube 31 Bolt, nut 24-27 lb in To vent tube
(2.7-3.1 N·m)
Tube 27 Tube 31 Coupling clamp 45 lb in
(5.1 N·m)
Nozzle 23 Tube 27 Coupling clamp 45 lb in
(5.1 N·m)
Strap Clamp 19 Nozzle 23 2 bolts, nuts 55-70 lb in To bracket, Comp
(6-8 N·m) Stage 2

Strap Clamp 25 Nozzle 23 2 bolts, nuts 55-70 lb in To bracket
(6-8 N·m)
Index Index
Tube 11 Nozzle 23 Coupling clamp 45 lb in

(5.1 N·m)
Strap Clamp 12 Tube 11 To bracket
Tube, Ejector Supply 16 Nozzle 23 Coupling clamp 45 lb in

(5.1 N·m)
Clamp 17 Tube 16 Bolt, nut, washer 24-27 lb in To bracket, comp
(2.7-3.1 N·m) mid flange
Clamp 18 Tube 16 Bolt, nut, washer 24-27 lb in To bracket, Comp
(2.7-3.1 N·m) Stage 5

GEK 97310
19\(20 Blank)
SWP 117 02
VOLUME II
GEK 97310
VOLUME II
WP 118 00
WORK PACKAGE
VARIABLE STATOR VANE SYSTEM

RIGGING AND CALIBRATION

1 - 36 . . . . . . . . . 0
ALPHABETICAL INDEX
Subject Page
VSV System Feedback Cable Rigging (Speed Sensor/Servo Valve System) . . . . . . . . . . . . 30

VSV System Feedback Cable Rigging (VSV Control PN L34379 Configuration) . . . . . . . 34
VSV System Operating Rigging Checks and Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . 20
VSV System Stage-to-Stage Rigging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
VSV System Static (Or Gang) Rigging (Speed Sensor/Servo Valve Configuration) . . . . . . 14
VSV System Static (Or Gang) Rigging (VSV Control PN L34379 Configuration). . . . . . . 19

1
GEK 97310
VOLUME II
WP 118 00
1. INTRODUCTION. This work package contains instructions for the variable stator vane sys-
tem stage-to-stage rigging, system rigging and operating rigging checks. In addition, it also
contains instructions for feedback cable rigging for the speed sensor/servo valve configuration
plus the unitized VSV control system.
NOTE

a. VSV System Stage-to-Stage.
1C3569 Hydraulic Actuation Unit
2C6103 Protractor-Tool Set-Gas Generator Rigging-Alt Tool 1C5714
b. VSV System Static Rigging
2C6103 Protractor-Tool Set-Gas Generator Rigging-Alt Tool 1C5714
c. Operating Rigging Checks.
1C6977 Variable Stator Vane Position Indicator Transmitter

Container, Plastic-5 Quart
Layout Fluid (Dykem)
Nitrogen, Dry
Safety Wire

2
GEK 97310
VOLUME II
WP 118 00
4. VSV SYSTEM STAGE-TO-STAGE RIGGING.
NOTE
The following procedure covers stage-to-stage rigging using the
2C6103 variable vane protractor set.
a. Mark vane lever arms in each of the IGV through sixth stages as indicated in table 1.
These vanes will be used to measure vane angles during final rigging. Locate vanes in each stage
by counting clockwise from 9:00 o’clock horizontal flange. Use layout fluid (Dykem or equiva-
lent) for marking.
Table 1. VARIABLE VANE MARKING
Stage Marked Vanes

IGV 5 ,13, 22, 30
1 5, 14, 23, 32
2 5, 14, 25, 35
3 6, 18, 29, 41
4 7, 19, 31, 45
5 8, 22, 38, 52
6 8, 25, 40, 57
b. Connect pressure source to the variable stator actuator head-end and rod-end ports, as
follows:
(1) Using a regulated dry nitrogen, gas turbine oil or clean shop air pressure source, con-
nect to the servo valve supply port by disconnecting oil supply connector (5, figure 1), and con-
necting pressure source to the disconnected hoses.
(2) Disconnect servo valve rod-end return hose (6). Using a slave hose installed on the
servo valve rod-end return fitting, route the slave hose to a suitable container provided to catch
any residual oil that may be discharged from the return port.

3
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VOLUME II
WP 118 00
Figure 1. Variable Stator Vane System Static Rigging

(Speed Sensor/Servo Valve Configuration) (Sheet 1 of 2)
4
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WP 118 00

(Speed Sensor/Servo Valve Configuration) (Sheet 2 of 2)

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NOTE
z Use calibrated 2C6103 tool set or equivalent.
z If piping or bracket interference occurs, it may not be possible
to install protractor on stage locations called for in table 1.
Place protractor on one of those locations called for in each
stage in table 1 that is accessible.
z To facilitate installation of the variable vane protractor, non-
locking nuts may be installed on the vane studs of the marked
vane lever arms in each stage (IGV through sixth) as shown in
table 1. Make sure that all non-locking nuts are properly
replaced with new locknuts of the correct type.
c. Install protractor from 2C6103 rigging tool set to marked lever arm in each variable stage
as follows. See figure 2.
(1) Attach locator (9, figure 2) to marked lever arm (10) by turning shaft (8) onto vane
stud (7). Tighten jamnut (11). Use large locator at IGV and stages 1 and 2; use medium locator at
stages 3 and 4; use small locator at stages 5 and 6.
(2) Place protractor over locator (9) engaging slots of protractor shaft onto pins at
locator.
(3) Attach shaft (6) at each end of protractor arms to vane stud (7) by turning knurled
nut (2). Keep shaft (6) as close as possible to center of protractor.
(4) Tighten jam stud (1).
(5) Tighten check nut (4).
(6) Tighten jamnut (3).
(7) Actuate variable vanes a minimum of one cycle from full closed to full open.
d. Adjust IGV angles for open position as follows:
WARNING
SERIOUS INJURY CAN OCCUR WHEN APPLYING
HYDRAULIC PRESSURE. EYE PROTECTION IS REQUIRED.
RELIEVE PRESSURE BEFORE DISCONNECTING LINES
AND FITTINGS.
(1) With the system actuated to fully open position (actuator fully extended), maintain
200-400 psi (1379-2758 kPa) pressure. Read and record each stage travel. The reading shall be
within the limits of table 2.

6
GEK 97310
VOLUME II
WP 118 00
Figure 2. 2C6103 Variable Vane Protractor Installation

7
GEK 97310
VOLUME II
WP 118 00
CAUTION
MAXIMUM LENGTH OF ACTUATION CLEVIS PUSHROD
ASSEMBLY (7, FIGURE 4) SHALL NOT EXCEED 3.85
INCHES (97.8 MM), AS MEASURED FROM CENTER OF THE
CLEVIS (12) MOUNTING HOLE TO CENTER OF ROD-END
BEARING (15) HOLE.
(2) Adjust the actuation vane pushrod clevis assembly length as required to meet limits
of table 2. Adjust pushrod clevis assemblies on both sides of gas generator equally. Actuate the
system away from, and then back to the full open position (actuator fully extended). Maintain
200-400 psi (1379-2758 kPa) pressure. Lightly tap actuation ring segments (2 or 2A, figure 3)
with a light weight plastic or rawhide mallet to remove hysteresis. Check results on the protrac-
tor. Repeat the procedure as necessary. Tighten the rod-end bearing jamnut to 40-80 lb in.
(4.52-9.04 N·m) of torque. Do not safety-wire at this time.

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WP 118 00
Figure 3. Actuation Ring Segments and Connecting Link

9
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WP 118 00
Table 2. Variable Vane Adjustment - All Models
Clevis Length Open Vane Angle Closed Vane Angle
Clevis Assembly Center to Center Length Average of 4 Vane Average of 4 Vane
Stage Inches MM Angles Angles
A. For use with grey VSV feedback bellcrank-P/N L21592.

IGV 3.683-3.689 93.54-93.70 30°53’ - 32°10’ 29°20’ - 30°40’
1 3.693-3.699 93.80-93.96 26°29’ - 28°00’ 25°10’ - 26°40’
2 3.642-3.648 92.50-92.66 24°50’ - 26°10’ 21°47’ - 23°00’
3 3.645-3.651 92.58-92.74 24°00’ - 25°10’ 20°00’ - 21°10’
4 3.645-3.651 92.58-92.74 22°20’ - 23°32’ 18°28’ - 19°40’
5 3.690-3.696 93.72-93.88 18°20’ - 20°36’ 17°40’ - 19°24’
6 3.681-3.687 93.49-93.65 18°30’ - 21°13’ 17°40’ - 19°12’
Feedback 3.735-3.765 94.87-95.63 N/A - N/A N/A - N/A
Clevis
B. For use with green VSV feedback bellcrank-P/N L43567.
IGV 3.683-3.689 93.54-93.70 30°53’ - 32°10’ 29°20’ - 30°40’
1 3.693-3.699 93.80-93.96 26°29’ - 28°00’ 25°10’ - 26°40’
2 3.642-3.648 92.50-92.66 24°50’ - 26°10’ 21°47’ - 23°00’
3 3.645-3.651 92.58-92.74 24°00’ - 25°10’ 20°00’ - 21°10’
4 3.645-3.651 92.58-92.74 22°20’ - 23°32’ 18°28’ - 19°40’
5 3.590-3.596 91.18-92.34 21°20’ - 23°36’ 14°40’ - 16°24’
6 3.621-3.627 91.97-92.13 21°30’ - 24°13’ 14°40’ - 16°12’
Feedback 3.735-3.765 94.87-95.63 N/A N/A
Clevis

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e. Adjust IGV angles for closed position as follows:
WARNING
SERIOUS INJURY CAN OCCUR WHEN APPLYING PNEU-
MATIC PRESSURE. EYE PROTECTION IS REQUIRED.
AND FITTINGS.
(1) With the system actuated to full closed position (actuator fully retracted), maintain
200-400 psi (1379-2758 kPa) pressure. Record each protractor readout. The reading shall be
within the limits of table 2.
CAUTION
MAXIMUM LENGTH OF CLEVIS PUSHROD ASSEMBLY (7,
FIGURE 4) SHALL NOT EXCEED 3.85 INCHES (97.8 MM) AS
MEASURED FROM CENTER OF THE CLEVIS (12) MOUNT-
ING HOLE TO CENTER OF ROD-END BEARING (15) HOLE.
of table 2. Adjust pushrod clevis assemblies on both sides of the gas generator equally. Actuate
the system away from, and then back to, the closed position. Maintain 200-400 psi
(1379-2758 kPa) pressure. Lightly tap the actuation ring segments (2 or 2A, figure 3) with a
lightweight plastic or rawhide mallet to remove hysteresis. Check results on the protractor.
Repeat the procedure as necessary. Tighten the pushrod jamnuts to 40-80 lb in. (4.52-9.04 N·m)
of torque. Tighten the rod-end bearing jamnuts to 40-80 lb in. (4.52-9.04 N·m) of torque and
safety-wire assembly.
f. Reposition the protractor to stage 1 per step c and repeat steps d and e.
g. When adjustments for each stage (IGV through stage 6) have been completed, inspect
installation by attempting to pass a 0.055 inch (1.40 mm) diameter wire or pin through the witness
hole in each actuation lever pushrod (7, figure 4). A correct installation will have a sufficient
number of rod-end bearing (15) threads blocking the witness hole so that test pin will not pass
through hole.
h. Repeat steps c, d, e, f, and g for stages 2 through 6.
i. Set variable stator vanes to the full open position and remove pressure source.
j. Check each stage to make certain sides of each actuation lever clevis (12, figure 4) are par-
allel to sides of the vane actuation lever (9), and actuation rod-end bearings (15) are parallel to
sides of the actuation ring connecting links (8).

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Figure 4. Rigging the Variable Stator Vane Actuating Mechanism (Sheet 1 of 2)

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Figure 4. Rigging the Variable Stator Vane Actuating Mechanism (Sheet 2 of 2)

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5. VSV SYSTEM STATIC (OR GANG) RIGGING (SPEED SENSOR/SERVO VALVE
CONFIGURATION). See figure 5.
CAUTION
IF 1C3569 HYDRAULIC ACTUATION UNIT OR EQUIVA-
LENT IS USED, IT SHALL BE FILED WITH GAS TURBINE
LUBE OIL ONLY.
a. Attach pressure source capable of delivering 200-400 psig (1379-2758 kPa) to oil supply
connector (5, figure 1). Attach slave hose to oil return connector (6) and provide suitable con-
tainer to collect oil leakage. Tighten supply connection to 270-300 lb in. (30.51-33.90 N·m) of
torque.
NOTE
z The vane actuators may be operated by either clean dry shop air
or dry nitrogen.
z Pressure may drop due to bleed orifice in vane actuator piston.
Maintain pressure throughout the rigging operation.
b. Screw input linkage rod-end bearings (9, figure 1) to maximum threaded depth, then back
off six turns. Do not tighten jamnut (10) at this time.
c. Connect input linkage rod-end bearings (9) between the speed sensor output lever (8) and
servo valve input lever arm (11) with nut, bolt, and washer (washer at speed sensor lever end).
Leave nut on speed sensor arm fingertight. Tighten nut on servo valve arm to 24-27 lb in.
(2.71-3.05 N·m) of torque.
d. Loosen rigging plate (7) mounting screw on speed sensor and position plate to clear
mechanical stop (23).
WARNING
AND FITTINGS.
e. Actuate the variable vane actuators by applying 200-400 psig (1379-2758 kPa) from the
pressure source. Manually actuate the input lever arm (11) to cycle the stator vane actuators from
fully open to fully closed positions a minimum of two times.

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(VSV Control PN L34379 Configuration) (Sheet 1 of 2)
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(VSV Control PN L34379 Configuration) (Sheet 2 of 2)

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NOTE
z Open and closed vane angles are measured on the vane angle
indicator mounted on the compressor stator second stage vanes.
Full open (actuators extended) should be -5.0 degrees for speed
sensor L21808P03 and -6.5 degrees for speed sensors
L21808P05 and P06 with the linkage between the speed sensor
and the servo valve disconnected. See figure 6.
z If vane angles need to be reset, refer to paragraph 4.
f. Disconnect the rod-end bearing (9, figure 1) at the speed sensor output lever (8).
g. Manually move the input lever arm (11) aft (toward the transfer gearbox) until stator vanes
are in the full open position. Maintain sufficient restraint on the input lever arm to keep the stator
vanes fully open.
h. Move the speed sensor output lever (8) aft until the indicator on the rigging plate is against
the mechanical stop (23).
CAUTION
DO NOT LOOSEN THE ROD-END BEARINGS BEYOND MIN-
IMUM THREAD ENGAGEMENT WITNESS HOLE.
i. Adjust rod-end bearing (9) as required to connect it to the speed sensor output lever (8).
Adjust the feedback cable rod-end bearings (12).
j. Following any adjustment of the feedback cable rod-end bearings, verify that the feedback
cable inner member has over travel at either end of its stroke when the stator vanes are cycled to
fully open (extended) and fully closed (retracted) positions. If the feedback cable bottoms out on
its internal stop at either end of its stroke, adjust rod-end bearings an equal amount to establish
cable over travel.
k. Tighten jamnuts (10 and 13) securing rod-end bearings to 24-27 lb in. (2.71-3.05 N·m) of
torque and safety-wire where applicable.
l. Disconnect pressure supply line and slave return hose. Reconnect oil supply and return
hoses (5 and 6) to servo valve. Tighten supply connectors to 450-550 lb in. (50.85-62.15 N·m) of
torque. Tighten oil return connector to 270-300 lb in. (30.51-33.90 N·m) of torque.

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Figure 6. Variable Vane Position Indicator (VPI)

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NOTE
z With the rigging plate (7) returned to its original position, a
-3 degree open angle should be obtained for the P03 speed sen-
sor and a -4 degree open angle for the P05 and P06 speed sen-
sors when the speed sensor lever is against the rigging plate.
z Full closed position should provide approximately +39.3
degrees for the P03 speed sensor and +40.3 degrees for the P05
and P06 speed sensors.
m. Return rigging plate (7) to its original position and tighten retaining screws to 24-27 lb in.
(2.71-3.05 N·m) of torque.
6. VSV SYSTEM STATIC (OR GANG) RIGGING (VSV CONTROL PN L34379 CON-
FIGURATION). See figure 5.
CAUTION
IF 1C3569 HYDRAULIC ACTUATION UNIT OR EQUIVA-
LENT IS USED, IT SHALL BE FILLED WITH GAS TURBINE
LUBE OIL ONLY.
a. Alternately connect actuator head-end hose (5, figure 5) and rod-end hose (6) to a
200-400 psig (1379-1758 kPa) pressure source. Vent the opposite side of the control to a suitable
container for collecting oil leakage.
WARNING
AND FITTINGS.
NOTE
z The vane actuators may be operated by either clean dry shop air,
gas turbine lube oil, or dry nitrogen.
z Pressure may drop due to bleed orifice in vane actuator piston.
Maintain pressure throughout the rigging operation.
b. Cycle the stator vane actuators from the full open (extended) to the full closed (retracted)
positions a minimum of two times.

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NOTE
z Open and closed vane angles are measured on the vane angle
indicator mounted on the compressor stator second stage vanes.
See figure 6.
z If vane angles require re-rigging, refer to paragraph 4.
c. Apply and maintain pressure to 200 psig (1379 kPa) minimum to the actuator head-end
supply hose to keep the stator vanes fully open (actuator rod fully extended). Vent the rod-end
supply hose to a suitable container for collecting oil leakage.
d. Adjust the feedback cable rod-end bearings (12, figure 5) to align the control lever arm (7)
in the center of the slot in the rig plate (19) on the control.
NOTE
Bracket (22, figure 5) is the latest configuration and allows bracket
(17) to be adjustable. The old configuration bracket (23) is a one
piece bracket, with no adjustment, since bracket (17) is not used.
e. Verify the feedback cable inner member has overtravel at each end of its stroke when actu-
ators are fully open (extended) and fully closed (retracted). If the feedback cable is bottomed out
on its internal stop at either end of its stroke, adjust the feedback cable rod-end bearings (12) an
equal amount to re-establish overtravel.
f. Do not adjust the feedback cable rod-end bearing past minimum thread engagement wit-
ness holes. If additional adjustment is necessary, reposition bracket (17) on gearbox accordingly.
g. Tighten rod-end bearing jamnuts (13) to 24-27 lb in. (2.7-3.0 N·m) of torque. Connect
head-end hose (5) to control and tighten to 450-500 lb in. (50.8-56.5 N·m) of torque. Connect
rod-end hose (6) to control and tighten to 270-300 lb in. (30.5-33.9 N·m) of torque.
h. Safety-wire all nuts, plugs, caps, and rod-end bearings, where applicable.
7. VSV SYSTEM OPERATING RIGGING CHECKS AND ADJUSTMENTS.

a. Start gas generator, and operate at idle. Bleed any air trapped in stator control system by
loosening supply and return fittings at servo valve. Retighten and safety-wire fittings when all air
has been eliminated.

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Figure 7. Variable Stator Vane Transducer Output vs Vane Angel (β)

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Figure 8. Gas Generator Variable Stator Vane Schedule-PN L21808P03 or L21035P02 Speed
Sensor and PN L21592 Feedback Bellcrank
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Figure 9. Gas Generator Variable Vane Schedule-PN L21808P05 Speed Sensor and
PN L21592 Feedback Bellcrank
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PN L34379 Controls (with PN L21592 Feedback Bellcrank)

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PN L34379 controls (with L43567 Feedback Bellcrank)

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CAUTION
THREE DIFFERENT SPEED SENSORS PLUS A UNITIZED
VSV CONTROL SYSTEM ARE AVAILABLE. EACH HAS A
DIFFERENT STATOR SCHEDULE. THE UNITIZED VSV
CONTROL PN L34379 HAS THE SAME SCHEDULE AS THE
L21808P06 SPEED SENSOR. ENSURE THE PROPER SCHED-
ULE IS USED.
b. The stator should remain nearly closed at gas generator idle (5000 rpm). The following
tabulation defines the applicable stator schedule for various combinations of controls and feed-
back bellcranks.
Stator Schedule Speed Sensor/VG Control PN Bellcrank PN Bellcrank Color
Figure 8 L21808P03 L21592 Grey
Figure 9 L21808P05 L21592 Grey
Figure 10 L21808P06 and L34379 L21592 Grey
Figure 11 L21808P06 and L34379 L43567 Green
These figures show the desired stator angles as a function of gas generator speed and compressor
inlet temperature. They also show the tolerance permitted at various stator angles.
c. Slowly increase gas generator speed until variable stators start to move. On
normal-temperature day (40° to 80°F) [4° to 27°C]) this should occur between 5600 and
5800 rpm. If they do not move, continue to increase gas generator speed to 6500 rpm. If they do
not move by this speed, return gas generator speed to idle and perform checks listed in Volume I,
Chapter 4.
d. Assuming that stators do move, slowly increase gas generator speed by 500 rpm incre-
ments to 7000 rpm, and plot the points on the schedule. If actual plotted points deviate from
schedule by more than allowable tolerance, shut down gas generator and make following
adjustments:

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CAUTION
FOLLOWING ANY ADJUSTMENT OF THE FEEDBACK
CABLE ROD-END BEARINGS, VERIFY THAT THE FEED-
BACK CABLE INNER MEMBER HAS OVERTRAVEL AT
EACH END OF ITS STROKE WHEN THE STATOR VANE
ACTUATORS ARE CYCLED TO BOTH THE FULLY OPEN
(EXTENDED) AND FULLY CLOSED (RETRACTED) POSI-
TIONS. IF THE STATOR VANE FEEDBACK CABLE IS BOT-
TOMED OUT ON ITS INTERNAL STOP AT EITHER
ACTUATOR STOP, ADJUST EACH FEEDBACK CABLE ROD-
END BEARING AN EQUAL AMOUNT TO RE-ESTABLISH
CABLE OVERTRAVEL.
NOTE
To allow for adjustment of the variable stators while the gas genera-
tor is operating at idle speed, a micro-adjust mechanism is made
available for retrofit at customer option. Located at the VSV end of
the feedback cable, the conduit end of the cable is attached to the
micro-adjust and adjustment of the cable is accomplished by loos-
ening a clamping screw and turning the adjustment feature. This
adjusts the cable length and allows the stator schedule to be
trimmed. To preclude the possibility of exceeding feedback cable
overtravel, the length of adjustment of the micro-adjust unit has
been limited to ±2 degrees stator angle. See figures 12 and 13.
(1) If plotted points are parallel with schedule, but offset either to right or left, adjust
length of feedback cable by turning rod-end bearing (12, figure 12) at upper end of feedback cable
(bellcrack [16] end) on or off cable. Shortening length of cable moves schedule to left; lengthen-
ing cable moves schedule to right. If sufficient adjustment is not available at this point, the rod-
end bearing at servo valve end of feedback cable can be utilized to shorten or lengthen cable.
NOTE
Ensure that a minimum thread engagement of 0.25 inch (6 mm)
exists between cable and rod-end bearing, following any adjust-
ment, by inserting a pin in the witness hole.
(2) If plotted points indicate that operating line is tilted with respect to schedule, adjust
schedule by moving Link L2 on speed sensor in its slot. This changes the effective length of Lever
L1. Increasing length of Lever L1 will increase slope of schedule 3.3% for each mark on the slot;
decreasing length of arm will have opposite effect (figure 12).

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Figure 12. Variable Stator Vane Control Configuration (Sheet 1 of 2)

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NOTE
In the case of one piece VSV control, L34379, do not adjust Links
Ll and L2. Change control.
e. Start gas generator and replot schedule points. Retrim, as required, until schedule is within
tolerances at all speeds.
8. VSV SYSTEM FEEDBACK CABLE RIGGING (SPEED SENSOR/SERVO VALVE

SYSTEM).
a. Verify that the feedback cable rod-end bearings (12, figure 14) have been installed cor-
rectly to each feedback end and are connected to the input lever arm (11) and to the feedback
cable bellcrank (16).
b. Connect a pressurizing source of clean dry air or nitrogen to servo valve (supply) head-
end port (5). Tighten coupling nuts to 270-300 lb in. (31-34 N·m) of torque.
c. Connect a drain hose to servo valve rod-end port (5) and provide a suitable container to
collect oil leakage.
WARNING
AND FITTINGS.
d. Apply a pressure of 200-400 psig (1378-2758 kPa) to servo valve head-in port. Manually
actuate linkage to cycle stator vane actuators from full open to full closed positions a minimum of
two times.
e. Manually move servo valve input lever arm (11) until stator vane actuators are at mid
stroke (approximately 18 degrees on variable vane position indicator - VPI).
f. Connect feedback cable to servo valve feedback lever arm (11) with bolt and nut. Connect
feedback cable to stator vane bellcrank (16) with bolt and nut.
g. Verify the feedback cable inner member (6, figure 15) has overtravel at each end of its
stroke when the stator vane actuators are cycled to both the fully extended (open) and fully
retracted (closed) positions. If the stator vane feedback cable is bottomed out on its internal stop
at either end, adjust each feedback cable rod-end bearing and equal amount to re-establish cable
overtravel.

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h. Remove the pressure source hose from the servo valve (supply) head-end hose
(5, figure 14). Remove the (return) rod-end drain hose from servo valve port (6, figure 14).
i. Connect the (supply) head-end hose (5, figure 14) coupling nut and tighten to
450-550 lb in. (50.9-62.2 N·m) of torque on the servo valve.
j. Connect the (return) rod-end hose (6, figure 14) coupling nut and tighten to 270-300 lb in.
(30.5-33.9 N·m) of torque on the servo valve.
k. Tighten rod-end bearing locknuts (4, figure 15) to 24-27 lb in. (2.7-3.1 N·m) of torque.
l. Tighten nut at the rod-end bearing to servo valve input lever arm (11, figure 14) connec-
tion to 24-27 lb in. (2.7-3.1 N·m) of torque. Tighten nut at the stator vane bellcrank (16), to rod-
end bearing connection to 24-27 lb in. (2.7-3.1 N·m) of torque.
m. Install clamp (18) to secure cable to aft side of transfer gearbox. Tighten clamp nut to
24-27 lb in. (2.7-3.1 N·m) of torque.
NOTE
Safety-wire all nuts, plugs, caps, etc., wherever applicable.
9. VSV SYSTEM FEEDBACK CABLE RIGGING (VSV CONTROL PN L34379 CON-

FIGURATION).
a. Verify that the feedback cable rod-end bearings (12, figure 14) have been installed cor-
rectly to each feedback cable end and are connected to the VSV control input lever (11) and to the
feedback cable bellcrank (16).
b. Connect a pressurizing source of clean dry air or nitrogen to VSV control (supply) head-
end port (3, figure 12). Tighten to 270-300 lb in. (31-34 N·m) of torque.
c. Connect a drain hose to VSV control (return) rod-end port (4) and provide a suitable con-
tainer to collect oil leakage.
WARNING
AND FITTINGS.
d. Apply a pressure of 200-400 psig (1379-3758 kPa) to VSV control (supply) head-end
port (3). Manually actuate linkage to cycle stator vane actuators from full open to full closed
positions a minimum of two times.

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e. Apply and maintain pressure to 200-400 psig (1379-2758 kPa) to the actuator (supply)
head-end hose to keep the variable stator vanes fully open (actuator rod fully extended).
f. Adjust the feedback cable rod-end bearings (2, figure 15) to align the VSV control
lever (7, figure 16) in the center of the slot of rig plate (21, figure 16) on the VSV control.
g. Verify the feedback cable inner member (6, figure 15) has overtravel at each end of its
stroke when the stator vane actuators are cycled to both the fully extended (open) and fully
retracted (closed) positions. If the stator vane feedback cable is bottomed out on its internal stop
at either end, adjust each feedback cable rod-end bearing an equal amount to re-establish cable
overtravel.
h. Remove the pressure source hose from the VSV control (supply) head-end hose
(5, figure 16). Remove the drain hose from the VSV (return) rod-end (4, figure 16).
i. Connect the (supply) head-end hose (5) coupling nut and tighten to 450-550 lb in.
(50.9-62.2 N·m) of torque on the VSV control.
j. Connect the (return) rod-end (6) coupling nut and tighten to 270-300 lb in.
(30.5-33.9 N·m) of torque on the VSV control.
k. Tighten rod-end bearing locknuts (4, figure 15) to 24-27 lb in. (2.7-3.1 N·m) of torque.
l. Tighten nut at the rod-end bearing to VSV control input lever arm (11, figure 14) connec-
tion to 24-27 lb in. (2.7-3.1 N·m) of torque. Tighten nut at the stator vane feedback cable
bellcrank (16, figure 12) to rod-end bearing connection to 24-27 lb in. (2.7-3.1 N·m) of torque.
m. Install clamp (18) to secure cable to aft side of transfer gearbox. Tighten clamp nut to
24-27 lb in. (2.7-3.1 N·m) of torque.
NOTE
Safety-wire all nuts, plugs, caps, etc., wherever applicable.

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Figure 16. Variable Stator Vane Control, PN L34379

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VARIABLE STATOR VANE SYSTEM RIGGING

AND CALIBRATION
EFFECTIVITY: LM2500 GAS GENERATOR MODEL - GA101 ONLY

1 - 21 . . . . . . . . . 0 22 Blank . . . . . . 0
ALPHABETICAL INDEX
Subject Page
VSV System Operating Rigging Checks and Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . 16

VSV System Stage-to-Stage Rigging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
VSV System Static Rigging (Feedback/Demand Cable Configuration). . . . . . . . . . . . . . . . 13

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1. INTRODUCTION. This subordinate work package contains instructions for the variable
stator vane system stage-to-stage rigging, system static rigging and operating rigging checks. In
addition, it also contains instructions for feedback/demand cable rigging.
NOTE
a. VSV System Stage-to-Stage Rigging.

2C6103 Protractor - Tool Set - Gas Generator - Rigging -
Alt Tool 1C5714
b. VSV System Static Rigging

2C6103 Protractor - Tool Set - Gas Generator - Rigging -
Alt Tool 1C5714
c. Operating Rigging Checks and Adjustments.

1C6977 Variable Stator Vane Position Indicator Transmitter

Container, Plastic - 5 Quart
Layout Fluid (Dykem)
Nitrogen, Dry
Safety Wire

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4. VSV SYSTEM STAGE-TO-STAGE RIGGING.
NOTE
The following procedure covers stage-to-stage rigging using the
2C6103 variable vane protractor set.
a. Mark vane lever arms in each of the IGV through sixth stages as indicated in Table 1.
These vanes will be used to measure vane angles during final rigging. Locate vanes in each stage
by counting clockwise from 9 o’clock horizontal flange. Use layout fluid (Dykem or equivalent)
for marking.
Table 1. VARIABLE VANE MARKING

Stage Marked Vanes
IGV 5, 13, 22, 30
1 5, 14, 23, 32
2 5, 14, 25, 35
3 6, 18, 29, 41
4 7, 19, 31, 45
5 8, 22, 38, 52
6 8, 25, 40, 57
b. Connect pressure source to the variable stator actuator head-end and rod-end ports, as
follows:
(1) Using a regulated dry nitrogen, gas turbine oil or clean shop air pressure source, con-
nect to the servo valve supply port by disconnecting head end pressure hose (figure 6), and con-
necting pressure source to the disconnected hose.
(2) Disconnect servo valve rod end return hose as shown in figure 6. Using a slave hose
installed on the servo valve rod end return fitting, route the slave hose to a suitable container pro-
vided to catch any residual oil that may be discharged from the return port.

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Figure 1. 2C6103 Variable Vane Protractor Installation

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Figure 2. Rigging the Variable Stator Vane Actuating Mechanism

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Figure 3. Actuation Ring Segments and Connecting Link

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Figure 4. Demand Cable at Speed Sensor

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Figure 5. Demand Cable, VSV Feedback Cable and Servo Valve

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Figure 6. Variable Stator Vane Control System

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NOTE
z Use calibrated 2C6103 tool set or equivalent.
z If piping or bracket interference occurs, it may not be possible
to get protractor on points called for in Table 1. Place protractor
on one of those locations called for in each stage in Table 1 that
are accessible.
z To facilitate installation of the variable vane protractor/nuts
non-locking may be installed on the vane studs of the marked
vane lever arms in each stage (IGV through sixth) as shown in
Table 1. Make sure that all non-locking nuts are properly
replaced with new lock nuts of the correct type.
c. Install protractor from 2C6103 rigging tool set to marked lever arm in each variable stage
as follows:
(1) Attach locator (9, figure 1) to marked lever arm (10) by turning shaft (8) onto vane
stud (7). Tighten jam nut (11). Use large locator at IGV and stages-1 and -2; use medium locator
at stages -3 and -4; use small locator at stages-5 and -6.
(2) Place protractor over locator (9) engaging slots of protractor shaft onto pins at
locator.
(3) Attach shaft (6) at each end of protractor arms to stud (7) of vane by turning knurled
nut (2). Keep shaft (6) as close as possible to center of protractor.
(4) Tighten jam stud (1).
(5) Tighten check nut (4).
(6) Tighten jamnut (3).

CAUTION
DO NOT EXCEED 400 PSIG (2758 KPA) PRESSURE WHEN
ACTUATING THE VARIABLE VANES. TO AVOID DAMAG-
ING THE EQUIPMENT, CHECK THE VARIABLE VANE
FEEDBACK SYSTEM CAREFULLY TO ENSURE THERE IS
NOT INTERFERENCE BEFORE APPLYING PRESSURE. THE
NORMAL PRESSURE REQUIRED TO ACTUATE THE SYS-
TEM IS 300 PSIG (2068 KPA). THE MINIMUM PRESSURE
REQUIRED IS 200 PSIG (1379 KPA).
d. Adjust IGV angles for open position as follows:
(1) With the system actuated to fully open position (actuator fully extended), maintain
200-400 psi (1379-2758 kPa) pressure. Read and record each stage travel. The reading shall be
within the limits of Table 2.

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GEK 97310
VOLUME II
SWP 118 01
Table 2. VARIABLE VANE ADJUSTMENT - GA101
CLEVIS LENGTH
Stage Clevis Assembly
Center to Center
Length
+ 0.005 in (0.13 mm)
IGV 3.710 in (94.23 mm)
1 3.710 in (94.23 mm)
2 3.650 in (92.71 mm)
3 3.650 in (92.71 mm)
4 3.650 in (92.71 mm)
5 3.690 in (93.73 mm)
6 3.690 in (93.73 mm)
Feedback Clevis 3.735-3.765 in (94.87-95.63 mm)
OPEN VANE ANGLE
Stage Average of 4 Vane Angles
IGV 29°51' - 28°51'

1 25°43' - 24°43'
2 24°32' - 23°32'
3 23°31' - 22°31'
4 22°03' - 21°03'
5 20°35' - 19°35'
6 20°36' - 19°36'
CLOSED VANE ANGLE
Stage Average of 4 Vane Angles
IGV 31°38' - 33°38'

1 27°21' - 29°21'
2 23°41' - 25°41'
3 22°00' - 24°00'
4 20°25' - 22°25'
5 17°46' - 19°46'
6 17°49' - 19°49'

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CAUTION
MAXIMUM LENGTH OF ACTUATION PUSHROD CLEVIS
ASSEMBLY (7, FIGURE 2) SHALL NOT EXCEED
3.850 INCHES (97.79 MM), AS MEASURED FROM CENTER
OF THE CLEVIS (12) MOUNTING HOLE TO CENTER OF
ROD-END BEARING (15) HOLE.
of table 2. Adjust pushrod clevis assemblies on both sides of gas generator equally. Actuate the
system away from, and then back to, the full open position (actuator fully extended). Maintain
200-400 psi (1379-2758 kPa) pressure. Lightly tap actuation ring segments (2 or 2A, figure 3)
with a lightweight plastic or rawhide mallet to remove hysteresis. Check results on the protractor.
Repeat the procedure as necessary. Torque the rod-end bearing jamnut to 40-80 lb in.
(4.52-9.04 N·m). Do not safety-wire at this time.
e. Adjust IGV angles for closed position as follows:
(1) With the system actuated to full closed position (actuator fully retracted), maintain
200-400 psi (1379-2758 kPa) pressure. Record each protractor readout. The average reading
shall be within the limits of Table 2.
CAUTION
MAXIMUM LENGTH OF PUSHROD CLEVIS ASSEMBLY
(7, FIGURE 2) SHALL NOT EXCEED 3.850 INCHES
(97.79 MM) AS MEASURED FROM CENTER OF THE
CLEVIS (12) MOUNTING HOLE TO CENTER OF ROD-END
BEARING (15) HOLE.
of Table 2. Adjust pushrod clevis assemblies on both sides of the gas generator equally. Actuate
the system away from, and then back to, the closed position. Maintain 200-400 psi
(1379-2758 kPa) pressure. Lightly tap the actuation ring segments (2, figure 3) with a lightweight
plastic or rawhide mallet to remove hysteresis. Check results on the protractor. Repeat the proce-
dure as necessary. Torque the pushrod jamnuts to 40-80 lb in. (4.52-9.04 N·m) and safety-wire
assembly.
f. Reposition the protractor to stage 1 per step c and repeat steps d and e.
g. When adjustments for each stage (IGV through stage 6) have been completed, inspect
installation by attempting to pass a 0.055 inch (1.40 mm) diameter wire or pin through the witness
hole in each actuation lever pushrod (7, figure 2). A correct installation will have a sufficient
number of rod-end bearing (15) threads blocking the witness hole so that test pin will not pass
through hole.

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GEK 97310
VOLUME II
SWP 118 01
h. Repeat steps c, d, e, f, and g for stages-2 thru -6.
i. Set variable stator vanes to the full open position and remove pressure source.
j. Check each stage to make certain sides of each actuation lever clevis (12, figure 2) are par-
allel to sides of the vane actuation lever (9), and actuation rod-end bearings (15) are parallel to
sides of the actuation ring connecting links (8).
5. VSV SYSTEM STATIC RIGGING (FEEDBACK/DEMAND CABLE

CONFIGURATION). See figures 4 through 7.
a. Initial operation and adjustments.
(1) The speed sensors are calibrated at the factory, and no internal adjustments are
permitted. The stator system is calibrated by means of a special protractor, which is mounted on
the 2nd-stage of the compressor, on the 6th vane up from the left-hand horizontal split-line,
viewed from aft looking forward, as shown in figure 7. This protractor, along with the variable
stator schedule paragraph should be used to calibrate the system. A rough indication of the stator
vane position may be obtained by using the speed sensor output schedule paragraph and the
“0-to-2” index scale on the stator vane speed sensor, but this indicator must not be used for mak-
ing any adjustments other than the initial “mid point” setting.
(2) The pressure source must maintain 200 ± 25 psi (1379 ± 172 kPa) constant pressure
during the rigging process. Do not use hand pump or other variable pressure source.
CAUTION
DO NOT PUSH ON DEMAND CABLE ROD ENDS OR APPLY
FORCE AT THE SERVO VALVE.
(3) All movement of the stator shall be accomplished using the output arm of the speed
sensor.
(4) After each adjustment, cycle the stator 2-3 times before reading the VPI.

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GEK 97310
VOLUME II
SWP 118 01
Figure 7. Variable Stator Vane Position Indicator (VPI)

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GEK 97310
VOLUME II
SWP 118 01
b. Static Rigging. See figures 4 through 7.
(1) Variable stators shall be in full-open position minus 4° 30' ± 15' with actuators in full
extended positions; stators shall be in full closed position (approximately 42 degrees) with actua-
tors in full retracted position. Length of actuator in fully extended position should be
11.376-11.384 inch (288.95-289.15 mm), measured from centerline of actuator mount to center-
line of rod-end bearing on end of piston shaft. This measurement must be made with 200 ± 25 psi
(1379 ± 172 kPa) regulated nitrogen, gas turbine oil or dry shop air pressure applied to actuator.
If actuators are not of proper length, adjust by loosening jamnut on rod, screwing rod end bearing
in or out of actuator as required, and retightening jamnut. This adjustment will normally not have
to be made, since actuators are adjusted at factory.
CAUTION
CABLE ROD END BEARINGS, VERIFY THAT THE FEED-
ACTUATOR STOP, ADJUST EACH FEEDBACK CABLE ROD
END BEARING AN EQUAL AMOUNT TO REESTABLISH
CABLE OVERTRAVEL.
(2) Adjust feedback cable from feedback bellcrank to servo valve, and demand cable
from speed sensor to servo valve, with actuators at mid-stroke. This can be accomplished by con-
necting a 200-400 psi (1379-2758 kPa) regulated supply of nitrogen, gas turbine oil or dry shop
air to supply port of servo valve. Movement of demand cable will then cause actuators to move.
With the index lever arm of speed sensor at mid-position (1.00), adjust cables so they are approx-
imately at right angles to speed sensor output lever arm, servo valve floating lever, and bellcrank.
Adjust the length of the demand cable to position the stators at 17 to 19 degrees, as indicated on
the variable stator vane position indicator (VPI) (figure 7).
(3) Adjust length of demand cable by loosening jamnuts where cable enters rod end
bearing and screwing cable end in or out of rod end. A 3/8 inch minimum engagement must be
maintained. Check engagement by inserting a pin through inspection hole in rod end. Pin should
not go completely through, and if it does, 3/8-inch thread engagement has not been maintained.
Adjustment can also be made by moving the cable housing position in the brackets. If adjustment
cannot be made in the cable, the output lever arm of the speed sensor can be disengaged and
shifted one serration (not normally required).

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GEK 97310
VOLUME II
SWP 118 01
(4) The position of the stators may also be adjusted using the feedback cable. This is not
normally required and demand cable adjustment is preferred. Feedback cable adjustment may be
made by changing length of cable in a manner similar to that described for the demand cable in
step (3) above. Minimum thread engagement is 1/4-inch for feedback cable.
(5) After the above adjustments have been made, rotate speed sensor output lever arm
from stop to stop. Protractor (VPI) should indicate travel from full-open operating position of
minus 3 degrees ± 10 minutes to full-closed operating position of 39° to 39° 30', see figure 7. If
not within these limits, proceed as follows:
(a) Case I - Total travel is 42° to 42° 30'. Adjust demand cable to produce the cor-
rect fully open position of 3 degrees ± 10 minutes. Closed position should now be within limits.
(b) Case II - Total travel is more or less than in Case I (Limit - ± 5 degrees). Adjust
the two output arm stops on the speed sensor equal amounts to give the required total travel; then
proceed as in Case I.
(6) To ensure correct setting of the open stop, loosen rigging plate on speed sensor index
arm, and hold out of way to allow 0.083-inch additional movement of output lever arm in the
open direction. With index arm at its rigging position against open stop, actuators should be fully
extended and stators fully open at minus 4 to 5 degrees (figure 7).
(7) The system should operate smoothly without binding. If erratic, disconnect feedback
and demand cables to check that they move freely in their conduits.
(8) After the static rigging procedure has been completed, remove oil, nitrogen or air
supply lines. Safety-wire all parts that were disturbed.
6. VSV SYSTEM OPERATING RIGGING CHECKS AND ADJUSTMENTS. See

figures 8 through 11.
a. Start gas generator, and operate at idle. Bleed any air trapped in stator control system by
loosening supply and return fittings at servo valve. Retighten and safety-wire fittings when all air
has been eliminated.
b. The stator should remain nearly closed at idle (5000 rpm). Figure 9 is the stator schedule
for gas generators equipped with PN L21808P03 or L21035P02 speed sensors. This figure shows
the desired stator angles as a function of gas generator speed and compressor inlet temperature
and also shows the tolerance permitted at various stator angles.
c. Slowly increase gas generator speed until variable stators start to move. On a normal-
temperature day (40° to 80°F [4 to 27°C]) this should occur between 5600 and 5800 rpm. If they
do not move, continue to increase gas generator speed to 6500 rpm. If they do not move by this
speed, return gas generator speed to idle and troubleshoot per Volume I, Chapter IV, as applicable.

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GEK 97310
VOLUME II
SWP 118 01
Figure 8. Gas Generator Variable Stator Vane Schedule - Speed Sensor PN L21808P03 or
L21035P02
17
GEK 97310
VOLUME II
SWP 118 01
Figure 9. Variable Stator Vane Control Functional Schematic

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GEK 97310
VOLUME II
SWP 118 01
Figure 10. Variable Feedback Cable - GA101

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VOLUME II
SWP 118 01
Figure 11. Variable Feedback Cable and Demand Cable - GA101

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GEK 97310
VOLUME II
SWP 118 01
d. Assuming that stators do move, slowly increase gas generator speed by 500 rpm incre-
ments to 7000 rpm, and plot the points on the schedule. If actual plotted points deviate from
schedule by more than allowable tolerance, shutdown gas generator and make the following
adjustments:
CAUTION
CABLE ROD-END BEARINGS, VERIFY THAT THE FEED-
ACTUATOR STOP, ADJUST EACH FEEDBACK CABLE ROD-
END BEARING AN EQUAL AMOUNT TO REESTABLISH
CABLE OVERTRAVEL.
(1) If plotted points are parallel with schedule, but offset either to right or left, adjust
length of feedback cable by turning rod-end bearing at upper end of feedback cable (bellcrank
end) on or off cable. Shortening length of cable moves schedule to left (opening); lengthening
cable moves schedule to right (closing). If sufficient adjustment is not available at this point, the
rod-end bearing at servo valve end of feedback cable can be utilized to shorten or lengthen cable.
NOTE
Assure that a minimum thread engagement of 1/4 inch (6 mm)
exists between cable and rod-end bearing, following any adjust-
ment, by inserting a pin through the witness hole.
(2) If plotted points indicate that operating line is tilted with respect to schedule, adjust
schedule by moving Link L2 on speed sensor in its slot. This changes the effective length of
Lever L1. Increasing length of Lever L1 will increase slope of schedule (i.e., make it move verti-
cally) 3.3% for each mark on the slot; decreasing length of arm will have opposite effect
(figures 8, 10 and 11).
e. Start gas generator and replot schedule points. Retrim, as required until schedule is within
tolerances at all speeds.

21/(22 Blank)
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VOLUME II
WP 120 00
WORK PACKAGE
REPLACEMENT OF AIR/OIL SEPARATOR

1-8.......... 0
ALPHABETICAL INDEX
Subject Page
Installation of Air/Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Removal of Air/Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
WP 120 00
1. INTRODUCTION. This work package contains the instructions for the removal and
installation of the air/oil separator.
NOTE

1C8033G01 Motoring Adapter
1C8067G01 Drive Motor
9415M88G01 Bearing Puller

MIL-L-23699 Lube Oil, Gas Turbine
GE Spec A50TF142 Petrolatum, Soft White
Safety Wire
4. REMOVAL OF AIR/OIL SEPARATOR. See figure 1.
a. Disconnect V-band clamp (16) at air/oil separator discharge port.
b. Disconnect discharge tube (5) (refer to packager’s manual) and move it out of the way.
c. Remove forward scavenge oil hose (18) as follows:
(1) Disconnect coupling nut between hose (18) and tube (6).
(2) Remove bracket (17) from air/oil separator. Leave bracket and clamp attached to
hose and reinstall bolt to air/oil separator.
(3) Remove 4 bolts securing hose flange to gearbox port. Remove and discard
gasket (4). Remove hose.

2
GEK 97310
VOLUME II
WP 120 00
Figure 1. Air/Oil Separator

3
GEK 97310
VOLUME II
WP 120 00
d. Disconnect air/oil separator manifold tube (7) from separator. Remove and discard
gasket (8). Loosen tube coupling (9) at gearbox and rotate tube down and out of way.
e. Disconnect sump vent tube (1) from air/oil separator. Rotate tube out of the way. Remove
and discard gasket (2).
f. Remove seal pressurizing tube (3).
g. Remove union (14) from pressurizing tube port on air/oil separator. Remove and discard
O-ring (15) and retain union.
h. Loosen all of the bolts holding the air/oil separator adapter (13) to gearbox. Remove all
except the top two bolts.
i. Support the air/oil separator by hand and install 3 jackscrews in the adapter flange
jackscrew holes. Remove the top two bolts.
NOTE
Bearing (12) will remain on air/oil separator impeller shaft.
j. Hold the air/oil separator securely by hand and carefully remove it by turning the
jackscrews alternately in small, equal amounts. When adapter rabbet is disengaged, pull
assembly straight out to avoid damage to gear teeth.
k. Remove and discard adapter O-ring (11).
NOTE
If the bearing housing (10) is a tight fit, it may be necessary to use a
bearing puller. Use 9415M88G01 puller if necessary.
l. Remove bearing housing and outer race (10) from the gearbox. Discard keywashers.
CAUTION
BEARING INNER AND OUTER RACE ARE A MATCHED
ASSEMBLY HAVING THE SAME SERIAL NUMBER.
FAILURE TO INSTALL A MATCHED BEARING ASSEMBLY
MAY CAUSE EXCESSIVE BEARING WEAR, RESULTING IN
DAMAGE TO GEARBOX ASSEMBLY.
m. Bag and tag bearing housing and outer race (10) and attach it to the air/oil separator.
n. Wrap protective covering around bearing (12) on impeller shaft.

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GEK 97310
VOLUME II
WP 120 00
5. INSTALLATION OF AIR/OIL SEPARATOR. See figure 1.
CAUTION
BEARING (12) AND OUTER RACE (10) ARE A MATCHED
ASSEMBLY HAVING THE SAME SERIAL NUMBER.
FAILURE TO INSTALL A MATCHED BEARING ASSEMBLY
MAY CAUSE EXCESSIVE BEARING WEAR, RESULTING IN
DAMAGE TO GEARBOX ASSEMBLY.
a. Make sure bearing outer race has same serial number as bearing inner race.
b. Lubricate roller bearing outer race with clean gas turbine lube oil.
NOTE
Use nylon drift and a lightweight hammer to tap bearing housing
into place, if necessary.
c. Place bearing housing and outer race (10) in gearbox boss. Carefully align boltholes and
push housing to seated position. Make sure bearing housing is straight and seated.
d. Install new keywashers, prebent tab aft, and rotate counterclockwise against edge of
retainer (see detail, figure 1). Do not force or distort the prebent tab into position. Install 3 bolts
and torque to 24-27 lb in. (2.7-3.1 N·m).
NOTE
An overtorque to 40 lb in. (4.5 N·m) is permitted to position a
bolthead flat to one of the tabs on the keywasher.
e. Make sure bolthead flat is aligned to keywasher tab. Bend one tab of each keywasher
against bolthead flat.
f. Lubricate O-ring (11) and install it in groove in air/oil separator adapter (13). A small
amount of petrolatum may be used to hold O-ring in place. Make sure O-ring is firmly seated in
groove.
g. Lubricate the roller bearing on the gearshaft with clean soft white petrolatum.

5
GEK 97310
VOLUME II
WP 120 00
CAUTION
GEAR TEETH ON AIR/OIL SEPARATOR MUST MESH WITH
GEAR TEETH IN GEARBOX TO PREVENT DAMAGE.
ROTATION OF AIR/OIL SEPARATOR IMPELLER MAY BE
NECESSARY TO ALIGN GEAR TEETH.
NOTE
Adapter flange has off-set bolthole to ensure proper positioning of
air/oil separator.
h. Carefully position the air/oil separator on the gearbox, making sure that bearing, gears,
and boltholes are aligned. Rotate the air/oil separator impeller by hand as the impeller gearshaft is
being inserted into the gearbox to make sure that gear teeth mesh.
i. Install bolts through adapter (13) flange and finger-tighten them.
j. Remove the access cover from the gearbox drive pad located on the aft side of the gearbox
between the starter and the lube/scavenge pump.
NOTE
For gas generators with optional hydraulic pump installed, use
1C8067 motoring adapter in lieu of 1C8033. 1C8067 motoring
adapter attaches to the accessory drive pad located on the left aft
side of the accessory gearbox. Prior to installing 1C8067 motoring
adapter, remove L21431G02 rear shaft seal assembly.
k. Insert a 3 inch long, 3/4 inch square drive extension and 1C8033 adapter drive into the
gearbox drive. Using a ratchet wrench, slowly rotate the geartrain. Observe for rotation of the
air/oil separator impeller.
CAUTION
DURING SEATING OF THE AIR/OIL SEPARATOR MAKE
SURE THE GEARS MESH. FAILURE TO PROPERLY
ENGAGE THE GEARS MAY RESULT IN EXTENSIVE
DAMAGE TO THE GEARBOX.
l. Using a criss-cross tightening pattern seat the air/oil separator while slowly rotating the
gearbox geartrain. Geartrain must turn freely without hang-up.

6
GEK 97310
VOLUME II
WP 120 00
CAUTION
MAKE SURE THAT THE ADAPTER (13) IS FIRMLY AND
SQUARELY SEATED ON THE GEARBOX FLANGE AS
FINAL TORQUE IS APPLIED OR DAMAGE TO GEARS,
BEARINGS OR SEALS MAY RESULT.
m. Using feeler (shim) stock make sure adapter (13) is seated.
n. Torque the air/oil separator adapter bolts to 70-80 lb in. (7.9-9 N·m) using a criss-cross
pattern. Safety-wire the bolts.
NOTE
If 1C8067 motoring adapter was used in lieu of 1C8033 adapter,
remove 1C8067 motoring adapter and reinstall L21431G02 rear
shaft seal assembly. Replace preformed packing, J221P14 and
J221P216, on rear shaft seal assembly prior to installation in
gearshaft. Torque nut on rear shaft seal assembly to 160 lb in.
(18 N·m). Install new gasket and cover plate and torque bolts to
225 lb in. (25.4 N·m). Angle bracket L21804P01 is assembled at
holes 3 and 4 counterclockwise from the 12 o’clock position as
viewed aft looking forward.
o. Remove 1C8033 adapter drive. Inspect the seal on the access cover and replace seal if
necessary. Install the access cover and torque the bolts to 55-70 lb in. (6.2-7.9.N·m).
p. Lubricate O-ring (15) and install it on union (14). Install union in air/oil separator and
torque to 270-300 lb in. (30.5-34 N·m.).
q. Install pressurizing tube (3). Torque coupling nuts to 450-550 lb in. (50.9-62 N·m).
r. Rotate sump vent tube (1) to mate with air/oil separator. Install gasket (2) and connect
tube with 6 bolts and washers. Torque bolts to 55-70 lb in. (6.2-7.9 N·m) and safety-wire in pairs.
s. Install gasket (8) and attach air/oil manifold tube (7) to air/oil separator with 4 bolts.
Torque to 55-70 lb in. (6.2-7.9 N·m) and safety-wire in pairs. Torque coupling nut at gearbox end
of tube to 100-110 lb in. (11.3-12.4 N·m) and safety-wire.
t. Install gasket (4) and attach hose (18) flange to gearbox with 4 bolts. Torque to
24-27 lb in. (2.7-3 N·m).
u. Connect coupling nut to tube (6) and torque to 112-128 lb in. (12.6-14.5 N·m).

7
GEK 97310
VOLUME II
WP 120 00
v. Attach bracket (17) to air/oil separator. Torque bolt to 24-27 lb in. (2.7-3 N·m) and
safety-wire.
w. Install air/oil separator air discharge tube (5).
x. Tighten the V-band clamp (16) per Volume I, Chapter 5 to a final torque of 45-55 lb in.
(5-6.2 N·m).

8
GEK 97310
VOLUME II
SWP 120 01
REPLACEMENT OF AIR/OIL SEPARATOR COVER

1-6.......... 0
ALPHABETICAL INDEX
Subject Page
Installation of Air/Oil Separator Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Removal of Air/Oil Separator Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
SWP 120 01
1. INTRODUCTION. This subordiante work package contains instructions for removal and
installation of the air/oil separator cover.
2. SUPPORT EQUIPMENT.

1C6842G01 Tool Set, Transfer Gearbox

BB-C-104 Dry Ice
VV-P-236 Petrolatum
4. REMOVAL OF AIR/OIL SEPARATOR COVER. See figures 1 and 2.
a. Remove air/oil separator cover (1, figure 1) from air/oil separator housing (2) as follows:
WARNING
TOUCH YOU. IRRITANT. PERSONAL PROTECTIVE EQUIP-
MENT REQUIRED. USE MECHANICAL EXHAUST VENTI-
LATION - IF NOT AVAILABLE, USE AN APPROVED
RESPIRATOR.
(1) Place suitable container under housing (2).
(2) Disconnect V-band clamp (9) at air/oil separator cover (1) discharge port.
(3) Disconnect discharge tube (10) per packager’s manual and move tube out of the way.
(4) Remove bolt (3) and nut (4) at seal pressurizing tube (5) clamp.
(5) Disconnect coupling nut (6) at pressurizing port on cover (1) and seal pressurizing
tube (5).
(6) Remove union (7) from pressurizing port. Remove and discard preformed
packing (8).
(7) Remove bolt (11) and washer (12) that secure TGB scavenge oil hose (13) bracket to
cover (1). Move hose away from cover.

2
GEK 97310
VOLUME II
SWP 120 01
Figure 1. Air/Oil Separator Cover Removal and Installation

3
GEK 97310
VOLUME II
SWP 120 01
Figure 2. Air/Oil Separator Cover Removal Using Air/Oil Separator Cover Puller, PN 9407M45

4
GEK 97310
VOLUME II
SWP 120 01
(8) Remove remaining bolts (11) and washers (12) that secure cover (1) to housing (2).
(9) Install air/oil separator cover puller (figure 2), part of transfer gearbox tool set,
1C6842, onto air/oil separator cover flange. Loosen cover. Slight, careful prying may be
required. Remove cover.
(10) Remove air/oil separator cover puller from cover.
(11) Remove and discard preformed packing from cover.
5. INSTALLATION OF AIR/OIL SEPARATOR COVER.
a. Install air/oil separator cover (1, figure 1) onto air/oil separator housing (2) as follows:
WARNING
DRY ICE, BB-C-104: DO NOT LET THIS MATERIAL TOUCH
YOU. LOW-TEMPERATURE SKIN DAMAGE. CAN
DECREASE AVAILABLE AIR. ASPHYXIANT. PERSONAL
PROTECTIVE EQUIPMENT REQUIRED, ESPECIALLY INSU-
LATED GLOVES AND EYE PROTECTION WHEN HAN-
DLING MATERIAL. USE IN A WELL-VENTILATED AREA.
(1) Using Dry Ice, chill replacement air/oil separator cover (1). Using heat gun, heat
air/oil separator housing (2).
(2) Using soft petrolatum, lubricate new preformed packing and mating surfaces of
housing (2) and cover (1). Install preformed packing into groove on cover.
(3) Position cover (1) onto housing (2) with pressurizing port located at 12:30 o’clock
position, forward looking aft. Using soft-faced mallet, lightly tap cover into position.
CAUTION
DO NOT ATTEMPT TO DRAW AIR/OIL SEPARATOR COVER
TO SEATED POSITION WITH BOLTS. DO NOT STRIKE
AIR/OIL SEPARATOR COVER ON FLANGE OR DAMAGE
MAY OCCUR.
(4) Secure TGB scavenge oil hose (13) clamp onto cover (1) with bolt (11) and
washer (12). Install remaining bolts (11) and washers (12). Continue to lightly tap cover and
tighten bolts until cover is seated.
(5) Tighten bolts (11) to 33-37 lb in. (3.7-4.2 N·m) of torque and safety-wire.

5
GEK 97310
VOLUME II
SWP 120 01
(6) Using soft petrolatum, lubricate preformed packing (8) and install onto union (7).
Install union into pressurizing port, and tighten to 270-300 lb in. (30.5-33.9 N·m) of torque.
(7) Connect seal pressurizing tube (5) at union (7). Tighten coupling nut (6) to
450-550 lb in. (50.8-62.1 N·m) of torque.
(8) Install bolt (3) and nut (4) at seal pressurizing tube (5) clamp. Tighten bolt to
33-37 lb in. (3.7-4.2 N·m) of torque.
(9) Install discharge tube (10) onto cover (1) discharge port per packager’s manual.
Tighten V-band clamp (9) to 45-55 lb in. (5.1-6.2 N·m) of torque.

6
GEK 97310
VOLUME II
WP 121 00
WORK PACKAGE
REPLACEMENT OF HYDRAULIC SUPPLY PUMP

1-5.......... 0 6 Blank . . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Installation of Hydraulic Supply Pump. (Optional Equipment) . . . . . . . . . . . . . . . . . . . . . . 4

Removal of Hydraulic Supply Pump. (Optional Equipment) . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
WP 121 00
installation of the optional hydraulic supply pump.
NOTE

Container, Plastic, 5 Quart
3. CONSUMABLE MATERIAL. None
4. REMOVAL OF HYDRAULIC SUPPLY PUMP. (OPTIONAL EQUIPMENT)

See figure 1.
WARNING
DISCONNECT ELECTRICAL POWER AND REMOVE
ELECTRICAL CONNECTION. TURN OFF FUEL AND LUBE
SUPPLY TO THE GAS GENERATOR ENCLOSURE.
CAUTION
USE WRENCH ON BOTH UNION AND LINE BEING
DISCONNECTED.
NOTE
When fluid lines are disconnected, spillage of fluids may occur. Be
prepared to collect fluids in suitable container.
a. Disconnect hydraulic pump inlet and outlet lines from port unions on forward face of
pump (marked on pump).
b. Disconnect line from relief valve bypass of pump (marked on pump).
c. Loosen unions, but do not remove from pump.

2
GEK 97310
VOLUME II
WP 121 00
Figure 1. Hydraulic Pump - Optional (Kit No. 537L162G02)

3
GEK 97310
VOLUME II
WP 121 00
d. Remove nuts and washers which secure the pump to the studs on the gearbox mounting
pad. Retain nuts and washers for reinstallation.
e. Remove pump and gasket. Discard gasket.
f. Remove unions from inlet, discharge, bypass and drain ports of pump. Remove O-rings
from unions and discard.
g. Plug ports with plastic protective plugs. Install protective covers to all mating surfaces
and to drive shaft spline.
5. INSTALLATION OF HYDRAULIC SUPPLY PUMP. (OPTIONAL EQUIPMENT)

See figure 1.
a. Remove protective covers from pump sealing surfaces and drive shaft spline.
b. Remove port protective plugs.
c. Install new O-rings on union fittings per the following:
O-ring Fitting
J221P908 R287P08 (supply)
R287P06 and R289P06

J221P906
(discharge and bypass)
NOTE
Equivalent commercially available O-rings may be used.
d. Install elbow and union fittings at the following locations:
R289P06 (elbow) Oil bypass port

R287P06 Oil discharge port
R287P08 Oil supply port
e. Snug tighten unions only. Do not torque at this time.
f. Install new L21803P1 gasket over gearbox studs used in mounting hydraulic pump.

4
GEK 97310
VOLUME II
WP 121 00
CAUTION
EXERCISE CAUTION DURING MATING OF PUMP DRIVE
SHAFT SPLINE AND GEAR SHAFT. TO AVOID DAMAGING
COMPONENTS, DO NOT LET PUMP REST ON SHAFT
SPLINE.
g. Install hydraulic pump as follows:
(1) Orient pump so that relief valve bypass port (elbow-located on top of pump) is at the
12 o’clock position.
(2) Rotate drive shaft spline until properly aligned with internal spline of gearshaft.
CAUTION
TO PREVENT DAMAGE TO THE DRIVE SHAFT AND/OR
SPLINES, KEEP THE PUMP SUPPORTED UNTIL WASHERS
AND NUTS ARE STARTED ONTO STUDS.
(3) Carefully install pump over gearbox mounting studs and engage splines of drive shaft
and gearshaft, keeping pump supported.
(4) Install washers and nuts onto studs. Torque nuts to 100-130 lb in. (11.3-14.7 N·m).
h. Torque unions to the following values:
R287P06 - 180-200 lb in. (20.3-22.6 N·m)
R289P06 - 180-200 lb in. (20.3-22.6 N·m)
R287P08 - 270-300 lb in. (30.5-33.9 N·m)
i. Attach lines to proper fittings as marked on pump.
CAUTION
USE A WRENCH ON BOTH THE UNION AND LINE FITTING.
j. Torque fittings per standard values.
k. Reconnect electrical power and turn on fuel and lube supply to the gas generator
enclosure.

5/(6 Blank)
GEK 97310
VOLUME II
WP 122 00
WORK PACKAGE
REPLACEMENT OF PNEUMATIC STARTER

1-5.......... 0 6 Blank . . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Installation of Pneumatic Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Removal of Pneumatic Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
WP 122 00
of the pneumatic starter.
NOTE


MIL-L-23699 Lube Oil, Gas Generator
Safety Wire
4. REMOVAL OF PNEUMATIC STARTER. See figure 1.
NOTE
The inlet air/gas tube (customer’s item) must be disconnected and
moved clear of starter prior to performing this procedure. If gas
(optional) is used as starting medium, the outlet tube also must be
disconnected and moved clear.
a. Remove the safety wire and disconnect the electrical connector. Place the flexible
electrical lead end out of the way.
b. Place a clean plastic pail or other suitable container under the starter. Remove the safety
wire and drain plug at 6 o’clock. Allow the starter to completely drain. Do not discard the metal
seal on drain plug. Discard oil.
c. Remove safety wire and pipe plugs from lube in and lube out ports in starter. Discard
O-rings. Cap all openings, bag, tag and identify the 3 plugs.

2
GEK 97310
VOLUME II
WP 122 00
Figure 1. Pneumatic Starter
CAUTION
SUPPORT STARTER WHILE REMOVING TO PREVENT
DROPPING AND DAMAGE TO THE DRIVE SHAFT.
d. Remove 12 mounting flange nuts securing the starter to the accessory gearbox. Move
starter aft and clear of the gearbox. Discard flange gasket and drive spline O-ring. Tag and
identify the starter.
5. INSTALLATION OF PNEUMATIC STARTER. See figure 1.
a. Remove protective caps and covers from replacement starter. Remove starter drain plug
and drain any oil inside starter in plastic container. Discard oil.
b. Install the drain plug at 6 o’clock position in starter. Inspect and replace the metal seal of
drain plug if damaged. Torque to 135-150 lb in. (15-17 N·m) and safety-wire.

3
GEK 97310
VOLUME II
WP 122 00
CAUTION
WHEN REMOVING THE RELIEF VALVE IN THE TOP OF
THE STARTER, DO NOT TURN THE SCREW IN THE
CENTER OF THE RELIEF VALVE PLUG. THE RELIEF
VALVE STEM HAS 3 O-RINGS. USE CARE WHEN
REMOVING THE VALVE TO PREVENT CUTTING OR
DISLODGING THE O-RINGS. AFTER THE THREADS ARE
DISENGAGED, CAREFULLY PULL THE RELIEF VALVE UP
AND OUT OF THE STARTER PORT.
c. Remove relief valve plug in the top of the starter.
d. Pour approximately one quart (950 cc) of clean lube oil in the relief valve port.
NOTE
Refer to Volume I, Chapter V for servicing of installed pneumatic
starters.
e. Check O-rings on relief valve plug for serviceability and replace as required. Lubricate
the O-rings with gas generator lube oil, and carefully install the relief valve into the starter port.
Torque the relief valve to 135-150 lb in. (15-17 N·m) and safety-wire. DO NOT TURN THE
SLOTTED SCREW IN THE CENTER OF THE RELIEF VALVE PLUG.
f. Install a new MS9139-01 mounting flange gasket over the mounting studs. Install a new
MS17413-222 O-ring on the starter drive spline after coating with a light film of lube oil.
CAUTION
SUPPORT STARTER WHILE INSTALLING TO PREVENT
DROPPING AND DAMAGE TO THE DRIVE SPLINE AND
MOUNTING FLANGES.
g. Mount starter over studs. Starter must be oriented to position drain plug in the down
(6 o’clock) position. Secure with 12 mounting nuts. Torque nuts 190-230 lb in. (22-26 N·m)
above run on torque.
h. Install the flexible electrical lead connector and safety-wire.

4
GEK 97310
VOLUME II
WP 122 00
NOTE
Install inlet air/gas tube and outlet gas tube (optional). They are
customer items.
i. Install plastic plugs in old starter. Place in container.

5/(6 Blank)
GEK 97310
VOLUME II
SWP 122 01
REPLACEMENT OF PNEUMATIC STARTER
EFFECTIVITY: LM2500 ENGINE MODELS - GA101

1-3.......... 0 4 Blank . . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Installation of Pneumatic Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Removal of Pneumatic Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
SWP 122 01
and installation of the pneumatic starter.
2. APPLICABLE SUPPORT EQUIPMENT. None

Safety Wire
4. REMOVAL OF PNEUMATIC STARTER. See figure 1.
a. Remove V-band clamp from inlet and exhaust tube mounting flanges.
b. Disconnect electrical connector.
NOTE
Starter and hoses may have oil in them at time of removal. Drain
the oil into a suitable container.
c. Disconnect the lube supply and return hoses. Remove O-ring from fittings; discard
O-rings.
NOTE
Plug lube inlet and return ports of starter to prevent spilling of oil
during removal of starter.
d. Loosen V-band clamp securing starter to gearbox and remove starter.
5. INSTALLATION OF PNEUMATIC STARTER.
a. Install new O-ring on replacement starter drive spline. Lubricate starter drive spline and
O-ring using lube oil.
b. Carefully position starter on gearbox. Align starter drive spline and position starter
locating pins in holes in gearbox mounting pad. Position V-band clamp on mounting flange. Tap
rim of clamp with mallet, to enable clamp to seat properly, while tightening bolt. Torque and
lockwire.
c. Fill starter cavity with gas generator lube oil.

2
GEK 97310
VOLUME II
SWP 122 01
Figure 1. Typical Starter - Cutaway
NOTE
Ensure that hose fitting with metering orifice is connected to inlet
port of starter.
d. Install new O-rings on lube supply and return hose fittings. Install lube supply and return
hoses; torque and lockwire.
e. Connect electrical lead to electrical connector on starter.
f. Install V-band clamps, and connect inlet and exhaust tubes to starter.

3/(4 Blank)
GEK 97310
VOLUME II
SWP 122 02
REPLACEMENT OF CONTINUOUS LUBE STARTER

(NON-SHROUDED)

1 - 10 . . . . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Installation of Continuous Lube Starter (Non-shrouded) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Removal of Continuous Lube Starter (Non-shrouded) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
SWP 122 02
and installation of the continuous lube starter.
NOTE
None

MIL-L-23699 or Lube Oil, Gas Generator
MIL-L-7808
Safety Wire
4. REMOVAL OF CONTINUOUS LUBE STARTER (NON-SHROUDED).

See figure 1 and table 1.
WARNING
ELECTRICAL POWER SHALL BE OFF BEFORE CONNECT-
ING OR DISCONNECTING ELECTRICAL CONNECTORS.
ELECTRICITY CAUSES SHOCK, BURNS, AND DEATH.
NOTE
The inlet air tube (customer’s item) must be disconnected and
moved clear of starter prior to performing this procedure.
a. Remove the safety wire and disconnect the flexible electrical lead connector from the
starter (15) speed switch located at the starter 7 o’clock position. Position the flexible electrical
lead end out of the way.

2
GEK 97310
VOLUME II
SWP 122 02
Figure 1. Continuous Lube Starter (Non-Shrouded)

3
4
Table 1. CONTINUOUS LUBE STARTER (NON-SHROUDED) See figure 1

VOLUME II
GEK 97310
SWP 122 02
(15-17 N·m)
Elbow & O-ring 30, 28 Starter Air 15 Jamnut 29 180-200 lb in
Elbow & O-ring 32, 27 Starter Lube 15 Jamnut 31 135-150 lb in
Nipple & O-ring 21, 22 Starter Lube 270-300 lb in
Scavenge Port (31-33.9 N·m)
Starter & Gasket 15, 11 Gearbox 35 Self-locking Nuts 12 190-230 lb in
(22-26 N·m)
(20-23 N·m)
Hose Assembly 10 Nipple & 5, 30 Coupling Nuts 270-300 lb in
Elbow (31-33.9 N·m)
O-ring (31-33.9 N·m)
Oil Scavenge Tube 18 Union 34, 21 Coupling Nut 450-550 lb in
Assy (Screen Assy) (57-692 N·m)
Oil Supply Tube 23 Elbow 32 Coupling Nut 135-150 lb in
Assy (15-17 N·m)
Bracket 17 Starter 15 Self-locking Nuts 12 190-230 lb in

(22-26 N·m)
Table 1. CONTINUOUS LUBE STARTER (NON-SHROUDED) See figure 1 - Continued
Loop Clamp 20 Bracket 17 Bolt, Nut 19, 16 24-27 lb in

(2.7-3.1 N·m)
Loop Clamp 26 Gearbox 35 Bolt, Washer 24, 25 24-27 lb in
(28-31 Kg cm)
Oil Drain Plug & 1, 2 Starter Oil 15 135-150 lb in Safety wire
Gasket Drain Port (15-17 N·m)

GEK 97310
5
SWP 122 02
VOLUME II
GEK 97310
VOLUME II
SWP 122 02
WARNING
z LUBRICATING OIL, MIL-L-7808: COMBUSTIBLE. DO
NOT INHALE, INGEST, OR LET THIS MATERIAL TOUCH
YOU. IF INGESTED, CENTRAL NERVOUS SYSTEM
DAMAGE, PARALYSIS, OR ADVERSE EFFECTS MAY
OCCUR. IRRITANT. THERMAL DECOMPOSITION MAY
RELEASE TOXIC BY-PRODUCTS AND RESIDUES. PER-
SONAL PROTECTIVE EQUIPMENT REQUIRED. USE
(NORMALLY AND WHEN HEATING) IN A WELL-VENTI-
LATED AREA OR WITH MECHANICAL VENTILATION -
IF NOT AVAILABLE, USE AN APPROVED RESPIRATOR.
z LUBRICATING OIL, MIL-PRF-23699F (C/I): COMBUSTI-
BLE. DO NOT INHALE, INGEST, OR LET THIS MATE-
RIAL TOUCH YOU. IRRITANT. PERSONAL
PROTECTIVE EQUIPMENT REQUIRED. USE MECHANI-
CAL EXHAUST VENTILATION - IF NOT AVAILABLE,
USE AN APPROVED RESPIRATOR.
b. Place a plastic pail or other suitable container under the starter. Remove the safety wire
and drain plug (1) with metal gasket (2) located at the starter 6 o’clock position. Allow the starter
to completely drain. Do not discard the drained oil. Reinstall the drain plug (1) with metal
gasket (2).
c. Disconnect the oil scavenge tube (18) from nipple (21) at the starter lube scavenge port.
Cap and plug openings.
d. Disconnect the oil supply tube (18) from elbow (32) at the starter lube supply port. Cap
and plug openings.
e. Disconnect the air supply hose (10) from elbow (30) at the starter air supply port. Cap and
plug openings.
WARNING
THE STARTER WEIGHS APPROXIMATELY 50 LBS
(22.7 KG). PROPERLY SUPPORT THE STARTER WHILE
REMOVING IT TO PREVENT PERSONNEL INJURY OR
DROPPAGE WITH SUBSEQUENT DAMAGE TO THE
STARTER AND/OR DRIVE SPLINE.
f. Remove the 12 mounting flange self-locking nuts (12) securing the starter to the accessory
gearbox (35). Discard flange gasket (11) and drive spline O-ring (3).

6
GEK 97310
VOLUME II
SWP 122 02
g. Remove nipple (21) from the starter lube scavenge port. Discard O-ring (22). Install a
suitable shipping plug.
h. Remove jamnut (31) and elbow (32) from the starter lube supply port. Discard
O-ring (27). Install a suitable shipping plug.
i. Remove jamnut (29) and elbow (30) from the starter air supply port. Discard seal (28).
Install a suitable shipping plug. Tag and identify the starter.
5. INSTALLATION OF CONTINUOUS LUBE STARTER (NON-SHROUDED).

See figure 1 and table 1.
a. Remove protective caps, plugs, and covers from replacement starter (15).
WARNING
b. Remove the starter oil drain plug (1) with the metal gasket (2), located at the 6 o’clock
position. Drain any oil inside the starter into a suitable plastic container. Discard the oil.
c. Inspect and replace the metal gasket (2), if damaged. Install drain plug (1) with metal
gasket (2) into the starter oil drain port. Torque to 135-150 lb in. (15.3-17.0 N·m) and safety-wire.
d. Install a new O-ring (22) on nipple (21) and install in the starter lube scavenge port.
Torque to 270-300 lb in. (30.5-33.9 N·m). Place a suitable protective cap on the nipple (21) outer
end.

7
GEK 97310
VOLUME II
SWP 122 02
e. Install elbow (32), jamnut (31), and a new O-ring (27) into the starter lube supply port. Do
not torque the jamnut (31) at this time. Install a suitable protective cap on outer end of
elbow (32).
f. Install elbow (30), jamnut (29), and a new O-ring (28) into the starter air supply port. Do
elbow (30).
g. Ensure that plug (13) with a serviceable O-ring (14) is installed and torqued to
135-150 lb in. (15.3-17.0 N·m) and safety-wired.
h. Install a new gasket (11) over the starter mounting studs of the gearbox (35). Install a new
O-ring (3) on the starter drive spline after coating with a light film of lube oil.
WARNING
INSTALLING IT TO PREVENT PERSONNEL INJURY OR
i. Mount the starter over the gearbox mounting studs. Starter must be oriented to position
the drain plug (1) in the down (6 o’clock position). Locate the oil scavenge tube (18) bracket (17)
over the studs. Secure the starter with 12 self-locking nuts (12). Torque nuts to 190-230 lb in.
(21.5-26.0 N·m) above run-on torque.
j. Remove protective caps from elbows (30 and 32) and nipple (21). Remove protective
plugs from hose (10), tube (23), and tube (18).

8
GEK 97310
VOLUME II
SWP 122 02
WARNING
k. Position a clean plastic pail or other suitable container beneath the starter. Add
400 ± 50 cc of lubricating oil which will be used in the gas generator lubrication system, either
MIL-L-23699 or MIL-L-7808 to the starter through the air supply port. Excess oil will drain from
oil scavenge port.
l. Align elbow (30) to proper angle to allow for proper connection of air supply hose (10).
Torque jamnut (29) to 180-200 lb in. (20.3-22.6 N·m). Connect air supply hose (10) to
elbow (30). Torque hose coupling nut to 270-300 lb in. (30.5-33.9 N·m).
m. Align elbow (32) to proper angle to allow for proper connection of oil supply tube (23).
Torque jamnut (31) to 135-150 lb in. (15.3-17.0 N·m). Connect oil supply tube (23) to
elbow (32). Torque coupling nut to 135-150 lb in. (15.3-17.0 N·m).
n. Connect oil scavenge tube (18) to nipple (21). Torque coupling nut to 450-550 lb in.
(50.9-62.2 N·m). Ensure that oil scavenge tube (18) is properly connected to union
(screen assembly) (34) and properly torqued to 450-550 lb in. (50.9-62.2 N·m).
o. Ensure that air supply hose (10) is properly connected at nipple (5) and is properly torqued
to 270-300 lb in. (30.5-33.9 N·m).

9
GEK 97310
VOLUME II
SWP 122 02
WARNING
p. Install the flexible electrical lead connector to the starter speed switch and safety-wire.
NOTE
The inlet air tube (customers item)
q. Ensure the removed starter has the proper shipping plugs, caps, and covers installed. Tag
and identify starter.

10
GEK 97310
VOLUME II
SWP 122 03
REPLACEMENT OF CONTINUOUS LUBE STARTER

(SHROUDED)

1-8.......... 0
ALPHABETICAL INDEX
Subject Page
Installation of Continuous Lube Starter (Shrouded) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Removal of Continuous Lube Starter (Shrouded) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
SWP 122 03
and installation of the continuous lube starter (shrouded).
NOTE
None

MIL-L-7808
Safety Wire
4. REMOVAL OF CONTINUOUS LUBE STARTER (SHROUDED). See figure 1 and

table 1.
WARNING
NOTE
The inlet air/gas tube (customers item) must be disconnected and
moved clear of starter prior to performing this procedure. If gas
(optional) is used as starting medium, the outlet tube also must be
disconnected and moved clear.
a. Remove the safety wire and disconnect the flexible electrical lead connector from the
starter (15) speed switch, located at the starter 7 o’clock position. Position the flexible electrical
lead end out of the way.

2
GEK 97310
VOLUME II
SWP 122 03
Figure 1. Continuous Lube Starter (Shrouded)

3
4
Table 1. CONTINUOUS LUBE STARTER (SHROUDED) See figure 1.
VOLUME II
GEK 97310
SWP 122 03
(15-17 N·m)
Elbow & O-ring 30, 28 Starter Air Supply Port 15 Jamnut 29 180-200 lb in
(20-23 N·m)
Elbow & O-ring 32, 27 Starter Lube Supply Port 15 Jamnut 31 135-150 lb in
(15-17 N·m)
Nipple & O-ring 21, 22 Starter Lube Scavenge Port 15 270-300 lb in
(31-34 N·m)
Starter & Gasket 15, 11 Gearbox 35 Self-locking Nuts 12 190-230 lb in
(22-26 N·m)
(20-23 N·m)
Hose Assembly 10 Nipple & Elbow 5, 30 Coupling Nuts 270-300 lb in
(31-34 N·m)
O-ring (31-34 N·m)
Oil Scavenge Tube 18 Union (Screen Assembly) 34, 2l Coupling Nut 450-550 lb in
Assy (51-62 N·m)
Oil Supply Tube 23 Elbow 32 Coupling Nut 135-150 lb in
Assy (15-17 N·m)
Bracket 17 Starter 15 Self-locking Nuts 12 190-230 lb in
(22-26 N·m)
Loop Clamp 20 Bracket 17 Bolt, Nut 19, 16 24-27 lb in
(2.7-3.1 N·m)
Loop Clamp 26 Gearbox 35 Bolt, Washer 24, 25 24-27 lb in
(2.7-3.1 N·m)

Oil Drain Plug & 1, 2 Starter Oil Drain Port 15 135-150 lb in Safety-wire
Gasket (15-17 N·m)
GEK 97310
VOLUME II
SWP 122 03
WARNING
b. Place a plastic pail or other suitable container under the starter. Remove the safety wire
and drain plug (1) with metal gasket (2), located at the starter 6 o’clock position. Allow the starter
to completely drain. Do not discard the metal gasket (2). Discard the drained oil. Reinstall the
drain plug (1) with metal gasket (2).
c. Disconnect the oil scavenge tube (18) from nipple (21) at the starter lube scavenge port.
Cap and plug openings.
d. Disconnect the oil supply tube (23) from elbow (32) at the starter lube supply port. Catch
drainage in suitable container. Cap and plug openings.
e. Disconnect the air supply hose (10) from elbow (30) at the starter air supply port. Cap and
plug openings.
WARNING
f. Remove the 12 mounting flange self-locking nuts (12) securing the starter to the accessory
gearbox (35). Discard flange gasket (11) and drive spline O-ring (3).
g. Remove nipple (21) from the starter lube scavenge port. Discard O-ring (22). Install a
suitable shipping plug.

5
GEK 97310
VOLUME II
SWP 122 03
h. Remove jamnut (31) and elbow (32) from the starter lube supply port. Discard
O-ring (27). Install a suitable shipping plug.
i. Remove jamnut (29) and elbow (30) from the starter air supply port. Discard seal (28).
Install a suitable shipping plug. Tag and identify the starter.
5. INSTALLATION OF CONTINUOUS LUBE STARTER (SHROUDED). See figure 1

and table 1.
a. Remove protective caps, plugs, and covers from replacement starter (15).
WARNING
b. Remove the starter oil drain plug (1) with the metal gasket (2), located at 6 o’clock posi-
tion. Drain any oil inside the starter into a suitable plastic container. Discard the oil.
c. Inspect and replace the metal gasket (2), if damaged. Install drain plug (1) with metal gas-
ket (2) into the starter oil drain port. Torque to 135-150 lb in. (15-17 N·m) and safety-wire.
d. Install a new O-ring (22) on nipple (21) and install in the starter lube scavenge port.
Torque to 270-300 lb in. (31-40 N·m). Place a suitable protective capon the nipple (21) outer end.
e. Install elbow (32), jamnut (31), and a new O-ring (27) into the starter lube supply port. Do
not torque the jamnut (31) at this time. Install a suitable protective cap on the outer end of
elbow (32).
f. Install elbow (30), jamnut (29), and a new O-ring (28) into the starter air supply port. Do
elbow (30).

6
GEK 97310
VOLUME II
SWP 122 03
g. Ensure that plug (13) with a serviceable O-ring (14) is installed and torqued to
135-150 lb in. (15-17 N·m) and safety-wire.
h. Install a new gasket (11) over the starter mounting studs of the gearbox (35). Install a new
O-ring (3) on the starter drive spline after coating with a light film of lube oil.
WARNING
i. Mount the starter over the gearbox mounting studs. Starter must be oriented to position
the drain plug (1) in the down (6 o’clock) position. Locate the oil scavenge tube (18) bracket (17)
over the studs. Secure the starter with 12 self-locking nuts (12). Torque nuts to 190-230 lb in.
(22-26 N·m) above run-on torque.
j. Remove protective caps from elbows (30 and 32) and nipple (21). Remove protective
plugs from hose (10), tube (23), and tube (18).
WARNING
k. Position a clean plastic pail or suitable container beneath the starter. Add 400 ± 50 cc of
lubricating oil which will be used in the gas generator lubrication system, either MIL-L-23699 or
MIL-L-7808 to the starter sump through the air supply port. Excess oil will drain from oil scav-
enge port.

7
GEK 97310
VOLUME II
SWP 122 03
l. Align elbow (30) to proper angle to allow for proper connection of air supply hose (10).
Torque jamnut (29) to 180-200 lb in. (20-23 N·m). Connect air supply hose (10) to elbow (30).
Torque hose coupling nut to 270-300 lb in. (31-34 N·m).
m. Align elbow (32) to proper angle to allow for proper connection of oil supply tube (23).
Torque jamnut (31) to 135-150 lb in. (15-17 N·m). Connect oil supply tube (23) to elbow (32).
Torque coupling nut to 135-150 lb in. (15-17 N·m).
n. Connect oil scavenge tube (18) to nipple (21). Torque coupling nut to 450-550 lb in.
(57-62 N·m). Ensure that oil scavenge tube (18) is properly connected to union (screen
assembly (34) and properly torqued to 450-550 lb in. (51-62 N·m).
o. Ensure that air supply hose (10) is properly connected at nipple (5) and is properly torqued
to 270-300 lb in. (31-34 N·m).
WARNING
p. Install the flexible electrical lead connector to the starter speed switch and safety-wire.
NOTE
Install the inlet air/gas tube and outlet gas tube (optional). They are
customer items.
q. Ensure the removed starter has the proper shipping plugs, caps, and covers installed. Tag
and identify starter.

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GEK 97310
VOLUME II
SWP 122 04
REPLACEMENT OF HYDRAULIC STARTER

1-6.......... 0
ALPHABETICAL INDEX
Subject Page
Installation of Hydraulic Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Removal of Hydraulic Starter.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
SWP 122 04
1. INTRODUCTION. This subordinate work package contains the instructions for removal
and installation of the hydraulic starter.
NOTE


MIL-L-17672 Hydraulic Fluid
MIL-L-7808
Safety Wire
Plastic Bags
Tags
Plastic Caps
4. REMOVAL OF HYDRAULIC STARTER. See figure 1 and table 1.
a. Remove the seal drain hose (18, figure 1). Allow fluid to drain into plastic container.
Remove union (17). Remove and discard O-ring (16).
b. Remove outlet hose (6). Remove outlet distributor (5) by removing four bolts (3).
Remove and discard O-ring (4).
c. Remove inlet hose (9). Remove inlet distributor (8) by removing four bolts (10). Remove
and discard O-ring (7).
d. Remove case drain hose (11). Remove union (12). Remove and discard O-ring (13).

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GEK 97310
VOLUME II
SWP 122 04
Figure 1. Hydraulic Starter - Kit No. 537L316

3
4
Table 1. SUPPLY CONNECTIONS - HYDRAULIC STARTER
CAUTION
ALL LINES MUST BE FLEXIBLE ENOUGH TO ALLOW 3/4 INCH (19 MM) THERMAL
VOLUME II
GEK 97310
SWP 122 04
GROWTH OF GAS GENERATOR WITHOUT PLACING STRAIN ON LINES OR ON GAS

GENERATOR. IF EXCESSIVE FORCE IS REQUIRED TO COMPLETE A CONNECTION,
LOOSEN ALL CONNECTIONS AND CHECK/ADJUST ROUTING AS REQUIRED.
Supply Connections: Mates with:
Oil In AN818-16C or MS9197-16
Oil Out AN818-16C or MS9197-16
Case Drain AN818-12C or MS9197-12
Seal Drain AN818-4C or MS9197-4C
NOTE
For all other supply connections needed, see figure 2, Installation Drawings, at the end of
Volume I.

GEK 97310
VOLUME II
SWP 122 04
WARNING
THE HYDRAULIC STARTER WEIGHS APPROXIMATELY
100 LBS (45.4 KG). PROPERLY SUPPORT THE STARTER
WHILE REMOVING IT TO PREVENT PERSONNEL INJURY
OR DROPPAGE WITH SUBSEQUENT DAMAGE TO THE
e. Support the starter by hand and remove 12 flange nuts (2). Carefully move the starter aft
until the drive spline clears. Remove and discard flange gasket (14) and O-ring (15).
f. Plug all ports with suitable plastic plugs. Tag and identify the starter.
5. INSTALLATION OF HYDRAULIC STARTER. See figure 1 and table 1.
a. Remove protective caps and covers from replacement starter and drain any oil inside
starter in plastic container. Discard oil.
b. Position flange gasket (14, figure 1) on gearbox mounting studs. Lubricate O-ring (15)
with gas generator lube oil MIL-L-23699 and install on the drive spline.
WARNING
THE HYDRAULIC STARTER WEIGHS APPROXIMATELY
100 LBS (45.4 KG). PROPERLY SUPPORT THE STARTER
WHILE REMOVING IT TO PREVENT PERSONNEL INJURY
OR DROPPAGE WITH SUBSEQUENT DAMAGE TO THE
c. Lubricate the drive spline with gas generator lube oil. Position the starter, engage the
drive spline, and mount the starter on the gearbox mounting studs. Secure with 12 nuts (2).
Torque nuts to 190-230 lb in. (21.5-26 N·m).
NOTE
z The following listed O-rings shall be lubricated with
MIL-L-17672 hydraulic fluid only. DO NOT USE GAS
GENERATOR LUBE OIL.
z Refer to Table 1 for interface connections.
d. Lubricate O-ring (16) and install it on union (17). Install union (17) in starter. Torque
union to 135-150 lb in. (15.3-17 N·m). Install seal drain hose (18) on union (17). Torque coupling
nut to 135-150 lb in. (15.3-17 N·m).

5
GEK 97310
VOLUME II
SWP 122 04
e. Lubricate O-ring (4) and install it in outlet distributor (5). Position distributor (5) on
starter and secure with four bolts (3). Torque bolts to 160-210 lb in. (18-23.7 N·m) and
safety-wire.
f. Install outlet hose (6) on outlet distributor (5) and secure coupling nut. Torque coupling
nut to 112-128 lb ft (152-174 N·m).
g. Lubricate O-ring (13) and install it on union (12). Install union (12) in starter and torque
to 135-150 lb in. (15.3-17 N·m). Install case drain hose (11) on union, and torque coupling nut to
135-150 lb in. (15.3-17 N·m).
h. Lubricate O-ring (7) and install in inlet distributor (8). Position inlet distributor (8) on
starter and secure with four bolts (10). Torque bolts to 160-210 lb in. (18-23.7 N·m) and
safety-wire.
i. Install inlet hose (9) on inlet distributor (8) and secure coupling nut. Torque coupling nut
to 112-128 lb ft (152-174 N·m).
CAUTION
ENSURE HYDRAULIC STARTER HAS BEEN SERVICED PER
OEM OR MANUFACTURER’S INSTRUCTIONS BEFORE
INITIAL START OF GAS GENERATOR IS ACCOMPLISHED.

6
GEK 97310
VOLUME II
WP 123 00
WORK PACKAGE
REPLACEMENT OF FUEL MANIFOLDS (LIQUID)

1-8.......... 0
ALPHABETICAL INDEX
Subject Page
Installation of Fuel Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Removal of Fuel Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
WP 123 00
1. INTRODUCTION. This work package contains the instructions for removal and installation
of liquid fuel manifolds.
NOTE

1C6881 Adapter Set, Leak Check
2C6081 Wrench Set

MIL-C-23827 Grease
Leak-Tek
Nitrogen
Safety Wire
4. REMOVAL OF FUEL MANIFOLD. See figure 1.
a. Remove fuel manifold supply tube (27) as follows:
(1) Remove bolt, washer, and nut attaching the supply line clamp (28) to bracket.
Disconnect shroud coupling (26) and slide it forward.
(2) Disconnect shroud flanges from fuel manifolds (1 and 2).
(3) Disconnect fuel manifold supply tube forward and aft couplings, using 2C6081 fuel
manifold wrench set. Remove tube (27) and shroud (23) as an assembly.
(4) Remove and discard O-ring (25) from inside the shroud. Remove and discard shroud
seals (22) from the aft flanges of the supply tube.

2
GEK 97310
VOLUME II
WP 123 00

3
GEK 97310
VOLUME II
WP 123 00

4
GEK 97310
VOLUME II
WP 123 00
b. Remove fuel nozzle supply tubes (12), using wrench set, 2C6081, as follows:
(1) Disconnect fuel nozzle supply tube shrouds (5) and move shrouds forward to expose
fuel tube fittings.
(2) Disconnect nozzle supply tube fittings (10) and remove supply tube and shroud
assemblies.
(3) Remove and discard nozzle O-rings (9). Remove and discard seals (6) from fuel
manifold.
c. Disconnect manifold clamps (19) from brackets (21) at 6 places.
d. Remove manifold connecting bolts (3) from each end of manifold half. Remove fuel
manifold halves.
e. Remove clamps (19) from manifold.
f. Cap all open fittings on tube and shroud assemblies, fuel nozzles, and manifold.
5. INSTALLATION OF FUEL MANIFOLD. See figure 1.
a. Attach clamps (19) to liquid fuel manifold halves (1 and 2) and place fuel manifold halves
on brackets (21). Position the fuel manifold halves so that the fuel inlets are at the 6:00 o’clock
position, aft facing forward.
b. Clamp manifold to positioning brackets (21) with bolts, nuts, and washers (washers under
nuts). Torque to 24-27 lb in. (2.7-3.1 N·m).
c. Engage end fittings of manifold halves at 6:00 and 12:00 o’clock positions and secure
with shoulder bolts (3). Torque to 24-27 lb in. (2.7-3.1 N·m) and safety-wire.
d. Lubricate O-ring (9), metal seal (6) and supply tube nut-to-ferrule interface surfaces with
MIL-G-23827 grease.
e. Install O-ring (9) in groove on nozzle. Install metal seal (6) on manifold nozzle supply
port.
f. Place nozzle supply tube (12) and shroud (5) assembly in between nozzle and manifold.

5
GEK 97310
VOLUME II
WP 123 00
NOTE
When applying torque at fuel tube to fuel nozzle coupling nut, the
fuel tube shroud must be rotated approximately 1/8 turn in opposite
direction of tightening torque.
g. Using wrench set, 2C6081, torque coupling nuts (10) at each end of the 30 supply tubes to
130-150 lb in. (14.7-17.0 N·m).
h. Leak check the fuel nozzle supply tubes as follows:
(1) Connect nitrogen supply, or dry filtered compressed air, to the fuel manifold inlet
fitting.
(2) Apply Leak-Tek or soap solution at each fuel tube coupling nut on fuel tubes and
manifold.
(3) Pressurize fuel tubes/manifold to 200 psig (1379 kPa). No leaks allowed.
(4) If leak is present, loosen coupling nut and check condition of fitting seat. If seal is
not damaged, retighten nut to 130-150 lb in. (14.7-17.0 N·m) and check for leakage. If seat is
damaged, replace fuel nozzle or manifold and check for leakage.
(5) After leak check is complete, check torque of fuel nozzle supply tube fittings. Safety-
wire the coupling nuts (60 places).
(6) Slide fuel tube shrouds (5) aft, making sure that the seal ring (6) at the forward end is
seated and that the tangs of the shroud engage the slots on the fuel manifold.
(7) Check to ensure that O-ring (9) on the fuel nozzle is seated and lubricated. Hold
shroud in position and hand-tighten the knurled nut (8) to the fuel nozzle.
(8) Tighten nut (7) on the forward end of the fuel tube shroud (5) at the manifold
connection and torque to 360-500 1b in. (40.5-56.5 N·m).
i. Perform a leak test of the fuel nozzle and manifold shrouds using 1C6881 adapter set as
follows:
(1) Install plugs on each of the 2 fuel inlet fittings.
(2) Connect nitrogen supply, or dry filtered compressed air, to the manifold shrouds at
the fuel inlet openings.
(3) Pressurize the system with 50-55 psig (344.7-379.2 kPa) and shut off the nitrogen, or
air supply.

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GEK 97310
VOLUME II
WP 123 00
(4) Monitor pressure for 2 minutes. A maximum of 10 psig (69 kPa) drop in pressure is
permitted.
(5) If limit is exceeded, check for leakage around the coupling nuts using Leak-Tek or
soap solution. Tighten the knurled nuts by hand to stop the leaks. Be sure that the hex head nuts
are tightened to the specified torque. If leakage continues, replace the seal rings in the area of the
leakage.
(6) Repeat the leak check after seal ring replacement.
(7) Safety-wire both ends of the fuel nozzle shrouds (60 places) after completion of the
leak test.
j. Install fuel manifold shroud (23) as follows:
(1) Install O-ring (25) inside the forward end of the fuel manifold shroud (23).
(2) Slide fuel manifold shroud (23) forward to expose inner fuel tube coupling nuts.
Position shroud so that interface connections (F2 inlet and F4 drain) are facing down towards the
6:00 o’clock position.
(3) Install metal seals (22) and inner fuel tube coupling nuts to left and right fuel
manifold (1 and 2) inlet fittings. Torque coupling nuts to 550-600 lb in. (62.2-67.8 N·m).
(4) Move fuel manifold shroud (23) aft and install 6 bolts and nuts to left and right fuel
manifold (1 and 2) inlet flanges. Hand-tighten bolts and ensure metal seals (22) are not crushed.
(5) Connect knurled coupling nut (26) on fuel supply tube (27) to fuel manifold
shroud (23) loosely.
NOTE
Refer to Volume I, Installation Drawings Addendum for all
interface connections.
(6) Connect customer interface fuel inlet hose (F2) to fuel supply tube (27) inlet fitting
and drain hose (F4) to fuel manifold shroud drain port (24).

7
GEK 97310
VOLUME II
WP 123 00
NOTE
Ensure metal seals (22) are in correct position before applying final
torque to fuel manifold shroud (23) flange bolts.
(7) Torque fuel manifold shroud (23) aft flange bolts (2 places) to 24-27 lb in.
(2.7-3.1 N·m).
(8) Hand-tighten knurled coupling nut (26).
(9) Torque customer interface connections as follows:
z F2 - Fuel Manifold Inlet/75-91 lb ft (101.7-123.4 N·m)

z F4 - Fuel Manifold Shroud Drain/450-550 lb in.
(50.9-62.2 N·m)
z F5 and F7 - Fuel Inlet No. 1 and 2 Pressure Taps/270-300 lb in.
(30.5-33.9 N·m)
(10) Attach clamp (28) to bracket with one bolt, washer, and nut. Torque clamp bolt to
24-27 lb in. (2.7-3.1 N·m). Install any remaining clamps which may have been loosened during
removal.
(11) Safety-wire hose fittings as necessary.
(12) If necessary perform leak test per step i. above.

8
GEK 97310
VOLUME II
SWP 123 01
REPLACEMENT OF FUEL MANIFOLD

(NATURAL GAS)
EFFECTIVITY: LM2500 GAS Generator G Series Models

1 - 10 . . . . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Alignment of Gas Fuel Manifold and Gas Fuel Feeder Tubes . . . . . . . . . . . . . . . . . . . . . . . 9

Installation of Fuel Manifold (682L310G11 Fuel System) . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal of Fuel Manifold (682L310G11 Fuel System) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
SWP 123 01
and installation of natural gas fuel manifolds.
NOTE
None
None
a. Remove the 2 bolts and washers at each fuel nozzle to manifold connection.
b. Remove bolts, nuts, and washers that secure the 6 manifold clamps to flange brackets.
c. Remove bolts, nuts, and washers that secure manifold halves together near 6 o’clock
position.
d. Remove and discard seal from between manifold halves. Remove and discard O-rings at
fuel nozzle to manifold connections.
e. Remove clamps from manifold halves.
5. REMOVAL OF FUEL MANIFOLD (682L310G11 FUEL SYSTEM).
a. Disconnect coupling nuts (1, figure 2) on gas tubes (2) from gas manifold (3).
b. Remove two nuts (4), washers (5), and bolts (6) at six locations attaching six clamps (7) to
hinged brackets (8). See sheet 2 for location of brackets.
c. Remove four nuts (9, sheet 1), eight washers (10), and four bolts (11) attaching manifold
(3) halves together at 5:30 o’clock position, forward looking aft.

2
GEK 97310
VOLUME II
SWP 123 01
Figure 1. Fuel Manifold and Nozzles - Configuration I (Sheet 1 of 3)

3
GEK 97310
VOLUME II
SWP 123 01
Figure 1. Fuel Manifold and Nozzles - Configuration II (Sheet 2 of 3)

4
GEK 97310
VOLUME II
SWP 123 01
Figure 1. Fuel Manifold and Nozzles - Configuration III (Sheet 3 of 3)

5
GEK 97310
VOLUME II
SWP 123 01
Figure 2. Fuel Manifold (682L310G11 Fuel System) (Sheet 1 of 2)

6
GEK 97310
VOLUME II
SWP 123 01
Figure 2. Fuel Manifold (682L310G11 Fuel System) (Sheet 2 of 2)
d. Remove and discard seal gasket (12).
e. Carefully remove manifold (3).
f. Remove six clamps (7) from manifold (3).
a. Install 6 clamps on manifold halves. Locate clamps as shown in figure 1.
NOTE
Consult GEK 35634, Illustrated Parts Breakdown, for clamp and
bracket configuration required for the LM2500GA101 model gas
generator.
b. Position manifold halves around compressor rear frame with fuel nozzle ports facing
forward and fuel inlet at 6:30 o’clock position (aft looking forward).

7
GEK 97310
VOLUME II
SWP 123 01
c. Install new seal between manifold ends. Install bolts, nuts, and washers to secure mani-
fold halves together. Torque to 100-130 lb in. (11.3-14.7 N·m).
d. Align fuel nozzle outlets to fuel nozzles. Install new O-rings on fuel nozzles.
e. Install 2 bolts and washers to each fuel nozzle to manifold connection. Torque bolts to
55-70 lb in. (6.2-7.9 N·m) and safety-wire.
f. Attach manifold clamps to frame flange brackets. Secure each with 2 bolts, nuts, and
washers. Torque to 24-27 lb in. (2.7-3.1 N·m).
7. INSTALLATION OF FUEL MANIFOLD (682L310G11 FUEL SYSTEM).
a. Install six clamps (7, figure 2) onto gas manifold (3) halves.
b. Position manifold (3) halves around CRF with fuel nozzle ports facing forward and fuel
inlet at 5:30 o’clock position, forward looking aft.
c. Install new seal gasket (12) between flanges of manifold (3) ends.
d. Install four bolts (11), eight washers (10), and four nuts (9) to secure manifold (3) halves
together at 5 o’clock position, forward looking aft. Tighten nuts to 100-130 lb in.
(11.3-14.7 N·m) of torque.
e. Align manifold (3) to allow connection of coupling nuts (1, section A-A) on gas tubes (2).
f. Connect nuts (1) on tubes (2) to manifold (3) at 30 locations. Tighten nuts to
900-1100 lb in. (101.7-124.3 N·m) of torque.
g. Install two bolts (6), washers (5), and nuts (4) to attach six clamps (7) to six hinged brack-
ets (8) to secure manifold (3). See sheet 2 for bracket locations. Tighten nuts to 24-27 lb in.

8
GEK 97310
VOLUME II
SWP 123 01
CAUTION
FLEXIBLE GAS FUEL FEEDER TUBES ARE NOT INCLUDED.
NOTE
generator.

9
GEK 97310
VOLUME II
SWP 123 01
(5) Tighten all fuel nozzle flange bolts to 55-70 lb in. (6.2-7.9 N·m) of torque and safety-
wire.
l. Using six bolts, connect gas fuel manifold to customer interface flexible hose. Tighten
bolts per packager’s manual.
75-91 lb ft (101.7-123.4 N·m) of torque.

10
GEK 97310
VOLUME II
SWP 123 02
REPLACEMENT OF FUEL MANIFOLDS (DUAL FUEL-

LIQUID AND NATURAL GAS)

1-8.......... 0
ALPHABETICAL INDEX
Subject Page


1
GEK 97310
VOLUME II
SWP 123 02
and installation of both liquid and natural gas fuel manifolds used on dual fuel gas turbines.
NOTE

1C6881 Leak Check Adapter Set
2C6081 Wrench Set

MIL-G-23827 Grease
Leak-Tek
Nitrogen
Safety Wire
a. Natural gas fuel manifold.
(1) Remove 2 bolts (14) used to connect each fuel nozzle to the fuel manifold.
(2) Remove 4 bolts, washers, and nuts (20) used to connect the manifold halves together.
(3) Remove 2 bolts, washers, and nuts (2) used to attach each of the 6 manifold
clamps (3) to the flange bracket (1).
(4) Remove and discard the seal (19) from between the manifold halves. Remove and
discard each of the 30 O-rings (15) used at the fuel nozzle to fuel manifold connections.
(5) Remove clamps (3) from the manifold halves.

2
GEK 97310
VOLUME II
SWP 123 02

3
GEK 97310
VOLUME II
SWP 123 02

4
GEK 97310
VOLUME II
SWP 123 02
b. Liquid fuel manifolds.
(1) Remove fuel manifold supply tube (30) as follows:
(a) Remove bolt, washer, and nut attaching the supply line clamp (3l) to bracket.
Disconnect shroud coupling (29) and slide it forward.
(b) Disconnect shroud flanges from fuel manifolds (11 and 18).
(c) Disconnect fuel manifold supply tube forward and aft couplings, using fuel
manifold wrench set, 2C6081. Remove tube (30) and shroud (26) as an assembly.
(d) Remove and discard O-ring (28) from inside the shroud. Remove and discard
shroud seals (25) from the aft flanges of the supply tube.
(2) Remove fuel nozzle supply tubes (21), using 2C6081 wrench set as follows:
(a) Disconnect fuel nozzle supply tube shrouds (5) and move shrouds forward to
expose fuel tube fittings.
(b) Disconnect nozzle supply tube (21) fittings and remove supply tube and shroud
assemblies.
(c) Remove and discard nozzle O-rings (4). Remove and discard seals (22) from
fuel manifold.
(3) Disconnect manifold clamps (24) from brackets (23) at 6 places.
(4) Remove manifold connecting bolts (10) from each end of manifold half. Remove
fuel manifold halves.
(5) Remove clamps (24) from manifold.
(6) Cap all open fittings on tube and shroud assemblies, fuel nozzles, and manifold.
a. Natural gas fuel manifold.
(1) Install 6 clamps (3) on manifold halves. Position clamps as shown in figure 1.
(2) Position manifold halves around the compressor rear frame so that the fuel nozzle
ports face forward and the fuel supply inlet is located at 6:30 o'clock position, aft looking forward.

5
GEK 97310
VOLUME II
SWP 123 02
(3) Install a new seal (19) between the manifold halves and install 4 bolts, nuts, and
washers (20). Torque bolts to 100-130 lb in. (11.3-14.7 N·m).
b. Liquid fuel manifolds.
(1) Attach clamps (24) to liquid fuel manifold halves (11 and 18) and place fuel manifold
halves on brackets (23). Position the fuel manifold halves so that the fuel inlets are at the 6:00
o'clock position, aft facing forward.
(2) Clamp manifold to positioning brackets (23) with bolts, nuts, and washers (washers
under nuts). Torque to 24-27 lb in. (2.7-3.1 N·m).
(3) Engage end fittings of manifold halves at 6:00 and 12:00 o'clock positions and secure
with shoulder bolts (10). Torque to 24-27 lb in. (2.7-3.1 N·m) and safety-wire.
(4) Lubricate O-ring (4), metal seal (22), and supply tube nut-to-ferrule interface sur-
faces with MIL-G-23827 grease.
(5) Install O-ring (4) in groove on nozzle. Install metal seal (22) on manifold nozzle
supply port.
(6) Place nozzle supply tube (21) and shroud (5) assembly in between nozzle and
manifold.
NOTE
When applying torque at fuel tube to fuel nozzle coupling nut, the
fuel tube shroud must be rotated approximately 1/8 turn in opposite
direction of tightening torque.
(7) Using wrench set, 2C6081, torque coupling nuts at each end of the 30 supply
tubes (21) to 130-150 lb in. (14.7-17.0 N·m).
c. Leak check the fuel nozzle supply tubes as follows:
(1) Connect nitrogen supply, or dry filtered compressed air, to the fuel manifold inlet
fitting.
(2) Apply Leak-Tek or soap solution at each fuel tube coupling nut on fuel tubes and
manifold.
(3) Pressurize fuel tubes/manifold with 200 psig (1379 kPa). No leaks allowed.

6
GEK 97310
VOLUME II
SWP 123 02
(4) If leak is present, loosen coupling nut and check condition of fitting seat. If seal is
not damaged, retighten nut to130-150 lb in. (14.7-17.0 N·m) and check for leakage. If seat is
damaged, replace fuel nozzle or manifold and check for leakage.
(5) After leak check is complete, check torque of fuel nozzle supply tube fittings
(60 places).
(6) Slide fuel tube shrouds (5) aft, making sure that the metal seal (22) at the forward end
is seated and that the tangs of the shroud engage the slots on the fuel manifold.
(7) Check to ensure that O-ring (4) on the fuel nozzle is seated and lubricated. Hold
shroud in position and hand-tighten the knurled nut (8) to the fuel nozzle.
(8) Tighten nut (7) on the forward end of the fuel tube shroud (5) at the manifold
connection and torque to 360-500 lb in. (40.5-56.5 N·m).
d. Perform a leak test of the fuel nozzle and manifold shrouds using adapter set, 1C6881 as
follows:
(1) Install plugs on each of the 2 fuel inlet fittings.
(2) Connect nitrogen supply, or dry filtered compressed air, to the manifold shrouds at
the fuel inlet openings.
(3) Pressurize the system with 50-55 psig (344.7-379.2 kPa) and shut off the nitrogen, or
air supply.
(4) Monitor pressure for 2 minutes. A maximum of 10 psig (69 kPa) drop in pressure is
permitted.
(5) If limit is exceeded, check for leakage around the coupling nuts using Leak-Tek or
soap solution. Tighten the knurled nuts by hand to stop the leaks. Be sure that the hex head nuts
are tightened to the specified torque. If leakage continues, replace the seal rings in the area of the
leakage.
(6) Repeat the leak check after seal ring replacement.
(7) Safety-wire both ends of the fuel nozzle shrouds (60 places) after completion of the
leak test.
e. Install fuel manifold shroud (26) as follows:
(1) Install O-ring (28) inside the forward end of the fuel manifold shroud (26).

7
GEK 97310
VOLUME II
SWP 123 02
(2) Slide fuel manifold shroud (26) forward to expose inner fuel tube coupling nuts.
Position shroud so that interface connections (F2 inlet and F4 drain) are facing down towards the
6:00 o'clock position.
(3) Install metal seals (25) and inner fuel tube coupling nuts to left and right fuel
manifold (11 and 18) inlet fittings. Torque coupling nuts to 550-600 lb in. (62.2-67.8 N·m).
(4) Move fuel manifold shroud (26) aft and install 6 bolts and nuts to left and right fuel
manifold (11 and 18) inlet flanges. Hand-tighten bolts and ensure metal seals (25) are not
crushed.
(5) Connect knurled coupling nut (29) on fuel supply tube (30) to fuel manifold
shroud (26) loosely.
(6) Connect customer interface fuel inlet hose (F2) to fuel supply tube (30) inlet fitting
and drain hose (F4) to fuel manifold shroud drain port (27).
NOTE
Ensure metal seals (25) are in correct position before applying final
torque to fuel manifold shroud (26) flange bolts.
(7) Torque fuel manifold shroud (26) aft flange bolts (2 places) to 24-27 lb in.
(2.7-3.1 N·m).
(8) Hand-tighten knurled coupling nut (29).
(9) Torque customer interface connections as follows:
z F2 - Fuel Manifold Inlet/75-91 lb ft (101.7-123.4 N·m)

z F4- Fuel Manifold Shroud Drain/450-550 lb in.
(50.9-62.2 N·m)
z F5 and F7 - Fuel Inlet No. 1 and 2 Pressure Taps/270-300 lb in.
(30.5-33.9 N·m)
(10) Attach clamp (31) to bracket with one bolt, washer, and nut. Torque clamp bolt to
24-27 lb in. (2.7-3.1 N·m). Install any remaining clamps which may have been loosened during
removal.
(11) Safety-wire hose fittings as necessary.
(12) If necessary perform leak test per step d. above.

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REPLACEMENT OF FUEL MANIFOLDS (NATURAL

GAS WITH WATER INJECTION)

1 - 14 . . . . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Alignment of Gas Fuel Manifold and Gas Fuel Feeder Tubes . . . . . . . . . . . . . . . . . . . . . . . 13

Installation of Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation of Manifolds (682L310G13 Fuel System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal of Manifolds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal of Manifolds (682L310G13 Fuel System). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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the natural gas fuel and water injection manifolds. Prior to performing the tasks described herein,
remove tubing and electrical leads, as required to gain access to the fuel manifolds, per
WP 117 00, SWP 117 01, or, SWP 117 02.
NOTE
The S.I. unit shown in this work package are direct mathematical
None

Lubricant MIL-G-23827
Leak-Tek Solution Commercial
4. REMOVAL OF MANIFOLDS. See figure 1.
a. Removal of large gas fuel manifold.
(1) Remove the 2 bolts and washers at each fuel nozzle to manifold flange.
(2) Remove the bolts, nuts and washers that secure the 6 manifold clamps to the flange
brackets. See figure 1, sheet 2 of 2.
(3) Remove the bolts, nuts and washers that secure the manifold halves together at the
7:00 o’clock position, as viewed aft looking forward.
(4) Remove and discard the seal from between the manifold halves. Remove and discard
the preformed packing located between the fuel nozzle and manifold mating flanges. Carefully
remove the manifold halves.
(5) Remove clamps from the manifold halves.
(6) If required, remove the nozzle tube and hose assemblies by removing the bolts, nuts
and washers securing the assemblies to the fuel nozzles. Discard the preformed packing.
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b. Removal of water manifold.
(1) Disconnect feeder tubes from the fuel nozzles (30 locations). Exercise care to prevent
damage to the feeder tubes and fuel nozzle fittings. See figure 1, view D-D.
(2) Disconnect feeder tubes from the small water manifold (30 locations) and remove the
tubes. Use backup wrench when disconnecting tube end fittings.
(3) Remove the 2 bolts, nuts, and washers securing the manifold halves at the 6:00 and
12:00 o’clock positions. See figure 1, view H. Tag manifold end connectors indicating
orientation.
(4) Disconnect the fuel inlet fittings securing the manifold halves to the water tube
located at the 6:00 o’clock position.
(5) Remove the bolts, nuts and washers securing the manifold halves to the 12 hinge
brackets. Remove manifold halves from around compressor rear frame. See figure 1, view E-E.
NOTE
Gas turbine models 7LM2500-PE-MGX, 7LM2500-PE-NGX,
7LM2500PC101D, and 7LM2500PC104D will not require the
hinged bracket normally located (aft looking forward) at the
3:00 o’clock counterclockwise bolthole locations 13, 14, and 15
(figure 1, sheet 1). This bracket must be eliminated on these
models if the 682L359 T3 sensor is installed.
(6) Remove clamps from manifold halves as required.
5. REMOVAL OF MANIFOLDS (682L310G13 FUEL SYSTEM).
a. Remove fuel manifold assembly (1, figure 2) as follows:
(1) Disconnect 30 coupling nuts (2, section A-A) on gas tubes (3) from manifold
assembly (1).
(2) Remove 2 nuts (4), washers (5), and bolts (6) at 6 locations attaching clamps (7)
securing manifold assembly (1) to hinged brackets (8). See sheet 2 for bracket locations.
(3) Remove 4 nuts (9, sheet 1), 8 washers (10), and 4 bolts (11) attaching manifold
assembly (1) halves at 5:00 o'clock position, forward looking aft.
(4) Remove and discard gasket (12).
(5) Carefully remove manifold assembly (1).

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Figure 2. Manifolds and Fuel Nozzles (682L310G13 Fuel System) (Sheet 1 of 2)

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Figure 2. Manifolds and Fuel Nozzles (682L310G13 Fuel System) (Sheet 2 of 2)

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(6) Remove clamps (7) from manifold assembly (1).
(7) If required, remove tubes (3, section A-A) as follows:
(a) Disconnect coupling nut (13) on 30 tubes (3) from fuel nozzles (14) or fuel noz-
zle adapters (15, detail B).
(b) Remove tubes (3).
b. Remove water manifold assembly as follows:
(1) Disconnect coupling nuts (16) on feeder tubes (17) from 30 fuel nozzles
(14 or 18, detail B). Exercise care to prevent damage to tubes and nozzles. Use backup wrench
when disconnecting nuts.
(2) Disconnect coupling nuts (19) on tubes (17) from left water manifold (20) and right
water manifold (21) at 30 locations. Use backup wrench when disconnecting nuts.
(3) Remove 30 tubes (17).
(4) Remove nuts (22, sheet 2, detail C), washers (23), and bolts (24) securing
manifolds (20 and 21) at 6:00 and 12:00 o'clock positions. Tag manifold end connectors
indicating orientation.
(5) Disconnect two coupling nuts (25, sheet 1) on manifolds (20 and 21) at 6:00 o'clock
position from water tube (26).
(6) Remove nut (27, sheet 2, section E-E), washer (28), and bolt (29) at 11 locations
attaching clamps (30) securing manifolds (20 and 21) to hinged brackets (31). See sheet 2 for
bracket locations.
(7) Remove manifolds (20 and 21) from CRF.
(8) Remove clamps (30) from manifolds (20 and 21).

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6. INSTALLATION OF MANIFOLDS. See figure 1.
a. Installation of large gas fuel manifold.
(1) Install 6 clamps on manifold halves and locate clamps as shown in figure 1.
(2) Position manifold halves around compressor rear frame with the fuel nozzle ports
facing forward and the fuel inlet port at the 6:30 o’clock position, as viewed aft looking forward.
(3) Install a new seal between the flanges of the manifold halves. Install bolts, nuts, and
washers to secure manifold halves together. Torque bolts to 100-130 lb in. (11.3-14.7 N·m).
(4) Install new preformed packing on each of the 30 fuel nozzles and align the fuel
manifold outlet ports with the fuel nozzles. Install 2 bolts and washers at each fuel nozzle to
manifold flange connection. Assure adequate clearance exists between fuel nozzles and adjoining
components. Torque bolts1to 55-70 lb in. (6.2-7.9 N·m).
(5) Install positioning brackets as shown in figure 1, sheet 2 of 2.
(6) Attach manifold clamps (6 each) to flange mounted hinge brackets Secure clamps
using 2 bolts, nuts, and washers at each location. Torque bolts to 24-27 lb in. (2.7-3.1 N·m).
b. Installation of water manifold.
(1) Install 12 clamps on manifold halves and locate clamps as shown in figure 1.
(2) Position manifold halves around compressor rear frame with the fuel manifold to
feeder tube nipples facing forward and the fuel inlet fittings at the 5:30 and 6:30 o’clock positions.
Remove orientation tag and secure manifold halves together using 2 bolts, nuts and washers.
Torque bolts to 55-70 lb in. (6.2-7.9 N·m). See figure 1, view H.
(3) Install manifold clamps to hinge brackets using bolts, nuts, and washers at 12
locations. Torque bolts to 24-27 lb in. (2.7-3.1 N·m). See figure 1, view E-E.

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NOTE
Gas turbine models 7LM2500-PE-MGX, 7LM2500-PE-NGX,
7LM2500PC101D, and 7LM2500PC104D will not require the
hinged bracket normally located (aft looking forward) at the
3:00 o’clock counterclockwise bolthole locations 13, 14, and 15
(figure 1, sheet 1). This bracket must be eliminated on these
models if the 682L359 T3 sensor is installed.
(4) Install feeder tubes as follows:
(a) Lubricate all feeder tube nut to ferrule interfaces using lubricant, MIL-G-23827.
(b) Position feeder tubes as shown in figure 1, view D-D and connect fittings to fuel
nozzles and manifold connectors. Hand-tighten only at this time.
(c) Torque feeder tube to fuel nozzle fittings to 120-135 lb in. (13.6-15.3 N·m).
(d) Torque feeder tube to fuel manifold fittings to 120-135 lb in. (13.6-15.3 N·m).
(e) Connect fuel manifold inlet fittings located at the 5:30 and 6:30 o’clock
positions. Torque fittings to 270-300 lb in. (30.5-33.9 N·m).
c. Perform a leak check of each liquid (water injection system) connector as follows:
(1) Connect a pressure source of dry, regulated, filtered shop air or nitrogen to the small
gas fuel manifold inlet (customer interface) fitting.
(2) Apply Leak-Tek or soap water solution at each feeder tube to fuel nozzle and small
gas fuel manifold coupling nut.
(3) Pressurize the feeder tube and manifold with 200 psig (1379 kPa) air. No leaks
allowed.
(4) If a leak is present, loosen coupling nut and check condition of seat. If seat is not
damaged, re-tighten coupling nut to 120-135 lb in. (13.6-15.3 N·m) and re-check for leakage. If
coupling nut seat is damaged, replace feeder tube, fuel nozzle, or small gas fuel manifold as
appropriate.
(5) After leak check has been completed, disconnect pressure source from small gas fuel
manifold inlet fitting and reconnect water supply line.

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7. INSTALLATION OF MANIFOLDS (682L310G13 FUEL SYSTEM).
a. Install fuel manifold assembly (1, figure 2) as follows:
(1) If required, install gas tubes (3, section A-A) as follows:
(a) Connect coupling nut (13) on tube (3) to fuel nozzle (14) or fuel nozzle
adapter (15, detail B). Finger-tighten nuts.
(b) Repeat step (a) for remaining tubes (3).
(2) Install six clamps (7, section A-A) on manifold assembly (1).
(3) Position manifold assembly (1) halves around CRF with fuel nozzle ports facing for-
ward and fuel inlet port at 5:30 o'clock position, forward looking aft.
(4) Install new gasket (12) between flanges of manifold assembly (1) halves.
(5) Install four bolts (11), eight washers (10), and four nuts (9) to attach manifold assem-
bly (1) halves at 5:00 o'clock position, forward looking aft. Tighten nuts to 100-130 lb in.
(11.3-14.7 N·m) of torque.
(6) Connect 30 coupling nuts (2, section A-A) on tubes (3) to manifold assembly (1).
Finger-tighten nuts.
(7) Install two bolts (6), washers (5), and nuts (4) at six locations to attach clamps (7) to
hinged brackets (8) to secure manifold assembly (1). See sheet 2 for bracket locations. Tighten
nuts to 24-27 lb in. (2.7-3.1 N·m) of torque.
(8) Tighten nuts (2), and if required, nuts (13), to 900-1100 lb in. (101.7-124.3 N·m) of
torque.
b. Install water manifold assembly as follows:
(1) Install 11 clamps (30, sheet 2, section E-E), six onto left water manifold (20) and
five onto right water manifold (21).
(2) Position manifolds (20 and 21, sheet 1) around CRF with feeder tube nipples facing
forward and coupling nuts (25) at 5:30 and 6:30 o'clock positions.
(3) Remove orientation tag and install bolts (24, sheet 2, detail C), washers (23), and
nuts (22) to attach manifolds (20 and 21) together at 6:00 and 12:00 o'clock positions. Tighten
nuts to 55-70 lb in. (6.2-7.9 N·m) of torque.

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(4) Install bolt (29, section E-E), washer (28), and nut (27) at 11 locations to attach
clamps (30) to secure manifolds (20 and 21) to hinged brackets (31). See sheet 2 for bracket loca-
tions. Tighten nuts to 24-27 lb in. (2.7-3.1 N·m) of torque.
(5) Install feeder tubes (17, sheet 1, section A-A) as follows:
(a) Apply lubricant, MIL-G-23827, to threads and seating surfaces of coupling

nuts (16 and 19) on tubes (17) and fittings on fuel nozzles (14) or fuel nozzles (18, detail B) and
manifolds (20 and 21).
(b) Position tubes (17) and connect nuts (16) to nozzles (14) or
nozzles (18, detail B). Hand-tighten nuts.
(c) Connect nuts (19, section A-A) to manifolds (20 and 21). Hand-tighten nuts.
(d) Tighten nuts (16 and 19) to 120-135 lb in. (13.6-15.3 N·m) of torque.
(6) Connect two nuts (25) on manifolds (20 and 21) to water tube (26) at 5:30 and
6:30 o'clock positions. Tighten nuts to 270-300 lb in. (30.5-33.9 N·m) of torque.
c. Perform leak check of each tube (17, sheet 1, section A-A) as follows:
(1) Connect pressure source of dry, regulated, filtered shop air or nitrogen to customer
interface fitting (32).
(2) Apply Leak-Tek or soap water solution to each nut (16 and 19).
(3) Apply 200 psig (1379 kPa) to fitting (32).
(4) Check each nut (16 and 19) for leaks. If leak exists, proceed as follows:
(a) Disconnect nut (16 or 19) and check condition of seating surfaces. If any seat-
ing surface is damaged, replace tube (17), nozzle (14 or 18), or manifold (20 or 21) as appropriate.
(b) Reconnect nut (16 or 19). Tighten nut to 120-135 lb in. (13.6-15.3 N·m) of
torque.
(5) After leak check is complete, relieve pressure at fitting (32) and disconnect pressure
source.

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CAUTION
INCLUDED.
NOTE
(1) Visually sight two ends of gas fuel manifold at 1:00 to 2:00 o'clock positions.
generator.

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safety-wire.
bolts per packager's manual.
75-91 lb ft (101.7-123.4 N·m) of torque.

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REPLACEMENT OF FUEL MANIFOLDS

FUEL FEEDER TUBES AND FUEL TUBE/HOSES
(DUPLEX DUAL FUEL)

1 - 30 . . . . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Alignment of Gas Fuel Manifold and Feeder Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Installation of Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation of Manifolds (682L310G12 Fuel System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Removal of Manifolds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal of Manifolds (682L310G12 Fuel System). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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installation of the fuel manifolds and the primary and secondary fuel tubes for the duplex dual
fuel system. Prior to performing the tasks described herein, remove all external tubing and electri-
cal leads, as required to gain access to the fuel manifolds and fuel tubes, per WP 117 00,
SWP 117 01, or SWP 117 02.
NOTE
The S.I. unit shown in this subordinate work package are direct

2C6081 Wrench Set

MIL-G-23827 Grease
Commercial Leak-Tek

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4. REMOVAL OF MANIFOLDS. See figure 1.
NOTE
z Prior to performing the tasks described herein, remove all exter-
nal tubing to gain access to the fuel manifolds and fuel tubes per
WP 117 00, SWP 117 01, or SWP 117 02.
z Wrench set 2C6081 is referenced in this paragraph. If a required
wrench is not a part of this wrench set, use an equivalent
wrench to perform the task specified.
a. Remove the gas fuel manifold as follows:
(1) Remove the two bolts (60), two washers (61) and safety wire (63) at the nozzle tube/
hose (64) to gas manifold (53 and 65) flange at 30 locations. Discard the preformed packing (62)
at each location.
(2) Remove the four bolts (57), eight washers (56) and four locknuts (54) that secure the
gas fuel manifold halves (53 and 65) together at the 7 o’clock position, as viewed aft looking for-
ward. Discard seal (55).
(3) Remove the 12 bolts (66), 12 washers (67) and nuts (68) securing the six loop clamps
(69) to the gas fuel manifold (53 and 65) halves and hinge brackets (41, 43, 44, 46, 48 and 49).
(4) Remove the eight machine bolts (79) and nuts (80), securing the four retaining straps
(81) to the gas fuel manifold (53 and 65) halves and four brackets (42, 45, 47 and 50). Carefully
remove the manifold (53 and 65) halves.
(5) If required, remove the loop clamps (69) and retaining straps (81) from the gas fuel
manifold (53 and 65) halves.
b. Remove the nozzle tube/hose (64) as follows:
(1) Remove the bolts (70), washers (71) and nuts (72) from the nozzle tube/hose (64) at
the dual fuel nozzle (74 or 75) mounting flanges at 30 locations. Remove the nozzle tube/hose
(64) and discard the preformed packings (73).
c. Remove the primary (82) and secondary (84) fuel feeder tubes, as follows:
(1) Remove the safety wire at each end of the primary (82) and secondary (84) fuel
feeder tubes at 30 locations.
(2) Use the 2C6081 wrench set to disconnect and remove the secondary fuel feeder
tubes (84) at the dual fuel nozzles (74 or 75) connectors and at the secondary fuel/water
manifold (5 and 9) halves connectors at 30 locations.

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Figure 1. Fuel Manifolds and Feeder Tubes (Sheet 1 of 6)

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(3) Use the 2C6081 wrench set to disconnect and remove the primary fuel feeder
tubes (82) at the dual fuel nozzles (74 or 75) connector and at the primary fuel manifold (4 and
10) halves connectors at 30 locations.
d. Remove the secondary fuel/water manifold (5 and 9) halves and the primary fuel
manifold (4 and 10) halves, as follows:
(1) Remove the bolts (1), nuts (2) and washers (3) at the manifold clevis end to connector
end at the 12 o’clock and 6 o’clock positions. See views B and C, figure 1, sheet 2.
(2) Use 2C6081 wrench set and disconnect the secondary fuel/water manifold (7) at the
secondary fuel/water manifold (5 and 9) connectors.
(3) Use 2C6081 wrench set and disconnect the primary fuel manifold (8) at the primary
fuel manifold (4 and 10) halves connector.
(4) Remove machine bolts (23 and 27), nuts (25 and 29) and washers (24 and 28) con-
necting loop clamps (26) to hinge brackets (13, 14, 15 and 18) at 8 locations.
(5) Remove the clamped secondary (5) and primary fuel manifold (4) halves carefully.
Remove the clamped secondary (9) and primary fuel manifold (10) halves carefully.
(6) Remove loop clamps (22, 26 and 40), from manifold halves as required.
5. REMOVAL OF MANIFOLDS (682L310G12 FUEL SYSTEM).

NOTE
z Prior to performing the following tasks, remove all external tub-
ing to gain access to the fuel manifolds and fuel tubes per
WP 117 00, SWP 117 01, or SWP 117 02.
z Wrench set, 2C6081, is referenced in this paragraph. If a
required wrench is not part of this wrench set, use an equivalent
wrench to perform the specified task.
a. Remove natural gas fuel manifold assembly (1, figure 2) as follows:
(1) Disconnect coupling nuts (2, sheet 1, section A-A) on gas tubes (3) from manifold
assembly (1) at 30 locations.
(2) Remove four nuts (4), eight washers (5) and four bolts (6) attaching manifold assem-
bly (1) halves together at 5:00 o’clock position, forward looking aft.
(3) Remove and discard seal gasket (7).

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Figure 2. Natural Gas Manifold Assembly and Fuel Tubes

(682L310G12 Fuel System) (Sheet 1 of 2)

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Figure 2. Natural Gas Manifold Assembly and Fuel Tubes

(682L310G12 Fuel System) (Sheet 2 of 2)
(4) Remove two nuts (8, section A-A), washers (9) and bolts (10) at 6 locations attaching
six clamps (11) securing manifold assembly (1) to six hinged brackets (12). See sheet 2 for
bracket locations.
(5) Carefully remove manifold assembly (1) halves.
(6) Remove clamps (11) from manifold assembly (1).
b. Remove gas tubes (3, section A-A) as follows:
(1) Disconnect coupling nut (13) on tube (3) from fuel nozzle adapter (14).
(2) Remove tube (3).
(3) Repeat steps (1) and (2) for remaining tubes (3).
c. Remove primary fuel tubes (15, section A-A) and secondary fuel tubes (16) as follows:
(1) Use 2C6081 wrench set to disconnect coupling nuts (17) on tubes (15) and coupling
nuts (18) on tubes (16) from 30 fuel nozzles (19).

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(2) Use 2C6081 wrench set to disconnect coupling nuts (20) on tubes (15) primary from
primary left-side fuel manifold assembly (21) and primary right-side fuel manifold assembly (22)
at 30 locations.
(3) Remove tubes (15).
(4) Use 2C6081 wrench set to disconnect coupling nuts (23) on tubes (16) from
secondary left-side fuel manifold assembly (24) and secondary right-side fuel manifold assembly
(25) at 30 locations.
(5) Remove tubes (16).
d. Remove primary left and right-side fuel manifold assemblies (1 and 2, figure 3) and
secondary left and right-side fuel manifold assemblies (3 and 4) as follows:
(1) Remove nut (7, sheet 2, views A and B), washer (6) and bolt (5) attaching manifold
assemblies (1 and 2) together at 6:00 and 12:00 o’clock positions.
(2) Remove nut (7), washer (6) and bolt (5) attaching manifold assemblies (3 and 4)
together at 6:00 and 12:00 o’clock positions.
(3) Use 2C6081 wrench set to disconnect coupling nut (8, sheet 2, view C) on manifold
assembly (3) and coupling nut (9) on manifold assembly (4) from secondary fuel manifold
assembly (10).
(4) Use 2C6081 wrench set to disconnect coupling nut (11) on manifold assembly (1)
and coupling nut (12) on manifold assembly (2) from primary fuel manifold assembly (13).
(5) Remove nut (14, sheet 2, section D-D), washer (15) and bolt (16) attaching clamp
(17) on manifold assembly (3) to hinged bracket (18). See sheet 1 for bracket location.
(6) Remove nuts (14, sheet 2, section E-E), washers (15) and bolt (16) at seven locations
attaching clamps (17) on manifold assemblies (3 and 4) to hinged brackets (19). See sheet 1 for
bracket locations.
(7) Carefully remove clamped manifold assemblies (1 and 2) and clamped manifold
assemblies (3 and 4).
(8) If required, remove nuts (20, section F-F), bolts (21), and clamps (22) at four loca-
tions marked H on sheet 1, clamping manifold assemblies (1 and 3) or manifold assemblies
(2 and 4) together.
(9) If required, remove nuts (20, sheet 2, Section G-G), bolts (21) and clamps (22) at
four locations marked J on sheet 1, clamping manifold assemblies (1 and 3) or manifold
assemblies (2 and 4) together.

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.
Figure 3. Primary and Secondary Fuel Manifold Assemblies (Sheet 1 of 2)

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Figure 3. Primary and Secondary Fuel Manifold Assemblies (Sheet 2 of 2)

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6. INSTALLATION OF MANIFOLDS. See figure 1.
NOTE
Wrench set 2C6081 is referenced in this paragraph. If a required
wrench is not a part of this wrench set, use an equivalent wrench to
perform the task specified.
a. Install the gas manifold (53 and 65) halves, as follows:
(1) Position the six loop clamps (69) and the four retaining straps (81) on the gas fuel
manifold (53 and 65) halves as shown in figure 1, sheet 4.
(2) Place the gas fuel manifold (53 and 65) in position around the compressor rear frame,
as shown in figure 1, sheet 4.
(3) Position a new seal (55) between the connecting flanges of the gas fuel manifold
halves at the 7 o'clock position, as viewed aft looking forward.
(4) Hold seal (55) in position and install 4 bolts (57), eight washers (56) and four lock-
nuts (54). Torque locknuts to 100-130 lb in. (11.3-14.7 N·m).
(5) Align the gas fuel manifold and the 4 retaining straps (81) with the 4 brackets (42, 45,
47 and 50). See figure 1, sheet 3.
(6) Install the machine bolts (79) and nuts (80), securing the 4 retaining straps (81) to the
gas fuel manifold (53 and 65 and the 4 brackets (42, 45, 47 and 50). Torque the nuts to 55-70 lb in.
(6.2-7.9 N·m).
(7) Align the 6 loop clamps (69) with the hinge brackets (41, 43, 44, 46, 48 and 49).
Install bolts (66), washers (67) and nuts (68) securing the loop clamps (69) to the gas fuel mani-
fold (53 and 65) halves and to the hinge brackets (41, 43, 44, 46, 48 and 49). Torque each nut to
24-27 lb in. (2.7-3.1 N·m).
b. Install the nozzle tube/hose as follows:
(1) Position a new preformed packing (62) between the nozzle fuel tube/hose (64)
mounting flange and the gas fuel manifold (53 and 65) mounting flange. Install bolts (60) and
washers (61). Torque each bolt to 55-70 lb in. (6.2-7.9 N·m), at 30 locations. Safety wire
bolts (60).
(2) Position a new preformed packing (73) between the nozzle fuel tube/hose (64)
mounting flange and the dual fuel nozzle (74 or 75) mounting flange. Install bolts (70) and wash-
ers (71). Torque bolts to 55-70 lb in. (6.2-7.9 N·m), at 30 locations.

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c. Install the secondary fuel/water manifold (5 and 9) halves and the primary fuel manifold
(4 and 10) halves, as follows:
(1) If loop clamps (22, 26 and 40) were removed, reinstall and position the clamps per
figure 1, sheet 2. Leave the clamps loosely installed until the secondary fuel/water manifolds
(4 and 10) are in position around the compressor rear frame.
(2) Position the clamped secondary (5) and primary (4) fuel manifold halves around the
compressor rear frame, as shown in figure 1, sheet 2.
(3) Position the clamped secondary (9) and primary (10) fuel manifold halves around the
compressor rear frame, as shown in figure 1, sheet 2.
(4) Install bolts (1), washers (2) and nuts (3) at the manifold clevis end to connector end
at the 12 and 6 o'clock position, see figure 1, sheet 2, views B and C. Torque nuts (3) to
55-70 lb in. (6.2-7.9 N·m).
(5) Install bolts (20) and nuts (21) securing loop clamps (22) at four locations marked
"M", figure 1, sheet 2. Torque nut (21) to 24-27 lb in. (2.7-3.1 N·m).
(6) Install bolts (38) and nuts (39) securing loop clamps (40) at four locations marked
"N", figure 1, sheet 2. Torque nut (21) to 24-27 lb in. (2.7-3.1 N·m).
(7) Install bolt (23), washer (24) and nut (25) securing loop clamp (26) to hinge
bracket (15), see section H-H, figure 1, sheet 2. Torque nut (25) to 24-27 lb in. (2.7-3.1 N·m).
(8) Install bolts (27), washers (28) and nuts (29) securing loop clamps (26) to hinge
brackets (13, 14 and 18) total of 7 locations, see section G-G, figure 1, sheet 2. Torque nuts (29) to
24-27 lb in. (2.7-3.1 N·m).
(9) Use 2C6081 wrench set and connect the secondary fuel/water manifold (7) to the sec-
ondary fuel/water manifold (5 and 9) halves. Torque the coupling nut to 90-100 lb in.
(10.2-11.3 N·m).
(10) Use 2C6081 wrench set and connect the primary fuel manifold (8) to the primary fuel
manifold (4 and 10) halves. Torque coupling nuts to 90-100 lb in. (10.2-11.3 N·m).
d. Install the primary (82) and secondary (84) fuel feeder tubes as follows:
(1) Lubricate with MIL-G-23827 grease the nut-to-ferrule interfaces on the primary fuel
feeder tube (82) coupling nut to primary fuel manifolds (4 and 10) connectors. Connect primary
fuel feeder tubes (82) but do not tighten coupling nut.

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(2) Lubricate with MIL-G-23827 grease the nut-to-ferrule interfaces on the primary fuel
feeder tube (82) coupling nut to dual fuel nozzle (74 or 75) primary connector. Connect the pri-
mary fuel feeder tube (82) coupling nuts.
(3) Use 2C6081 wrench set and torque each primary fuel feeder tube (82) coupling nut at
each end to 120-135 lb in. (13.6-15.3 N·m) and safety wire. Repeat substeps (1) through (3) at 30
locations.
(4) Lubricate with MIL-G-23827 the nut-to-ferrule interfaces on the secondary fuel
feeder tube (84) coupling nut to secondary fuel manifold (5 and 9) connector. Connect secondary
fuel feeder tube (84) but do not tighten coupling nut.
(5) Lubricate with MIL-G-23827 the nut-to-ferrule interfaces on the secondary fuel
feeder tube (84) coupling nut to dual fuel nozzle (74 or 75) secondary connector. Connect the sec-
ondary fuel feeder tube (84) coupling nut.
(6) Use 2C6081 wrench set to torque the secondary fuel feeder tube (84) coupling nut to
the secondary fuel manifold (5 and 9) connector to 120-135 lb in. (13.6-15.3 N·m).
(7) Use 2C6081 wrench set and torque the secondary fuel feeder tube (84) coupling nut
to the dual fuel nozzle (74 or 75) secondary connector to 160-180 lb in. (18-20.3 N·m). Repeat
substeps (4) through (7) at 30 locations.
e. Perform a leak check of the primary fuel manifolds (4, 10 and 8) and the primary fuel
feeder tubes (82) as follows:
(1) The primary (82) and secondary (84) fuel feeder tubes must be disconnected at the
dual fuel nozzle (74 or 75) primary and secondary connectors; refer to paragraph 4, step c.
(2) To pressure test the primary fuel system, obtain 30 plugs P/N R494P04 or equivalent
with a thread size of 0.4375-20 UNJF-3A.
(3) Lubricate the nut-to-ferrule interfaces of primary feeder tubes (82) coupling nut to
the plugs with MIL-G-23827 grease.
(4) Install the plugs into the primary fuel feeder tube (82) coupling nuts at 30 locations.
Use the 2C6081 wrench set and torque the coupling nuts to 120-135 lb in. (13.6-15.3 N·m).
(5) Inspect and confirm that cap (86) is installed and torqued to 270-300 lb in.
(30.5-33.9 N·m). Inspect and confirm that thermocouple sensor (86A) is installed and torqued to
135-150 lb in. (15.25-16.95 N·m).

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(6) Connect a pressure source of dry, regulated and filtered shop air or nitrogen to the
primary fuel manifold (8) interface, item (F2) figure 1, sheet 5. Torque the pressure source cou-
pling nut to 54-64 lb ft (73.2-86.8 N·m).
(7) Apply Leak-Tek or soap water at the following locations:
(a) Each primary fuel feeder tube (82) to plug connection.
(b) Each primary fuel feeder tube (82) to primary fuel manifold (4 and 10)
connection.
(c) Primary fuel manifold (8) to primary fuel manifold (4 and 10) connections.
(d) Primary fuel manifold (8) cap (86) connection.
(e) Temperature sensor (86A).
(f) Primary fuel manifold (8) fuel inlet (F2).
(8) Pressurize the primary fuel manifolds and primary fuel feeder tubes with 200 psig
(1379 kPa) air or nitrogen. No leaks allowed.
(9) If leak is present at temperature sensor (86A), loosen sensor and inspect seal boss
(86B) for damage. If damage is present, replace seal boss (86B). Retorque temperature sensor to
135-150 lb in. (15.25-16.95 N·m). If a leak is present at other location, loosen coupling nut and
inspect condition of seat. If seat is not damaged, retorque coupling nut to the following torque
values:
(a) Primary fuel feeder tubes (82) coupling nuts - each end - torque 120-135 lb in.
(13.6-15.3 N·m).
(b) Primary fuel manifold (8) coupling nuts to primary fuel manifold (4 and 10)
connectors - torque 90-100 lb in. (10.2-11.3 N·m).
(c) Primary fuel manifold (8) - cap (86) - torque 270-300 lb in. (30.5-33.9 N·m).
(d) Primary fuel manifold (8) fuel inlet (F2) - torque 54-64 lb ft (73.2-86.8 N·m).
(10) Recheck for leakage.
(11) If coupling nut seat is damaged, replace feeder tube, cap or fuel manifold as
appropriate.

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(12) After leak check has been completed on the primary fuel system, disconnect the pres-
sure source from the primary fuel manifold (8) inlet (F2).
(13) Disconnect and remove the 30 plugs at the primary fuel feeder tube (82) coupling
nuts. Do not connect the primary fuel feeder tubes (82) coupling nuts to the dual fuel nozzles at
this time.
f. Perform a leak check of the secondary fuel/water manifolds (5, 9 and 7) and the secondary
fuel feeder tubes (84) as follows:
(1) The secondary fuel feeder tubes should still be disconnected at the dual fuel nozzle
(74 or 75) secondary connector, as instructed in step 3.(1).
(2) To pressure test the secondary fuel system, obtain 30 plugs PN R494P05 or equiva-
lent with thread size of 0.500-20 UNJF-3A.
(3) Lubricate the nut-to-ferrule interfaces of secondary fuel feeder tube (84) coupling
nuts to the plugs with MIL-G-23827 grease.
(4) Install the plugs into the secondary fuel feeder tube (84) coupling nuts at 30 loca-
tions. Use the 2C6081 wrench set and torque the coupling nuts to 160-180 lb in. (18-20.3 N·m).
(5) Inspect and confirm that cap (87) is installed at (F7) and torqued to 270-300 lb in.
(30.5-33.9 N·m). Inspect and confirm that temperature sensor (87A) is installed and torqued to
135-150 lb in. (15.25-16.95 N·m). Inspect and confirm that cap (100) is installed at (W1) and
torqued to 75-91 lb ft (102-123.4 N·m).
(6) Connect a pressure source of dry, regulated filtered shop air or nitrogen to the sec-
ondary fuel/water manifold (7) inlet - item (F6) (customer interface connector). See figure 1,
sheet 5.
(7) Apply Leak-Tek or soap water solution at the following locations:
(a) Each secondary fuel feeder tube (84) to plug connection.
(b) Each secondary fuel feeder tube (84) to secondary fuel/water manifold (5 and 9)
connection.
(c) Secondary fuel/water manifold (7) to secondary fuel/water manifold (5 and 9)

connections.
(d) Cap (87) and cap (100).
(e) Secondary fuel/water manifold (7) inlet (F6).

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(f) Temperature sensor (87A).
(8) Pressurize the fuel manifolds and fuel feeder tubes with 200 psig (1379 kPa) air or
nitrogen. No leaks allowed.
(9) If leak is present at temperature sensor (87A), loosen sensor and inspect seal boss
(87B) for damage. If damage is present, replace seal boss (87B). Retorque temperature sensor to
135-150 lb in. (15.25-16.95 N·m). If a leak is present at other location, loosen coupling nut and
check condition of seat. If seat is not damaged, retorque coupling nut to the following torque
values:
(a) Secondary fuel feeder tube (84) coupling nut to plug - torque 160-180 lb in.
(18.1-20.3 N·m).
(b) Secondary fuel feeder tube (84) coupling nuts to secondary fuel/water manifold
(5 and 9) connectors - torque 120-135 lb in. (13.6-15.3 N·m).
(c) Secondary fuel/water manifold (7) coupling nut to secondary fuel/water mani-
fold (5 and 9) connectors - torque 90-100 lb in. (10.2-11.3 N·m).
(d) Secondary fuel/water manifold (7) cap (87) - torque 270-300 lb in.
(30.5-34 N·m).
(e) Secondary fuel/water manifold (7) cap (100) - torque 75-91 lb ft

(101.7-123.4 N·m).
(f) Secondary fuel/water manifold (7) inlet (F6) - torque 75-91 lb ft

(101.7-123.4 N·m).
(10) Recheck for leakage.
(11) If coupling nut seat is damaged, replace feeder tube, cap or fuel manifolds as
appropriate.
(12) After leak check has been completed on the secondary fuel feeder tubes and second-
ary fuel/water manifolds, disconnect the pressure source from the secondary fuel/water
manifold (7) inlet (F6).
(13) Disconnect the plugs from the secondary fuel feeder tube (84) coupling nuts at
30 locations.
(14) Reconnect the primary fuel feeder tubes (82) per step d. (3).
(15) Reconnect the secondary fuel feeder tubes (84) per step d. (7).

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7. INSTALLATION OF MANIFOLDS (682L310G12 FUEL SYSTEM).
NOTE
Wrench set, 2C6081, is referenced in this paragraph. If a required
wrench is not part of this wrench set, use an equivalent wrench to
perform the specified task.
a. Install natural gas manifold assembly (1, figure 2) as follows:
(1) Install six clamps (11, section A-A) onto manifold assembly (1) at same locations as
hinged brackets (12). See sheet 2 for bracket locations.
(2) Position manifold assembly (1) halves around CRF.
(3) Install new seal gasket (7) between manifold assembly (1) flanges.
(4) Hold gasket (7) in place and install four bolts (6), eight washers (5) and four nuts (4)
to secure manifold assembly (1) halves together. Tighten nuts to 100-130 lb in. (11.3-14.7 N·m)
of torque.
(5) Align six clamps (11, section A-A) with brackets (12). See sheet 2 for bracket
locations.
(6) Install two bolts (10, sheet 1, section A-A), washers (9) and nuts (8) at six locations
to attach clamps (11) to secure manifold assembly (1) to brackets (12). Tighten nuts to
24-27 lb in. (2.7-3.1 N·m) of torque.
b. Install gas tubes (3, section A-A) as follows:
(1) Position gas tube (3) between manifold assembly (1) and fuel nozzle adapter (14).
(2) Connect coupling nut (2) on tube (3) to manifold assembly (1). Hand-tighten nut.
(3) Connect coupling nut (13) on tube (3) to adapter (14). Hand-tighten nut.
(4) Tighten nuts (2 and 13) to 900-1100 lb in. (101.7-124.3 N·m) of torque.
(5) Repeat steps (1) through (4) for remaining tubes (3).

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c. Install primary left and right-side fuel manifold assemblies (1 and 2, figure 3) and second-
ary left and right-side fuel manifold assemblies (3 and 4) as follows:
(1) If required, clamp manifold assemblies (1 and 3) together as follows:
(a) Install two clamps (22, sheet 2, section G-G) onto manifold assemblies
(1 and 3) at 2 locations marked J on sheet 1.
(b) Install two clamps (22, sheet 2, section F-F) onto manifold assemblies (1 and 3)
at 2 locations marked H on sheet 1.
(2) If required, clamp manifold assemblies (2 and 4) together as follows:
(a) Install two clamps (22, sheet 2, section G-G) onto manifold assemblies (2 and 4)
at two locations marked J on sheet 1.
(b) Install two clamps (22, section F-F) onto manifold assemblies (2 and 4) at
two locations marked H on sheet 1.
(3) Position clamped manifold assemblies (1 and 3) and clamped manifold assemblies
(2 and 4) around CRF.
(4) Install nut bolt (5, Views A and B), washer (6) and nut (7) to attach manifold assem-
blies (1 and 2) together at 6:00 and 12:00 o’clock positions. Tighten nuts to 55-70 lb in.
(5) Install nut bolt (5), washer (6) and nut (7) to attach manifold assemblies (3 and 4)
together at 6:00 and 12:00 o’clock positions. Tighten nuts to 55-70 lb in. (6.2-7.9 N·m) of torque.
(6) Install one bolt (21, section G-G) and nut (20) to attach two clamps (22) together at
four locations marked J on sheet 1 to secure manifold assemblies (1 and 3) and manifold assem-
blies (2 and 4) together. Tighten nuts to 24-27 lb in. (2.7-3.1 N·m) of torque.
(7) Install one bolt (21, section F-F) and nut (20) to attach two clamps (22) together at
four locations marked H on sheet 1 to secure manifold assemblies (1 and 3) and manifold assem-
blies (2 and 4) together. Tighten nuts to 24-27 lb in. (2.7-3.1 N·m) of torque.
(8) Install nut (14, section D-D), washer (15) and bolt (16) to attaching clamp (17) on
manifold assembly (3) to hinged bracket (18). Tighten nuts to 24-27 lb in. (2.7-3.1 N·m) of torque.
See sheet 1 for bracket location.
(9) Install nut (14, section E-E), washer (15) and bolt (16) to attaching clamp (17) on
manifold assemblies (3 and 4) at seven locations to hinged brackets (19). Tighten nuts to
24-27 lb in. (2.7-3.1 N·m) of torque. See sheet 1 for bracket location.

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(10) Use 2C6081 wrench set to connect coupling nut (8, sheet 2, View C) on manifold
assembly (3) and coupling nut (9) on manifold assembly (4) to secondary fuel manifold assembly
(10). Tighten nuts to 90-100 lb in. (10.2-11.3 N·m) of torque.
(11) Use 2C6081 wrench set to connect coupling nut (11) on manifold assembly (1) and
coupling nut (12) on manifold assembly (2) to primary fuel manifold assembly (13). Tighten nuts
d. Install primary fuel tubes (15, figure 2) and secondary fuel tubes (16) as follows:
(1) Apply MIL-G-23827 grease to threads and seating surfaces of coupling nuts (17 and
23, sheet 1, section A-A) on 30 tubes (15) and coupling nuts (18 and 20) on 30 tubes (16).
(2) Apply MIL-G-23827 grease to threads and seating surfaces of fittings on 30 fuel noz-
zles (19) where tubes (15 and 16) will connect.
(3) Apply MIL-G-23827 grease to threads and seating surfaces of fittings on primary left
and right-side manifolds assemblies (21 and 22) and secondary left and right-side manifold
assemblies (24 and 25) where tubes (15 and 16) will connect.
(4) Connect tubes (15 and 16) to nozzles (19) and manifold assemblies (21, 22, 24 and
25) as follows:
(a) Position tube (15) so that coupling nut (17) aligns with nozzle (19) and coupling
nut (23) aligns with manifold assembly (24 or 25), as applicable.
(b) Connect nut (17) to nozzle (19) and nut (23) to manifold assembly (24 or 25), as
applicable. Use 2C6081 wrench set to tighten nuts (17 and 23) to 120-135 lb in. (13.6-15.3 N·m)
of torque.
(c) Position tube (16) so that coupling nut (18) aligns with nozzle (19) and coupling
nut (20) aligns with manifold assembly (21 or 22), as applicable.
(d) Connect nut (18) to nozzle (19) and nut (20) to manifold assembly (21 or 22), as
applicable. Use 2C6081 wrench set to tighten nuts (16 and 20) to 120-135 lb in. (13.6-15.3 N·m)
of torque.
(e) Repeat steps (a) through (d) for remaining tubes (15 and 16).

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e. Perform leak check of primary left-side manifold assembly (1, figure 3), primary right-
side manifold assembly (2), primary fuel manifold assembly (13) and primary fuel tubes (15,
figure 2) as follows:
(1) Disconnect primary fuel tubes (15) and secondary fuel tubes (16) from fuel
nozzles (19) per step c. (1).
(2) Install R494P04 plugs or equivalent with thread size of 0.4375-20 UNJF-3A as
follows:
(a) Apply MIL-G-23827 grease to threads and seating surfaces of coupling nuts
(17) at 30 locations.
(b) Install R494P04 plugs or equivalent into nuts (17) at 30 locations. Use 2C6081
wrench set to tighten nuts to 120-135 lb in. (13.6-15.3 N·m) of torque.
(3) Verify that cap (23, figure 3, view C) is installed on manifold assembly (13) and
tightened to 270-300 lb in. (30.5-33.9 N·m) of torque.
(4) Verify that temperature sensor (24) is installed in manifold assembly (13) and tight-
ened to 135-150 lb in. (15.3-16.9 N·m) of torque.
(5) Connect pressure source of dry, regulated, filtered shop air or nitrogen to manifold
assembly (13) interface. Tighten pressure source coupling nut to 54-64 lb ft (73-87 N·m) of
torque.
(6) Apply Leak-Tek or soapy water at following locations:
(a) Each coupling nut (17, figure 2) and plug at 30 locations.
(b) Each coupling nut (23) at manifold assemblies (21 and 22) connections at
30 locations.
(c) Coupling nuts (11 and 12, figure 3, view C) connection to manifold
assembly (13).
(d) Manifold assembly (13) cap (23) connection.
(e) Sensor (24) connection at manifold assembly (13).
(f) Manifold assembly (13) connection to pressure source.
(7) Apply 200 psig (1379 kPa) of pressure. No leaks allowed.

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(8) If leak is present at sensor (24), loosen sensor and inspect seal boss (25) for damage.
If damaged, replace boss. Install sensor and tighten to 135-150 lb in. (15.3-16.9 N·m) of torque.
(9) If leak is present at other location, disconnect coupling nut at that location and
inspect condition of seating surfaces. If seating surface is damaged, replace parts as appropriate. If
seating surface is not damaged, reconnect coupling nut and tighten to proper torque value as
follows:
(a) Tighten primary fuel tube (15, figure 2, section A-A) coupling nuts (17 and 23)
(b) Tighten primary fuel manifold assembly (13, figure 3, sheet 2, view C) coupling
nuts (11 and 12) to 90-100 lb in. (10.2-11.3 N·m) of torque.
(c) Tighten primary fuel manifold assembly (13) cap (23) to 270-300 lb in.
(30.5-33.9 N·m) of torque.
(d) Tighten primary fuel manifold assembly (13) fuel inlet coupling nut to
54-64 lb ft (73-87 N·m) of torque.
(10) Recheck all connections for leaks.
(11) After leak check is complete, disconnect pressure source from manifold
assembly (13).
(12) Remove 30 plugs from coupling nuts (17, figure 2). Do not connect tubes (15) at this
time.
f. Perform leak check of secondary left-side manifold assembly (3, figure 3), secondary
right-side manifold assembly (4), secondary fuel manifold assembly (10) and secondary fuel
tubes (16, figure 2) as follows:
(1) Verify secondary fuel tubes (16) are still disconnected from fuel nozzles (19) per
step c. (1).
(2) Install R494P04 plugs or equivalent with thread size of 0.4375-20 UNJF-3A as
follows:
(a) Apply MIL-G-23827 grease to threads and seating surfaces of coupling

nuts (18) at 30 locations.
(b) Install R494P04 plugs or equivalent into nuts (18) at 30 locations. Use
2C6081 wrench set to tighten nuts to 120-135 lb in. (13.6-15.3 N·m) of torque.

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(3) Verify that cap (23, figure 3, view C) is installed on manifold assembly (10) and
tightened to 270-300 lb in. (30.5-33.9 N·m) of torque.
(4) Verify that temperature sensor (24) is installed in manifold assembly (10) and tight-
ened to 135-150 lb in. (15.3-16.9 N·m) of torque.
(5) Connect pressure source of dry, regulated, filtered shop air or nitrogen to manifold
assembly (10) interface. Tighten pressure source coupling nut to 54-64 lb ft (73-87 N·m) of
torque.
(6) Apply Leak-Tek or soapy water at following locations:
(a) Each coupling nut (18, figure 2) and plug at 30 locations.
(b) Each coupling nut (23) at manifold assemblies (24 and 25) connections at
30 locations.
(c) Coupling nuts (8 and 9, figure 3, view C) connection to manifold assembly (10).
(d) Manifold assembly (10) cap (23) connection.
(e) Sensor (24) connection at manifold assembly (10).
(f) Manifold assembly (10) connection to pressure source.
(7) Apply 200 psig (1379 kPa) of pressure. No leaks allowed.
(8) If leak is present at sensor (24), loosen sensor and inspect seal boss (25) for damage.
If damaged, replace boss. Install sensor and tighten to 135-150 lb in. (15.3-16.9 N·m) of torque.
(9) If leak is present at other location, disconnect coupling nut at that location and
inspect condition of seating surfaces. If seating surface is damaged, replace parts as appropriate. If
seating surface is not damaged, reconnect coupling nut and tighten to proper torque value as
follows:
(a) Tighten secondary fuel tube (16, figure 2, section A-A) coupling nuts (18 and
20) to 120-135 lb in. (13.6-15.3 N·m) of torque.
(b) Tighten primary fuel manifold assembly (10 and 11, figure 3, sheet 2, view C)
coupling nuts (8 and 9) to 90-100 lb in. (10.2-11.3 N·m) of torque.
(c) Tighten primary fuel manifold assembly (10) cap (23) to 270-300 lb in.
(30.5-33.9 N·m) of torque.

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(d) Tighten primary fuel manifold assembly (10) fuel inlet coupling nut to
54-64 lb ft (73-87 N·m) of torque.
(10) Recheck all connections for leaks.
(11) After leak check is complete, disconnect pressure source from manifold
assembly (10).
(12) Remove 30 plugs from coupling nuts (18, figure 2).
(13) Connect coupling nuts (17) on 30 tubes (15) and coupling nuts (18) on 30 tubes (16)
onto fuel nozzles (19) per step d. (4).
8. ALIGNMENT OF GAS FUEL MANIFOLD AND FEEDER TUBES.
CAUTION
INCLUDED.
NOTE
(1) Visually sight 2 ends of gas fuel manifold at 1:00 to 2:00 o’clock positions.
(2) Using nipple wrenching flats as guide, measure and record axial difference between 2
ends of gas fuel manifold.

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e. Cut and discard all safety cable or wire from fuel nozzle bolts. Back all bolts out 1 turn.
generator.
groups of 3. After snugging, loosen B-nut 1 flat (60 degrees). Continue until all 30 gas fuel
groups of 3. After snugging, loosen B-nut 1 flat (60 degrees). Continue until all 30 fuel feeder
tube B-nuts have been tightened. Use same sequence as performed in step (3) above.
safety-wire.
bolts per packager’s manual.

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75-91 lb ft (101.7-123.4 N·m) of torque.

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REPLACEMENT OF FUEL FLOW DIVIDER VALVE

(OFF-ENGINE) DUPLEX DUAL FUEL

1-4.......... 0
ALPHABETICAL INDEX
Subject Page
Installation of Fuel Flow Divider Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Removal of Fuel Flow Divider Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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the fuel divider valve (off engine) mounted, for the duplex dual fuel system.
NOTE
The S.I. unit shown in this work package are direct mathematical

2C6081 Wrench Set

4. REMOVAL OF FUEL FLOW DIVIDER VALVE. See figure 1.
NOTE
a. Remove safety wire from fuel line (2 and 5) coupling nuts at the fuel flow divider
valve (10) fuel outlet connectors.
b. Using the 2C6081 wrench set, disconnect fuel line (2 and 5) coupling nuts at the fuel flow
divider valve (10) fuel outlet connectors.
c. Remove safety wire from fuel inlet line (9) coupling nut.
d. Using the 2C6081 wrench set, disconnect fuel inlet line (9) coupling nut at the fuel flow
divider valve (10) fuel inlet connector.

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Figure 1. Fuel Flow Divider Valve (Off Engine)

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e. Remove the 4 mounting bolts, washers and nuts (7) and remove the flow divider
valve (10) from the mounting bracket (8).
5. INSTALLATION OF FUEL FLOW DIVIDER VALVE. See figure 1.
NOTE
a. Position fuel flow divider valve (10) on mounting bracket (8) and secure valve with
mounting bolts, nuts and washers (7).
b. Connect fuel inlet line (9) coupling nut to the fuel flow divider valve (10) fuel inlet
connector.
c. Connect fuel line (2 and 5) coupling nuts to the fuel flow divider valve (10) fuel outlet
connectors.
d. Using the 2C6081 wrench set, torque the fuel line (2, 5 and 9) coupling nuts to the
following values:
(1) Fuel outlet line (2) coupling nut - torque to 650-770 lb in. (73.5-87.0 N·m).
(2) Fuel outlet line (5) coupling nut - torque to 75-91 lb ft (101.7-123.4 N·m).
(3) Fuel inlet line (9) coupling nut - torque to 112-128 lb ft (151.9-173.6 N·m).
e. Safety wire fuel line (2, 5 and 9) coupling nuts to the connectors.

4
GEK 97310
VOLUME II
WP 124 00
WORK PACKAGE
REPLACEMENT OF FUEL PUMP

1-8.......... 0
ALPHABETICAL INDEX
Subject Page
Installation of Fuel Pump. (Optional Equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Removal of Fuel Pump. (Optional Equipment). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
WP 124 00
installation of the optional fuel pump.
NOTE

Container, 5 Quart

Safety Wire
4. REMOVAL OF FUEL PUMP. (OPTIONAL EQUIPMENT) See figure 1.
WARNING
DISCONNECT ELECTRICAL POWER AND REMOVE ELEC-
TRICAL CONNECTION. TURN OFF FUEL AND LUBE SUP-
PLY TO THE GAS GENERATOR ENCLOSURE.
CAUTION
USE WRENCH ON BOTH UNION AND LINE BEING
DISCONNECTED.
NOTE
When fluid lines are disconnected, spillage of fluids may occur. Be
prepared to collect fluids in suitable container.
a. Remove drain plug (29, figure 1) and drain fuel into a plastic container. Remove and
discard O-ring (30). If fuel pump is to be reinstalled, install new O-ring on drain plug and rein-
stall in drain port. Torque plug to 20-50 lb in. (2.3-5.7 N·m). If fuel pump is to be sent to over-
haul, reinstall plug fingertight.

2
GEK 97310
VOLUME II
WP 124 00
Figure 1. Fuel Pump - Optional (Kit No. L24093G01)

3
GEK 97310
VOLUME II
WP 124 00
b. Remove bracket (27) by removing 2 nuts and washers from the top 2 forward studs.
c. Disconnect pilot pressure hose (18) from the pump. Remove union (19) and O-ring (20).
Discard O-ring.
CAUTION
HOSES MUST BE HANDLED CAREFULLY TO PREVENT
KINKING DUE TO EXCESSIVE BENDING. KINKING CAN
BREAK HOSE LINER AND CAUSE FUEL LEAK.
d. Remove fuel supply hose (17) by removing 4 bolts and washers attaching it to the fuel
pump and drain fuel into a plastic container. Remove and discard gasket (31).
e. Remove plug (21). Remove and discard O-ring (22).
f. Disconnect fuel pressure hose (25). Remove union (24). Remove and discard
O-ring (23).
g. Disconnect bypass fuel hose (26) by removing 4 bolts and washers. Drain fuel into a
plastic container.
NOTE
It is not necessary to remove the locking bolt (14), ball seat
washer (15), and packing (16) from the bracket (12) unless these
parts are damaged.
h. Unscrew locking bolt (14), and remove ball seat washer (15), packing (16), and
bracket (12) from the outer ring (10).
CAUTION
TO PREVENT SPLINE DAMAGE AND TO AVOID DROPPING
THE PUMP, SUPPORT THE PUMP BY HAND DURING QUAD
RING REMOVAL.
i. Loosen the outer ring (10) by striking the lug at the bottom of the ring in a counterclock-
wise direction with a soft faced hammer. Rotate the ring until it stops.

4
GEK 97310
VOLUME II
WP 124 00
CAUTION
TO PREVENT DAMAGE TO THE DRIVE SPLINE, SUPPORT
PUMP AND REMOVE IT CAREFULLY. AFTER REMOVAL,
DO NOT ALLOW THE PUMP TO REST ON SPLINED END.
j. Carefully remove the pump from the gearbox by moving it aft in a straight line until the
drive spline clears. Remove O-ring (2) from the drive spline and discard. Remove seal (9) from
gearbox and discard.
k. Plug all ports with plastic plugs and install plastic caps on both splines to protect the
spline teeth.
5. INSTALLATION OF FUEL PUMP. (OPTIONAL EQUIPMENT) See figure 1.
a. If fuel pump is being installed for the first time on the gas generator, proceed as follows:
NOTE
Transfer gearbox main fuel pump adapter is located on aft side of
transfer gearbox, left hand pad, aft looking forward.
(1) Remove cover from transfer gearbox main fuel pump adapter by removing safety
wire and 8 bolts. Two of the bolts also secure a bracket which supports the VSV cable. Remove
the bracket attached to VSV cable. Discard the cover plate gasket; retain remaining hardware.
(2) Remove transfer gearbox gearshaft seal assembly, L21431G02, from ID of gearshaft
as follows: See figure 2.
(a) Hold end of tie rod with a 1/4 inch open end wrench on the flats provided, and
remove nut.
(b) Jiggle gearshaft seal assembly until clevis (swivel foot) disengages from behind
splines in gearshaft. Pull seal assembly from ID of gearshaft.
(c) Remove preformed packing, J221P216, from adapter of seal assembly. Remove
preformed packing, J221P14, from tie rod of seal assembly. Discard removed packing and retain
plug assembly.
b. Install fuel pump kit assembly, L24093G01, as follows: See figure 1.
(1) Install gasket (8) on adapter (7).
(2) Install adapter (7) on left aft gearbox pad and secure with 8 flathead screws (11).
Torque screws to 190-230 lb in. (21.5-26.0 N·m).
(3) Install bracket (12) and secure with 2 bolts (13). Torque to 190-230 lb in.
(21.5-26.0 N·m).

5
GEK 97310
VOLUME II
WP 124 00
(4) Install outer ring (10). Locate arrow on outer ring and align with ball socket
bracket (12). Rotate ring 180 degrees CW until remaining arrow aligns with bracket. This aligns
slots of ring to mounting pad slots.
(5) Install seal (9), with spring tangs positioned forward, into gearbox and snap over the
counterbore ID.
WARNING
LUBRICATING OIL IN LIQUID, VAPOR, OR MIST FORM IS
FLAMMABLE, IRRITATING TO THE SKIN AND RESPIRA-
TORY TRACT, AND POISONOUS IN THE DIGESTIVE
TRACT. REMOVE SATURATED CLOTHING, WASH SKIN
WELL, DON'T SWALLOW LIQUID, AND DON'T BREATHE
MIST OR VAPOR.
(6) Lightly lubricate preformed packing (2) with lube oil, MIL-L-23699, and install on
pump drive spline. Lightly lubricate drive spline with gas generator lube oil.
CAUTION
TO PREVENT SPLINE DAMAGE AND TO AVOID DROPPING
THE PUMP, SUPPORT THE PUMP BY HAND DURING
QUAD RING INSTALLATION.
(7) Rotate the outer quad ring (10) counterclockwise until it stops. Align the pump drive
shaft with its mating spline, align the dowel pins with their mating holes, and insert the pump into
the quad ring. Rotate the quad ring clockwise until the locking tabs on the ring are engaged with
the locking tabs on the pump flange.
(8) Install ball socket washer (15) on locking bolt (14) and insert in bracket (12). Install
packing (16) on the bolt so that it will be located between the bracket and the quad ring lug.
Screw the locking bolt (14) into the quad ring and torque to 190-230 lb in. (21.5-26.0 N·m).
Lockwire the 2 bracket bolts (13) and the outer ring bolt (14) together.

6
GEK 97310
VOLUME II
WP 124 00
Figure 2. Transfer Gearbox Gearshaft Seal Assembly - L21431G02
(9) Install O-ring (20) on union (19) and install union in the pump. Torque union to
135-150 lb in. (15-17 N·m).
(10) Install O-ring (23) on union (24) and install union in fuel pump. Torque union (24) to
180-200 lb in. (20-23 N·m).
(11) Install O-ring (22) on plug (21) and install in fuel pump. Torque plug to
135-150 lb in. (15-17 N·m).
(12) If required, install 2 O-rings (4) in the grooves of fuel pump adapter (3). Mount fuel
pump adapter (3) on the pump and install 3 nuts and washers on the 3 aft studs. Tighten nuts until
they contact the adapter.
(13) Mount angle bracket (27) on the forward top two pump adapter studs with the angle
bracket facing forward and the angle leg positioned away from the pump. Use nuts (6) and wash-
ers (5). Torque all nuts (6) to standard torque value.
(14) Remove bracket from variable stator vane position feedback cable by removing the
bolt, nut, clamp and washer.
(15) Install loop clamp (28) on VSV feedback cable and secure the feedback cable to the
angle bracket (27), installed in step (13), using bolt, nut and washer provided. Torque to standard
torque value.

7
GEK 97310
VOLUME II
WP 124 00
CAUTION
z USE WRENCH ON BOTH UNION AND LINE BEING
CONNECTED.
z HOSES MUST BE HANDLED CAREFULLY TO PREVENT
KINKING DUE TO EXCESSIVE BENDING. KINKING
CAN BREAK HOSE LINER AND CAUSE FUEL LEAK.
(16) Assemble bypass fuel hose (26) to fuel pump using gasket, bolts and washers.
Torque to standard torque values.
(17) Assemble fuel pressure hose (25) to reducer fitting (24) on fuel pump. Torque to
standard torque value.
(18) Assemble pilot pressure hose (18) to nipple (19) on fuel pump. Torque to
135-150 lb in. (15-17 N·m).
(19) Assemble fuel supply hose (17) to fuel pump using gasket (31), bolts and washers.
Torque to standard torque values.
(20) Reconnect electrical power and turn on fuel and lube supply to the gas generator
enclosure.

8
GEK 97310
VOLUME II
WP 125 00
WORK PACKAGE
REPLACEMENT OF AIR/OIL COOLER

1-4.......... 0
ALPHABETICAL INDEX
Subject Page
Installation of Air/Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Removal of Air/Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
WP 125 00
NOTE
This work package applies only to the GA101 engines that have not
complied with Service Bulletin LM2500-IND-007.
the air/oil cooler.
None
None
4. REMOVAL OF AIR/OIL COOLER. See figure 1.
a. Remove 10 bolts securing plenum to top flange of cooler.
b. Disconnect air tube from plenum by loosening coupling clamp nearest plenum. Remove
plenum from cooler.
c. Disconnect oil inlet and outlet tubes from cooler; remove fitting from cooler.
d. Remove 10 bolts from mounting flange, and remove cooler from adapter.
5. INSTALLATION OF AIR/OIL COOLER.
a. Install new gasket and cooler on adapter flange. Secure, using 10 bolts; torque 55-70 lb in.
(6.2-7.9 N·m).
b. Install fittings in oil inlet and outlet ports; connect tube to fittings.
c. Install new gasket on air cooler, and install plenum. Secure plenum, using 10 bolts; torque
to standard torque values.
d. Connect air tube to plenum; secure coupling clamp.

2
GEK 97310
VOLUME II
WP 125 00
Figure 1. Oil Cooler - GA101 (Before SB LM2500-IND-007) (Sheet 1 of 2)

3
GEK 97310
VOLUME II
WP 125 00
Figure 1. Oil cooler - GA101 (After SB LM2500-IND-007) (Sheet 2 of 2)

4
GEK 97310
VOLUME II
WP 126 00
WORK PACKAGE
REPLACEMENT OF FLAME SENSING SYSTEM
COMPONENTS
EFFECTIVITY: LM2500 GAS GENERATOR MODELS - ALL WITH OPTIONAL
FLAME SENSING KIT INSTALLED

1-5.......... 0 6 Blank . . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Installation of Flame Sensing System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Removal of Flame Sensing System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
WP 126 00
flame sensing systems components. Prior to performing the tasks described herein, remove fuel
manifolds, as required to gain access, per WP 123 00, SWP 123 01, SWP 123 02, SWP 123 03, or
SWP 123 04.
None

Safety Wire
4. REMOVAL OF FLAME SENSING SYSTEM COMPONENTS. See figure 1.
a. Remove bolts, washers, nuts and flanges securing flame sensors. Remove flame sensors.
NOTE
Note position of brackets to aid at assembly.
b. Remove bolts, washers and nuts securing brackets to compressor rear frame (CRF) mid
flange. Remove brackets.
c. Kits P/N 537L358-03 through -14 − Remove bolts and nuts securing flange stiffeners.
Remove flange stiffeners.
CAUTION
USE CAUTION WHEN REMOVING SIGHT ASSEMBLY TO
AVOID DAMAGING QUARTZ WINDOW.
d. Remove sight assembly and washer.

2
GEK 97310
VOLUME II
WP 126 00
Figure 1. Flame Sensing System Components (Sheet 1 of 2)

3
GEK 97310
VOLUME II
WP 126 00
Figure 1. Flame Sensing System Components (Sheet 2 of 2)

4
GEK 97310
VOLUME II
WP 126 00
5. INSTALLATION OF FLAME SENSING SYSTEM COMPONENTS. See figure 1.
CAUTION
USE CAUTION WHEN INSTALLING SIGHT ASSEMBLY TO
AVOID DAMAGING QUARTZ WINDOW.
a. Install washer and sight assembly. Torque sight assembly to 180-200 lb in.
(20.3-22.6 N·m). Safety-wire sight assembly.
b. Kits P/N 537L358-03 through -14 − Position right hand flange stiffener on compressor
rear frame (CRF) mid flange so that scribed line on forward side of flange stiffener is in line with
centerline of CRF No. 1 borescope boss. Ensure bolt holes in flange stiffener align with
holes 13 through 32 of CRF mid flange.
c. Kits P/N 537L358-03 through -14 − Install bolt, head forward, through flange stiffener
and hole No. 30 of CRF mid flange. Secure bolt with nut, tighten down, then back off nut one full
turn.
d. Kits P/N 537L358-03 through -14 − Position left hand flange stiffener on CRF mid flange
so that scribed line on forward side of flange stiffener is in line with centerline of CRF No. 5 bore-
scope boss. Ensure bolt holes in flange stiffener align with holes 157 through 176 in CRF mid
flange.
e. Kits P/N 537L358-03 thru -14 − Install five bolts, heads forward, through flange stiffener
and holes No. 160, 161, 162, 171 and 176 of CRF mid flange. Secure bolts with nuts, tighten
down, then back off nuts one full turn.
f. Install brackets on CRF mid flange per figure 1 and as noted at disassembly. Secure with
nuts, washers and bolts. Torque all bolts to 55-70 lb in. (6.2-7.9 N·m).
g. Install flame sensors. Secure with flanges, bolts, washers and nuts. Torque nuts to
55-70 lb in. (6.2-7.9 N·m).

5/(6 Blank)
GEK 97310
VOLUME II
WP 127 00
WORK PACKAGE
REPLACEMENT OF ACCESSORY GEARBOX

CARBON SEALS

1-7.......... 0 8 Blank . . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Installation of Accessory Gearbox Carbon Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Removal of Accessory Gearbox Carbon Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
WP 127 00
1. INTRODUCTION. This work package contains instructions for removing and installing
accessory gearbox carbon seals. Prior to performing the tasks described herein, remove starter
per WP 122 00, SWP 122 01, SWP 122 02, SWP 122 03 or SWP 122 04, or remove fuel pump per
WP 124 00, or remove variable stator vane (VSV) control per SWP 103 02, as required to gain
access.
2. APPLICABLE SUPPORT.

1C8182G01 Fixture Set, Mating Seal Removal

MIL-L-23699 Lubricating Oil
GE Spec A50TF142 Petrolatum
4. REMOVAL OF ACCESSORY GEARBOX CARBON SEALS. See figure 1.
a. Remove carbon face seal as follows:
(1) Unbend key washer (2) tabs.
NOTE
Seal retainer (3) is used at starter pad only.
(2) Remove bolts (1), key washers (2), and seal retainer (3). Discard key washers (2).
NOTE
Some seal configurations contain three removal slots on the inner
face of the flange midway between the boltholes. If these slots are
present, disregard step (3) below.
(3) Rotate seal (4) by inserting pin of offset driver, a component of fixture set,
1C8182G01, into bolthole of seal flange and tapping lightly with a hammer until seal tangs over-
lap the housing boss.

2
GEK 97310
VOLUME II
WP 127 00
Figure 1. Accessory Gearbox Carbon Seal Replacement

3
GEK 97310
VOLUME II
WP 127 00
CAUTION
USE CARE TO PREVENT COCKING SEAL OR DAMAGING
HOUSING DURING REMOVAL.
(4) Using pry bar, a component of fixture set, 1C8182G01, to apply leverage at seal (4)
flanges, lift seal from gearbox housing bore.
(5) Using seal pick, a component of fixture set, 1C8182G01, remove and discard
packing (5) from gearbox housing bore.
CAUTION
WHEN CARBON FACE SEAL IS REPLACED, THE MATING
SEAL RING AND PACKING MUST ALSO BE REPLACED.
b. Remove mating seal ring as follows. See figure 2.
NOTE
Tool numbers 1C8182P02 through P05 are for use at starter pad.
Tool numbers 1C8182P10 through P13 are for use at fuel pump and
VSV control pads. All are components of fixture set, 1C8182G01.
(1) Turn screw, PN 1C8182P06, counterclockwise to the end of its travel to retract
pusher plate, PN 1C8182P05 or P11, to expand.
(2) Slide the outer sleeve, PN 1C8182P04 or P12, back allowing the fingers of the inner
sleeve, PN 1C8182P03 or P10, to expand.
(3) Insert tool into the seal cavity until the plastic stop, PN 1C8182P02 or P13, contacts
the mating seal ring.
(4) Slide the outer sleeve over the inner sleeve, closing the flexible fingers over the mat-
ing seal ring.
(5) Using a 1/2-inch socket and a ratchet, or equivalent, turn screw clockwise until mat-
ing seal ring is pulled free of shaft.
(6) Remove tool and slide outer sleeve back to release the mating seal ring.
(7) Remove and discard packing (7, figure 1) from mating seal ring (6).

4
GEK 97310
VOLUME II
WP 127 00
Figure 2. Removal Tool, 1C8182
5. INSTALLATION OF ACCESSORY GEARBOX CARBON SEALS. See figure 1.
a. Install new mating seal ring as follows:
NOTE
Tool numbers 1C8182P07 through P08 are for use at starter pad.
Tool numbers 1C8182P14 through P15 are for use at fuel pump and
VSV control pads. All are components of fixture set, 1C8182G01.
(1) Lubricate new packing (7) with GE Spec A50TF142 petrolatum, and install into mat-
ing seal ring (6) packing groove.

5
GEK 97310
VOLUME II
WP 127 00
CAUTION
z TO PREVENT SEAL DAMAGE, ENSURE THAT THE
TANGS OF THE MATING SEAL RING FULLY ENGAGE
THE SLOTS OF THE BEARING INNER RACE. USE CAU-
TION TO PREVENT MATING SEAL RING SURFACE
FROM BECOMING SCRATCHED OR DAMAGED.
z CHILLING GEAR SHAFT AND HEATING MATING SEAL
RING WILL FACILITATE INSTALLATION AND HELP
KEEP PACKING FROM ROLLING. ROLLED PACKING
WILL PREVENT MATING SEAL RING FROM SEATING.
(2) Using arm 1C8182P07 or P14, and yoke, 1C8182P08 or P15, install new mating seal
ring (6) on shaft so that the tangs of the ring fully engage the slots of the bearing inner race.
b. Install new carbon face seal as follows:
(1) Lubricate new packing (5) with GE Spec A590TF142 petrolatum, and install in gear-
box housing bore.
(2) Lubricate internal elements of carbon face seal (4) with MIL-L-23699 lubricating oil,
then flex seal through its travel range several times to prevent excessive friction of internal
components.
(3) Apply light coat of MIL-L-23699 lubricating oil to seal face, seal housing outside
diameter, and face of mating seal ring.
NOTE
Guide pins may be locally fabricated by grinding heads off
#10-32 bolts.
(4) Install guide pins in gearbox housing inserts to align and seal tang boltholes with
inserts during installation.
CAUTION
z PRIOR TO INSTALLATION, ENSURE SEAL IS CLEAN
AND FREE OF DEBRIS.
z DURING SEAL INSTALLATION, ENSURE PACKING IS
NOT DISTURBED OR DAMAGED.
(5) Install seal (4) over guide pins and carefully push into housing until seal flange is
fully seated against face of housing. Remove guide pins.

6
GEK 97310
VOLUME II
WP 127 00
(6) At starter pad, install seal retainer (3).
CAUTION
ENSURE THAT PREBENT TABS OF THE KEY WASHER CON-
TACT COUNTERCLOCKWISE AGAINST THE TOP
RETAINER WITH ZERO CLEARANCE. DO NOT FORCE OR
DISTORT PREBENT TAB OF KEY WASHER INTO POSITION.
(7) Install new key washers (2) and bolts (1). See figure 3.
CAUTION
DO NOT LOOSEN BOLT TO POSITION A FLAT ON THE
BOLTHEAD ADJACENT TO THE TAB.
(8) Tighten bolts (1, figure 1) to 33-37 lb in. (3.7-4.1 N·m) of torque and determine if a
flat on the bolthead is adjacent to the tab of the key washer. If necessary, continue to tighten bolt
to a maximum of 45 lb in. (5.0 N·m) of torque until a flat on the bolthead is adjacent to the tab.
Bend tab into position.
Figure 3. Typical Key Washer Installation

7/(8 Blank)
GEK 97310
VOLUME II
WP 200 00
WORK PACKAGE
TRANSLATION OF GAS GENERATOR FROM

HORIZONTAL TO VERTICAL
(LEVEL 2 VERTICAL MAINTENANCE)

1-5.......... 0 6 Blank . . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Gas Generator Translation from Horizontal to Vertical . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Gas Generator Translation from Vertical to Horizontal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1
GEK 97310
VOLUME II
WP 200 00
1. INTRODUCTION. This work package contains instructions for turning the gas generator
from the horizontal (normal) position to the vertical position (with and without the turbine mid
frame installed) and back to the horizontal position after necessary tasks have been performed. To
accomplish the tasks described herein, the gas generator must be separated from the power turbine
per WP 220 00.
NOTE
Although the following level 2 maintenance procedure is intended
for the LM2500 G series gas generator models shown on the cover
of this work package, portions of or the complete maintenance pro-
cedure may also be applied to the LM2500GA101 gas generator
depending on configuration similarities. Should technical assis-
tance be required in determining the application of the following
procedure, contact:
Manager, Field Service

Customer Service & Product Support Department
Marine & Industrial Engine Division
General Electric Company
Mail Drop N155

1C5992 Lift Fixture, Turbine Mid Frame Engine Turnover
1C6803 Lift Fixture, Front Frame Gas Generator Turnover
1C6988G01 Lift and Turn Fixture, Gas Generator Aft
1C8027G01 Fixture, Dummy Turbine Mid Frame
None
4. GAS GENERATOR TRANSLATION FROM HORIZONTAL TO VERTICAL.
a. Remove outside piping, wiring and accessories as required to perform maintenance. Refer
to applicable work package of level 1 maintenance.
b. Remove power turbine assembly from gas generator per WP 220 00.

2
GEK 97310
VOLUME II
WP 200 00
c. If the turbine mid frame is installed, proceed to step d. If the turbine mid frame is not
installed, proceed to step e.
d. Turn gas generator, with turbine mid frame installed, from horizontal to vertical. See
figure 1.
(1) Attach 1C5992 lift fixture to aft flange of turbine mid frame.
(2) Attach 1C6803 lift fixture to compressor front frame at mount clevis
(12 o’clock position on frame).
(3) Adjust hoists to carry weight of gas generator.
(4) Carefully raise aft end of gas generator and turn to vertical position.
(5) Place gas generator forward end down in vertical stand. Secure forward flange of
front frame to stand.
(6) Remove 1C6803 lift fixture from front frame.
e. Turn gas generator, without turbine mid frame installed, from horizontal to vertical.
(1) Attach 1C8027G01 dummy turbine mid frame fixture to aft flange of compressor
rear frame.
(2) Attach 1C6988G01 lift and turn fixture to aft end of 1C8027G01 dummy fixture.
(4) Adjust hoists to carry weight of gas generator.
(5) Carefully raise aft end of gas generator and turn to vertical position.
(6) Place gas generator forward end down in vertical stand. Secure front flange of front
frame to stand.
(7) Remove 1C6988 and 1C8027 lift fixtures from compressor rear frame.
5. GAS GENERATOR TRANSLATION FROM VERTICAL TO HORIZONTAL.
a. Turn gas generator, with turbine mid frame installed, from vertical to horizontal. See
figure 1.

3
GEK 97310
VOLUME II
WP 200 00
Figure 1. Turning Gas Generator Horizontal to Vertical
(1) Attach 1C5992 lift fixture to aft flange of turbine mid frame.
(3) Attach hoists to lift fixtures.
(4) Lift gas generator with aft fixture.
(5) Carefully lift forward end of gas generator while lowering aft end.
(6) Place gas generator into horizontal rail supports. Secure to supports and remove lift
fixtures.
b. Turn gas generator, without turbine mid frame installed, from vertical to horizontal.
(1) Attach 1C8027G01 dummy turbine mid frame fixture to aft flange of compressor
rear frame.
(2) Attach 1C6988G01 lift and turn fixture to aft end of 1C8027G01 dummy fixture.

4
GEK 97310
VOLUME II
WP 200 00
(4) Attach hoists to lift fixtures.
(5) Lift gas generator with aft fixtures.
(6) Carefully lift forward end of gas generator while lowering aft end.
(7) Place gas generator into horizontal rail supports. Secure to supports and remove lift
fixtures.

5/(6 Blank)
GEK 97310
VOLUME II
WP 201 00
WORK PACKAGE
REPLACEMENT OF TURBINE MID FRAME

1 - 23 . . . . . . . . . 0 24 Blank . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Component Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation of Turbine Mid Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal of Turbine Mid Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1
GEK 97310
VOLUME II
WP 201 00
1. INTRODUCTION. This work package contains the instructions for the replacement of the
turbine mid frame. To accomplish the tasks described herein, the gas generator must have been
translated from the horizontal position to the vertical position per WP 200 00.

1C6988G02 Fixture, Gas Generator Lift and Turn
1C8011G01 Guide, TMF to HPTR
2C6148G01 Clamp Set, TMF Liner to TMF

A50TF54 Penetrating Oil, Liquid Wrench No. 1
MIL-T-5544 Anti-Seize Compound
VV-P-236 Soft White Petrolatum
4. REMOVAL OF TURBINE MID FRAME.
a. Remove turbine mid frame as follows (see figure 1):
(1) Remove four setscrews (1/8 inch Allen wrench) from threaded holes of turbine mid
frame front flange at approximately 2, 4, 8, and 10 o’clock positions. See figure 2.
(2) Attach hoist to lift and turn fixture, lC6988, and position lift fixture on aft flange of
turbine mid frame.
(3) Secure lift and turn fixture, 1C6988, to turbine mid frame using four threaded pins.
See figure 1. Finger-tighten threaded pins. Do not use hand tools.
(4) Remove all bolts and nuts securing turbine mid frame to compressor rear frame.
Install jackscrews into threaded holes located in aft side of turbine mid frame forward flange.

2
GEK 97310
VOLUME II
WP 201 00
Figure 1. Removal/Installation of Turbine Mid Frame
Figure 2. Installation of Setscrews - Compressor Rear Frame and Turbine Mid Frame
3
GEK 97310
VOLUME II
WP 201 00
WARNING
NOTE
Penetrating oil, WD-40, is not to be used on the gas turbine. Liquid
Wrench No. 1 is a suitable replacement.
(5) Very carefully raise hoist until turbine mid frame is clear of gas generator. If frame
tends to stick, use penetrating oil at forward flange and tap lightly with a plastic mallet.
(6) Install six clamps of clamp set, 2C6148, approximately equally spaced, to forward
outer flange of frame to hold liner axially in place.
CAUTION
FAILURE TO COMPLY WITH INSTRUCTIONS CONTAINED
IN VOLUME I, CHAPTER 5, OF THIS MANUAL CAN RESULT
IN BEARING FAILURE.
(7) Protect exposed bearings per Volume I, Chapter 5, of this manual.
(8) Install protective covers on front and rear of frame.
(9) Place frame on worktable and remove lift and turn fixture, 1C6988.
5. INSTALLATION OF TURBINE MID FRAME.
a. Install turbine mid frame as follows (see figure 1):
(1) Attach hoist to lift and turn fixture, 1C6988, and position lift fixture on aft flange of
turbine mid frame.
(2) Secure lift and turn fixture, 1C6988, to turbine mid frame using four threaded pins.
See figure 1. Tighten pins using fingers only, do not use hand tools.
(a) Install guide, 1C8011, to high pressure turbine (HPT) rotor shaft.
(3) Apply a light coating of soft white petrolatum, VV-P-236, to hold No. 5 rollers in
most outward position.

4
GEK 97310
VOLUME II
WP 201 00
WARNING
CAUTION
EXERCISE EXTREME CARE WHEN LOWERING MID
FRAME TO GAS GENERATOR TO PREVENT DAMAGE TO
SEALS OR BEARINGS. MAKE CERTAIN STAGE-2 HIGH
PRESSURE TURBINE NOZZLE SUPPORT REMAINS IN
PROPER POSITION.
(4) Raise frame into position above compressor rear frame (CRF) and very carefully
lower into place. Exercise care as No. 5 bearing goes over turbine rotor rear stubshaft.
(5) Remove clamp set, 2C6148, from forward outer flange of turbine mid frame.
(6) Align top vertical centerline of turbine mid frame with top vertical centerline of gas
generator. Make certain turbine mid frame is properly aligned, then use a drift pin in top vertical
centerline bolthole to properly align holes.
CAUTION
ANTISEIZE COMPOUND, MIL-T-5544. USE OF UNAUTHO-
RIZED LUBRICANT ON BOLT/NUT THREADS CAN CAUSE
SULFIDATION ATTACK AND PREMATURE FAILURES.
(7) Lubricate bolt threads lightly with anti-seize compound, MIL-T-5544.

(8) Install approximately every 6th bolt, from forward side, and secure with nuts.
Tighten but do not torque.
(9) Remove lift and turn fixture, 1C6988, and hoist from aft flange of turbine mid frame.
CAUTION
(10) Lubricate circumferential flange bolt threads lightly with anti-seize compound,
MIL-T-5544.

5
GEK 97310
VOLUME II
WP 201 00
(11) Install bolts (heads forward) in all circumferential holes except where brackets will
be attached. See figure 3. Install nuts and tighten snug, but do not torque.
(12) Install four setscrews into threaded holes of compressor rear frame aft flange and
four setscrews into threaded holes of turbine mid frame front flange at approximately 2, 4, 8, and
10 o’clock positions (see figure 2). Secure setscrews with square washers held in place by bolts
and nuts except at bracket (6, figure 3) location.
(13) Install all remaining circumferential flange bolts and brackets. See figure 3 for
bracket locations. Install all bolts from forward side and secure with nuts.
NOTE
The number of brackets and locations installed at the turbine mid
frame aft flange differs due to the type of thermocouple harness
installed. Select sheet 1 or 2 as appropriate for the configuration
being used.
Mount Bracket To Side of Flange With Tab Facing
1 Aft Fwd
2 Aft Fwd
3 Fwd Fwd
4 Fwd Fwd
5 Fwd Fwd
6 Aft Fwd
Install square
7 Fwd Fwd washer under nut to
8 Fwd Fwd cover setscrew.
(See figure 2.)
9 Fwd Fwd
10 Fwd Fwd
11 Fwd Fwd
12 Fwd Fwd
13 Aft Fwd
14 Aft Fwd
(14) Tighten all circumferential flange bolts to 160-180 lb in. (18.1-20.3 N·m) of torque.

6
GEK 97310
VOLUME II
WP 201 00
Figure 3. Turbine Mid Frame to Compressor Rear Frame Brackets (Early Configuration)
(Sheet 1 of 2)

7
GEK 97310
VOLUME II
WP 201 00
Figure 3. Turbine Mid Frame to Compressor Rear Frame Brackets (Later Configuration)
(Sheet 2 of 2)

8
GEK 97310
VOLUME II
WP 201 00
6. COMPONENT INSPECTION. Inspect turbine mid frame and C-sump area per table 1. and
NOTE
Refer to WP 221 00 for sump components.
Table 1. TURBINE MID FRAME
On-Site On-Site
CASE
1. Specific Areas to be Inspected for Cracks:
a. Indications in weld/heat affected zone areas are acceptable with the following
limitations:
- Indications must be than 0.10 in. (2.5 mm) maximum length.
- Indications confined to weld or heat affected zone within 0.10 in. (2.5 mm) of weld line.
- Indications transverse to weld line in heat affected zone.
- Minimum spacing between indications is two times maximum adjacent indication
dimension.
b. Indications in parent metal (outside weld/heat affected zone) are acceptable with the
following limitations:
- Indications 0.030-0.060 in. (0.76-1.52 mm) long and not interpreted as cracks are
allowed.
dimension.
2. Hat Sections (Fore and Aft) for:
a. Fillet weld Not serviceable in Not repairable Replace frame*
cracks excess of limits in
item 1 above
b. Seam weld Not seviceable in Not repairable Replace frame*
cracks excess of 2.0 in.
(51 mm) per segment

9
GEK 97310
VOLUME II
WP 201 00
Table 1. TURBINE MID FRAME - Continued
On-Site On-Site
c. Parent metal Not serviceable in Not repairable Replace frame*

(neutral areas item 1 above
only)
3. Forward Flange for:
a. Circumferential Not seviceable Not repairable Replace frame*
weld cracks
4. Aft Flange for:
a. Circumferential Not serviceable Not repairable Replace frame*
weld cracks
5. Casing/Strut Pads and Casing/Link Mount Pads for:
a. Butt weld Not seviceable Not repairable Replace frame*
cracks
6. Instrumentation (Thermocouple and Engine Pressure Ratio) Bosses for:
a. Cracks One crack, 0.250 in. Not repairable Replace frame*
(6.35 mm) long. One
boss per frame may be
cracked
b. Thread Not serviceable One complete thread Chase threads
damage may be removed
7. All Other Casing Areas for:
a. Axial welds/ Not serviceable Not repairable Replace frame*
parent metal
cracks

10
GEK 97310
VOLUME II
WP 201 00
On-Site On-Site
b. Nicks, scores, Any numbe, any Not repairable Replace frame*

and scratches length, 0.0156 in.
removal of high
metal, provided
defects do not cross
completely across
sealing surface
c. Dents Any number smooth Not repairable Replace frame*
contour dents,
0.250 in. (6.35 mm)
deep, except on inter-
face sealing surface
d. Local Any number, 0.20 in. Not repairable Replace frame*
distortion (5.1 mm) deep except
on interface sealing
surface
8. Case Strut Pads for:
a. Cracks Not serviceable Not repairable Replace frame*
b. Bent lugs Not serviceable Not repairable Replace frame*
LINER
1. All Surfaces (Unless Otherwise Specified) for:
a. Cracks in skin Any number not Not repairable Replace frame*
(no separation exceeding 2.0 in.
through aft (51 mm) length and
ring) not joining with
adjacent cracks.
Monitor for crack
propagation by
borescope inspection
at each opportunity
but not later than
500 hours of
operation

11
GEK 97310
VOLUME II
WP 201 00
On-Site On-Site
b. Missing Not serviceable Not repairable Replace frame*

material
c. Buckling or Any amount, 0.250 in. Not repairable Replace frame*
distortion (6.35 mm) from origi-
nal contour, 0.125 in.
(3.18 mm) buckles on
leading edge
d. Nicks, scores, Any number, any Not repairable Replace frame*
e. Dents Any number smooth Not repairable Replace frame*
contour dents,
0.250 in. (6.35 mm)
deep, except on seal-
ing surface or surface
evidencing hot spots
f. Hot spots Serviceable if metal Not repairable Replace frame*
not crazed
g. Wear on ID of 50 percent of stock Not repairable Replace frame*
fairing thickness
2. Inner Rear Seal for:
a. Gap at seal Any amount provided Any amount Re-form seal
fishmouth 0.55 in. (14.0 mm)
opening minimum gap exists
b. Loose or Not serviceable Replace rivets
missing rivets
3. Liner Deflectors for:
a. Missing Not serviceable Not repairable Replace frame*
deflector

12
GEK 97310
VOLUME II
WP 201 00
On-Site On-Site
b. Cracked or Not serviceable Not repairable Replace frame*

broken
deflector
4. Liner Beams for:
a. Missing pieces Any amount, beam Any amount Replace frame*
of insulation gap within limits
blanket
b. Beam gap 0.060 in. (1.52 mm) Any amount Replace frame*
between pins
at aft end of
beam and liner
ring
STRUT END CAPS
1. Visible damage to Not serviceable Not repairable Replace frame*
gasket or loss of
gasket material
2. Flanges (Cap and Tube) and Cap Lugs for:
a. Distortion,
out-of-flat
flange, and
bent cap lugs
LINER SUPPORT
1. All Areas Unless Otherwise Specified for:
a. Cracks
Inner support Not serviceable Not repairable Replace frame*
Outer support Accept one crack per Not repairable Replace frame*
bolthole, 0.50 in.
(12.7 mm) long,
provided cracked
boltholes are
separated by one
uncracked hole

13
GEK 97310
VOLUME II
WP 201 00
On-Site On-Site

c. Dents Any number smooth Replace frame*
contour dents,
0.125 in. (3.18 mm)
(sealing) surface
2. Liner Support Stops (for Stage 2 HPT Shroud) for:
b. Missing stops Maximum of 44 stops Not repairable Replace frame*
may be missing
provided no more
than six are adjacent
c. Bent Not serviceable Not repairable Replace frame*
3. Swaged Bushing for:
b. Wear at strut Local fretting or Local fretting or Replace frame*
pad/case holes grooving up to grooving up to
0.010 in. (0.25 mm) 0.010 in. (0.25 mm)
deep deep
c. Pickup and Not serviceable Any amount Remove high metal
high metal using file or stone

14
GEK 97310
VOLUME II
WP 201 00
On-Site On-Site
4. No. 5 and 6 Bearing Housing Bore for:

a. Wear No. 5 bearing Not repairable Replace frame*
7.5520 in.
(191.821 mm) dia.
No 6. bearing
7.8331 in.
(198.961 mm) dia.
Bore must be within
limits over entire axial
length. Use 8 point
diameter check
b. Surface Same as above Not repairable Replace frame*
damage
NOZZLE SUPPORT (TOROID)
1. All Surfaces ( Unless Otherwise Specified) for:
a. Cracks Not serviceable Replace frame*
contour dents,
0.125 in. (3.18 mm)
deep
2. Cone for:
a. Missing or Not serviceable Tighten loose and
loose replace missing
cone-to-seal rivets
support rivets

15
GEK 97310
VOLUME II
WP 201 00
On-Site On-Site
3. Seal for:
a. Distortion Any amount provided Any amount Re-form
mating part can be
assembled
b. Wear 50 percent of stock Not repairable Replace frame*
thickness
4. Safety-Wire Tabs for:
a. Broken/ Not serviceable Replace frame*
missing
POWER TURBINE STAGE 1 NOZZLE AIR SEAL
1. Flange for:
a. Cracks One crack per bolt- Replace seal
hole from hole to
outer edge of flange;
maximum of 12 holes.
No more than three
holes in a row with
cracks. No missing
pieces allowed
b. Nicks, dents, Any number, 0.020 in.
and scratches (0.51 mm) deep after
c. Wear 0.005 in. (0.13 mm) 0.010 in. (0.25 mm) Blend smooth
deep deep
d. Distortion 0.020 in. (0.51 mm)
out-of-contour
maximum of 2.0 in.
(51 mm) in individual
area, total not to
exceed 10.0 in.
(254 mm) provided
proper assembly can
be accomplished

16
GEK 97310
VOLUME II
WP 201 00
On-Site On-Site
2. Backing Strip for

a. Cracks Any number axial Replace seal
cracks 0.50 in.
(12.7 mm) long and
1.0 in. (25 mm) apart,
not across edge
b. Nicks, dents, Any number, 0.020 in.
and scores (0.51 mm) deep
c. Distortion 0.0625 in. (1.588 mm)
out-of-contour,
maximum of 4.0 in.
(102 mm) in
individual area, total
not to exceed 20.0 in.
(508 mm), provided
proper assembly can
be accomplished
3. Honeycomb for:
a. Wear Track not to exceed Replace seal
0.150 in. (3.81 mm)
maximum depth, any
width. Track may run
off end of honeycomb
b. Damage Not to exceed 10
caused by percent of total
foreign circumferential
objects or length, 25 percent of
handling honeycomb width,
and not into backing
strips after removal of
folded edges
c. Loose or Not serviceable
unbonded cells

17
GEK 97310
VOLUME II
WP 201 00
On-Site On-Site
POWER TURBINE STAGE 1 NOZZLE SUPPORT

1. Ring for:
a. Axial and Any number, any Not repairable Replace support
radial cracks length in axial or
radial direction.
Radial cracks may
sever support
provided each
remaining segment
contains a minimum
of two countersunk
screw holes used to
mount nozzle support
of turbine mid frame
b. Circumferential Not serviceable
cracks
c. Distortion Acceptable if proper
assembly can be made
d. Nicks and Any number, 0.0312
scores in. (0.792 mm) deep.
Remove high metal
e. Dent Any number,
0.0312 in. (0.792 mm)
deep
f. Wear 0.010 in. (0.25 mm) 0.020 in. (0.51 mm) Blend smooth
deep on OD of axial deep on OD of axial
flange, 0.095 in. flange
(2.41 mm) minimum
flange thickness
2. Pins for:
a. Loose or Not serviceable
missing
b. Bent Not serviceable Any amount Straighten pin

18
GEK 97310
VOLUME II
WP 201 00
On-Site On-Site
POWER TURBINE STATOR STAGE 1 NOZZLE INNER RETAINER

1. All Areas for:
a. Cracks Not serviceable Replace retainer
b. Nicks, scores, Any number, 0.010 in.
and scratches (0.25 mm) deep after
c. Bent Not serviceable Any amount Mechanically
straighten
*May be repairable, consult GE for disposition of replaced parts

19
GEK 97310
VOLUME II
WP 201 00
Figure 4. Turbine Mid Frame (Sheet 1 of 2)

20
GEK 97310
VOLUME II
WP 201 00

21
GEK 97310
VOLUME II
WP 201 00
Figure 5. Turbine Mid Frame Case Fluorescent-Penetrant Inspection Areas

22
GEK 97310
VOLUME II
WP 201 00
Figure 6. Turbine Mid Frame Casing-to-Casing Butt Weld Areas
Figure 7. Turbine Mid Frame Liner Inner Rear Seal and Nozzle Support (Toroid)
23/(24 Blank)
GEK 97310
VOLUME II
SWP 201 01
REPLACEMENT OF TURBINE MID FRAME

1 - 19 . . . . . . . . . 0 20 Blank . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Component Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation of Turbine Mid Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal of Turbine Mid Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1
GEK 97310
VOLUME II
SWP 201 01
1. INTRODUCTION. This subordinate work package contains instructions for the replace-
ment of the turbine mid frame. To accomplish the tasks described herein, the gas generator must
be translated from the horizontal position to the vertical position per WP 200 00.
NOTE
Although the following level 2 maintenance procedure is intended
for the LM2500 G series gas generator models shown on the cover
of this work package, portions of or the complete maintenance pro-
cedure may also be applied to the LM2500GA101 gas generator,
depending on configuration similarities. Should technical assis-
tance be required in determining the application of the following
procedure, contact:
Manager, Field Service

Customer Service & Product Support Department
Marine & Industrial Engine Division
General Electric Company
Mail Drop N155

1C6988G02 Fixture, Gas Generator Lift and Turn
1C8011G01 Guide, Turbine Mid Frame to High Pressure Turbine Rotor
2C6148G01 Clamp Set, Turbine Mid Frame Liner to Turbine Mid Frame

A50TF54 Penetrating Oil, Liquid Wrench No. 1
MIL-T-5544 Compound, Anti-Seize
VV-P-236 Petrolatum, Soft White

2
GEK 97310
VOLUME II
SWP 201 01
4. REMOVAL OF TURBINE MID FRAME.
a. Remove turbine mid frame as follows (see figure 1):
(1) Remove four setscrews (1/8 inch Allen wrench) from threaded holes of turbine mid
frame front flange at approximately 2, 4, 8, and 10 o’clock positions. See figure 2.
(2) Attach hoist to lift and turn fixture, 1C6988, and position fixture on aft flange of tur-
bine mid frame.
(3) Secure lift and turn fixture, 1C6988, to turbine mid frame using four threaded pins
provided. See figure 1. Secure threaded pins finger-tight. Do not use hand tools.
(4) Remove all nuts and bolts securing turbine mid frame to compressor rear frame
(CRF). Install four lubricated jackscrews, into threaded holes in forward side of CRF aft flange.
WARNING
NOTE
Penetrating oil WD-40 is not to be used on the gas generator. Liq-
uid Wrench No. 1 is a suitable replacement.
(5) Carefully raise hoist until turbine mid frame is clear of gas generator. If frame tends
to stick, use penetrating oil at forward flange and tap lightly with a plastic mallet.
(6) Install clamp set, 2C6148, to forward outer flange of frame to hold liner axially in
place. Ensure six clamps are equally spaced.
CAUTION
FAILURE TO COMPLY WITH INSTRUCTIONS CONTAINED
IN VOLUME I, CHAPTER 5, OF THIS MANUAL CAN RESULT
IN BEARING FAILURE.
(7) Protect exposed bearings per Volume I, Chapter 5, of this manual.
(8) Install protective covers on front and rear of turbine mid frame.
(9) Place turbine mid frame on worktable and remove lift and turn fixture, 1C6988.

3
GEK 97310
VOLUME II
SWP 201 01
Figure 1. Removal/Installation of Turbine Mid Frame
Figure 2. Installation of Setscrews - Compressor Rear Frame and Turbine Mid Frame

4
GEK 97310
VOLUME II
SWP 201 01
5. INSTALLATION OF TURBINE MID FRAME.
a. Install turbine mid frame as follows (see figure 1):
(1) Attach hoist to lift and turn fixture, 1C6988, and position fixture on aft flange of
turbine mid frame.
(2) Secure lift and turn fixture, 1C6988, to turbine mid frame using four threaded pins
provided. See figure 1. Secure threaded pins finger-tight. Do not use hand tools.
(a) Install guide, 1C8011, to high pressure turbine (HPT) rotor shaft.
(3) Apply a light coating of soft white petrolatum, VV-P-236, to hold No. 5 rollers in
most outward position.
WARNING
CAUTION
EXERCISE EXTREME CARE WHEN LOWERING TURBINE
MID FRAME TO GAS GENERATOR TO PREVENT DAMAGE
TO SEALS OR BEARINGS. ENSURE STAGE 2 HPT NOZZLE
SUPPORT REMAINS IN PROPER POSITION.
(4) Raise turbine mid frame into position above CRF and carefully lower into place.
Exercise care as No. 5 bearing goes over turbine rotor rear stubshaft.
(5) Remove clamp set, 2C6148, from forward outer flange of turbine mid frame.
(6) Align top vertical centerline of turbine mid frame with top vertical centerline of gas
generator. Ensure turbine mid frame is properly aligned. Use a drift pin in top vertical centerline
bolthole to properly align holes.

5
GEK 97310
VOLUME II
SWP 201 01
CAUTION
(7) Lubricate bolt threads lightly with anti-seize compound, MIL-T-5544.
(8) Install approximately every 6th bolt, from forward side, and secure with nuts.
Hand-tighten nuts.
(9) Remove lift and turn fixture, 1C6988, and hoist from aft flange of turbine mid frame.
CAUTION
(10) Lubricate circumferential flange bolt threads lightly with anti-seize compound,
MIL-T-5544.
(11) Install bolts (heads forward) in all circumferential holes except where brackets will
be attached. See figure 3. Install nuts and tighten snug. Do not torque.
(12) Install four setscrews into threaded holes of compressor rear frame aft flange and
four setscrews into threaded holes of turbine mid frame front flange at approximately 2, 4, 8, and
10 o’clock positions. See figure 2. Secure setscrews with square washers held in place by bolts
and nuts.
(13) Install all remaining circumferential flange bolts and brackets. See figure 3 for
bracket locations. Install all bolts from forward side and secure with nuts.
(14) Tighten all circumferential flange bolts to 160-180 lb in. (18.1-20.3 N·m) of torque.

6
GEK 97310
VOLUME II
SWP 201 01
Figure 3. Turbine Mid Frame to Compressor Rear Frame Brackets (Typical)

7
GEK 97310
VOLUME II
SWP 201 01
Mount Bracket With Tab of Flange With Tab Facing
18 Fwd Fwd
5 Fwd Fwd
7 Fwd Fwd
Install square
8 Fwd Fwd washer under nut to
9 Fwd Fwd cover setscrew. See
figure 2.
11 Fwd Fwd
12 Fwd Fwd
13 Fwd Fwd
6. COMPONENT INSPECTION. Inspect turbine mid frame and C-sump area per table 1 and
NOTE
Refer to WP 221 00 for sump components.
Table 1. TURBINE MID FRAME
On-Site On-Site
CASE
1. Specific Areas to be Inspected for Cracks:
a. Indications in weld/heat affected zone areas are acceptable with the following
limitations:
- Indications confined to weld or heat affected zone within 0.10 in. (2.5 mm) of weld line.
b. Indications in parent metal (outside weld/heat affected zone) are acceptable with the
following limitations:

8
GEK 97310
VOLUME II
SWP 201 01
On-Site On-Site
- Indications 0.030-0.060 in. (0.76-1.52 mm) long and not interpreted as cracks are
allowed.
dimension.
2. Hat Sections (Fore and Aft) for:
a. Fillet weld Not serviceable in Not repairable Replace frame*
item 1 above
b. Seam weld Not seviceable in Not repairable Replace frame*
cracks excess of 2.0 in.
(51 mm) per segment
c. Parent metal Not serviceable Not repairable in Replace frame*
cracks (neutral areas only) excess of limits in 1
above
3. Forward Flange for:
a. Circumferential Not seviceable Not repairable Replace frame*
weld cracks
4. Aft Flange for:
a. Circumferential Not serviceable Not repairable Replace frame*
weld cracks
5. Casing/Strut Pads and Casing/Link Mount Pads for:
a. Butt weld Not seviceable Not repairable Replace frame*
cracks
6. Instrumentation (Thermocouple and Engine Pressure Ratio) Bosses for:
a. Cracks One crack, 0.25 in. Not repairable Replace frame*
(6.4 mm) long. One
boss per frame may be
cracked
b. Thread Not serviceable One complete thread Chase threads
damage may be removed

9
GEK 97310
VOLUME II
SWP 201 01
On-Site On-Site
7. All Other Casing Areas for:

a. Axial welds/ Not serviceable Not repairable Replace frame*
parent metal
cracks
b. Nicks, scores, Any number, any Not repairable Replace frame*
removal of high
metal, provided
defects do not
completely cross seal-
ing surface
c. Dents Any number smooth Not repairable Replace frame*
contour dents 0.25 in.
(6.4 mm) deep, except
surface
d. Local Any number 0.20 in. Not repairable Replace frame*
distortion (5.1 mm) deep except
surface
8. Case Strut Pads for:
b. Bent lugs Not serviceable Not repairable Replace frame*

10
GEK 97310
VOLUME II
SWP 201 01
On-Site On-Site
LINER
a. Cracks in skin Any number not Not repairable Replace frame*
(no separation exceeding 2.0 in.
through aft (51 mm) length and
ring) not joining with adja-
cent cracks. Monitor
for crack propagation
by borescope inspec-
tion at each opportu-
nity but not later than
500 hours of
operation
b. Missing Not serviceable Not repairable Replace frame*
material
c. Buckling or Any amount, 0.25 in. Not repairable Replace frame*
distortion (6.4 mm) from origi-
nal contour, 0.125 in.
(3.18 mm) buckles on
leading edge
d. Nicks, scores, Any number, any Not repairable Replace frame*
e. Dents Any number smooth Not repairable Replace frame*
contour dents, 0.25 in.
(6.4 mm) deep, except
on sealing surface or
surface evidencing
hot spots
f. Hot spots Serviceable if metal Not repairable Replace frame*
not crazed
g. Wear on ID of 50 percent of stock Not repairable Replace frame*
fairing thickness

11
GEK 97310
VOLUME II
SWP 201 01
On-Site On-Site
2. Inner Rear Seal for:

a. Gap at seal Any amount provided Any amount Re-form seal
fishmouth 0.55 in. (14.0 mm)
opening minimum gap exists
b. Loose or Not serviceable Replace rivets
missing rivets
3. Liner Deflectors for:
a. Missing Not serviceable Not repairable Replace frame*
deflector
b. Cracked or Not serviceable Not repairable Replace frame*
broken
deflector
4. Liner Beams for:
a. Missing pieces Any amount, beam set Any amount Replace frame*
of insulation within limits
blanket
b. Beam gap 0.060 in. (1.52 mm) Any amount Replace frame*
between pins
at aft end of
beam and liner
ring
STRUT END CAPS
1. Visible damage to Not serviceable Not repairable Replace frame*
gasket or loss of
gasket material
2. Flanges (Cap and Tube) and Cap Lugs for:
a. Distortion, Not serviceable Not repairable Replace frame*
out-of-flat
flange, and
bent cap lugs

12
GEK 97310
VOLUME II
SWP 201 01
On-Site On-Site
LINER SUPPORT
1. All Areas Unless Otherwise Specified for:
a. Cracks
Inner support Not serviceable Not repairable Replace frame*
Outer support Accept one crack per Not repairable Replace frame*
bolthole 0.50 in.
(12.7 mm) long,
provided cracked
boltholes are
separated by one
uncracked hole
c. Dents Any number smooth Replace frame*
contour dents,
0.125 in. (3.18 mm)
(sealing) surface
2. Liner Support Stops (for Stage 2 HPT Shroud) for:
b. Missing stops Maximum of 44 stops Not repairable Replace frame*
may be missed
provided no more
than six are adjacent
c. Bent Not serviceable Not repairable Replace frame*
3. Swaged Bushing for:

13
GEK 97310
VOLUME II
SWP 201 01
On-Site On-Site
b. Wear at strut Local fretting or Local fretting or Replace frame*

pad/case holes grooving up to grooving up to
0.010 in. (0.25 mm) 0.010 in. (0.25 mm)
deep deep
c. Pickup and Not serviceable Any amount Remove high metal
high metal using fine file or
stone
4. No. 5 Bearing Housing Bore for:
a. Wear No. 5 bearing Not repairable Replace frame*
7.5520 in.
(191.821 mm) dia.
Bore must be over
entire axial length.
Use 8-point diameter
b. Surface Same as above Not repairable Replace frame*
damage
NOZZLE SUPPORT (TOROID)
a. Cracks Not serviceable Replace frame*
contour dents,
0.125 in. (3.18 mm)
deep
2. Cone for:
a. Missing or Not serviceable Tighten loose and
loose replace missing
cone-to-seal rivets
support rivets

14
GEK 97310
VOLUME II
SWP 201 01
On-Site On-Site
3. Seal for:
a. Distortion Any amount provided Any amount Re-form
mating part can be
assembled
b. Wear 50 percent of stock Not repairable Replace frame*
thickness
4. Safety-Wire Tabs for:
a. Broken/ Not serviceable Replace frame*
missing
*May be repairable, consult GE for disposition of replaced parts

15
GEK 97310
VOLUME II
SWP 201 01

16
GEK 97310
VOLUME II
SWP 201 01

17
GEK 97310
VOLUME II
SWP 201 01
Figure 5. Turbine Mid Frame Case Fluorescent-Penetrant Inspection Areas
Figure 6. Turbine Mid Frame Casing-to-Casting Butt Weld Area

18
GEK 97310
VOLUME II
SWP 201 01
Figure 7. Turbine Mid Frame Liner Inner Rear Seal and Nozzle Support (Toroid)

19/(20 Blank)
GEK 97310
VOLUME II
WP 202 00
WORK PACKAGE
REPLACEMENT OF HPT TWIN SHANK

ROTOR/STAGE 2 NOZZLE ASSEMBLY

1 - 91 . . . . . . . . . 0 92 Blank . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Inspection of HPT Twin Shank Rotor and Stage 2 Nozzle Assembly. . . . . . . . . . . . . . . . . . 34

Installation of HPT Twin Shank Rotor and Stage 2 Nozzle Assembly . . . . . . . . . . . . . . . . . 25
Installation of Stage 2 HPT Nozzle Assembly on HPT Rotor. . . . . . . . . . . . . . . . . . . . . . . . 23
Parts Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Parts Replacement - HPT Twin Shank Rotor Stage 1 Blade Pairs . . . . . . . . . . . . . . . . . . . . 73
Parts Replacement - HPT Twin Shank Rotor Stage 2 Blade Pairs . . . . . . . . . . . . . . . . . . . . 81
Parts Replacement - Stage 2 HPT Nozzle Segments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Removal of HPT Twin Shank Rotor and Stage 2 Nozzle Assembly. . . . . . . . . . . . . . . . . . . 3
Removal of Stage 2 HPT Nozzle Assembly from HPT Twin Shank Rotor . . . . . . . . . . . . . 22

1
GEK 97310
VOLUME II
WP 202 00
1. INTRODUCTION. This work package contains the instructions for the replacement of the
HPT twin shank rotor and stage 2 nozzle assembly. Also contained herein are instructions for the
removal, installation, inspection/repair and component replacement where applicable. To accom-
plish the tasks described herein, the gas generator must be separated from the power turbine and
translated from the horizontal position to the vertical position per WP 200 00, and the turbine mid
frame removed per WP 201 or SWP 201 01.

1C5937 Gage, Concentricity - No. 5 Bearing Inner Race
1C5964 Sling, Lift - High Pressure Turbine Twin Shank Stage 2
1C6804 Jackscrews
1C6950 Wrench - Horizontal/Vertical HPT Twin Shank Nut
(Alt Tool - 2C6062)
1C8059 Stand - Vertical - High Pressure Turbine Twin Shank Rotor EMU
2C6058 Wrench, Spanner - Oil Tube HPT Rotor
2C6063 Puller, Retainer Ring - No. 5 Bearing
2C6084 Wrench, Spanner Nut, No. 5 Bearing
2C6187 Fixture Lift - HPTR Vertical
2C6341 Wrench, Spanner, Hand Runup
2C6563 Tool Installation/Removal - Damper Sleeve
2C6610 Pins, Guide (or locally manufactured)
9470M55G01 Program, Balance - Blade Installation/Replacement
(Snap on CJ93A) Puller (or equivalent) - Stage 2 Nozzle Air Tubes
(Alt tool - 2C6623)

P-D-680 Cleaning Solvent
MIL-L-23699 Gas Turbine Lube Oil
Prussian Blue
Masking Tape
R297P04 Safety Wire

2
GEK 97310
VOLUME II
WP 202 00

Adhesive No. 77 or No. 1870 (3M Co.)
Petrolatum
Liquid Wrench No. 1 Penetrating Oil
DX100 Dykem
Plastic Bags
4. REMOVAL OF HPT TWIN SHANK ROTOR AND STAGE 2 NOZZLE ASSEMBLY.

See figures 1 - 11.
a. The removal portions of the following work packages must be accomplished before
removal of the HPT/stage 2 nozzle assembly.
(1) WP 201 00 or SWP 201 01 - Replacement of Turbine Mid Frame.
(2) WP 220 00 - Removal/Reinstallation of Power Turbine Assembly.
(3) WP 221 00 - Inspection and Replacement of Miscellaneous Sump Components.
(4) WP 400 00 or SWP 400 01 - Assembly Clearances and Drawings.
b. A distance of 1.6-1.8 meters will be needed to remove HPT rotor/stage 2 nozzle assembly.
CAUTION
BOTH STAGE 1 AND 2 NOZZLE BORESCOPE PLUGS MUST
BE REMOVED PRIOR TO REMOVING STAGE 2 NOZZLE
ASSEMBLY FROM ENGINE. STAGE 1 BORESCOPE PLUG
PASSES THROUGH SCREEN ASSEMBLY ON STAGE 2
NOZZLE ASSEMBLY. SCREEN ASSEMBLY WILL BE DAM-
AGED IF REMOVAL OF NOZZLE ASSEMBLY IS
ATTEMPTED PRIOR TO REMOVAL OF PLUGS.
NOTE
If same parts are to be reinstalled, matchmark HPT rotor/stage 2
nozzle assembly to compressor rear frame flange and all other parts
before they are removed to ease reinstallation.
c. Remove stage 1 and 2 nozzle borescope plugs and washers from compressor rear frame.
Plugs are located at approximately 3 o’clock position near rear of frame (aft looking forward).

3
GEK 97310
VOLUME II
WP 202 00
Figure 1. Removal/Installation of High Pressure Turbine Twin Shank Rotor and

Stage 2 Nozzle Assembly (Sheet 1 of 2)
4
GEK 97310
VOLUME II
WP 202 00
Figure 1. Removal/Installation of High Pressure Turbine Twin Shank Rotor and

Stage 2 Nozzle Assembly (Sheet 2 of 2)

5
GEK 97310
VOLUME II
WP 202 00
Figure 2. Location of Setscrews – Compressor Rear Frame and Turbine Mid Frame

6
GEK 97310
VOLUME II
WP 202 00
Figure 3. High Pressure Turbine Twin Shank Rotor and Stage 2 Nozzle Installation

7
GEK 97310
VOLUME II
WP 202 00
Figure 4. Removal/Installation of No. 5 Bearing Spanner Nut Using 2C6084 Wrench

8
GEK 97310
VOLUME II
WP 202 00
Figure 5. Removal of Keyed Retaining Ring Using 2C6063 Puller
Figure 6. Removal/Installation of HPT Oil Tube Using 2C6058 Wrench

9
GEK 97310
VOLUME II
WP 202 00
Figure 7. Removal/Installation of Damper Sleeve Using 2C6563

10
GEK 97310
VOLUME II
WP 202 00
Figure 8. High Pressure Turbine Twin Shank Rotor 2C6187 Lift Fixture and
1C6950 Coupling Nut Wrench
11
GEK 97310
VOLUME II
WP 202 00
Figure 9. Twin Shank HPT Coupling Nut Spanner Wrench Fixture 1C6950
Figure 10. Stage 2 High Pressure Turbine Nozzle Guide Pins, 2C6610

12
GEK 97310
VOLUME II
WP 202 00
Figure 11. Pressure Turbine Rotor Twin Shank High Vertical Stand, 1C8059
d. Using an Allen wrench, remove four setscrews from forward face of compressor rear
frame rear flange at 2, 4, 8, and 10 o’clock positions. See figure 2.
NOTE
Place suitable cover on/around HPT/Stage 2 nozzle assembly to
prevent dropping No. 5 bearing spanner nut pin (2, figure 1) into
gas generator.
e. Remove retaining ring (8, figure 3) and pin (9) which secure No. 5 bearing spanner
nut (7), from inside turbine rotor rear stub-shaft. Use needle nose pliers or screwdriver. Place
retaining ring and pin in a plastic bag and identify.
f. Remove No. 5 bearing spanner nut as follows. See figure 4.
WARNING
(1) Lift 2C6084 antitorque assembly with a hoist and place on aft flange of compressor
rear frame. Engage antitorque lugs of inner ring with slots in rotor rear shaft.

13
GEK 97310
VOLUME II
WP 202 00
(2) Secure outer ring of antitorque assembly to compressor rear frame flange with the six
clamps provided.
(3) Place 2C6084P25 torque tube through antitorque assembly and engage lugs of
wrench to slots in No. 5 bearing spanner nut.
(4) Place torque multiplier (0-10,000 lb ft (13,560 N·m) over torque tube. Secure torque
multiplier to antitorque assembly using thumbscrews provided.
CAUTION
NO. 5 BEARING SPANNER NUT HAS LEFT HAND
THREADS.
(5) Apply torque to turn spanner nut (7, figure 3) clockwise (left hand threads) and
loosen spanner nut.
(6) Remove torque multiplier and 2C6084P25 torque tube.
(7) Remove No. 5 bearing spanner nut.
NOTE
If keyed retainer ring can be removed by hand, disregard
substep (8).
(8) Remove oil tube keyed retainer as follows:
CAUTION
THE HPT ROTOR REAR SHAFT THREADS ARE LEFT HAND
THREADS.
(a) Insert 2C6063 oil tube key retainer puller through the antitorque assembly and
thread (counterclockwise) onto the HPT rotor aft shaft until puller seats against aft side of No. 5
bearing inner race. Seat puller hand tight only. See figure 5.
(b) Loosen the eight knobs, position fingers inward to catch forward side of key
retainer and tighten knobs.
(c) Insert 1/4 inch dowel rod in hole provided at OD of puller and rotate clockwise
(aft looking forward) until puller and key retainer are removed.
(d) Remove key retainer from puller. Place spanner nut and keyed retainer in a
plastic bag and identify.

14
GEK 97310
VOLUME II
WP 202 00
g. Remove oil tube (11, figure 3) from inside high pressure turbine rotor as follows:
NOTE
Oil tube threads are standard (right hand) threads.
(1) Install 2C6058 oil tube wrench through 2C6084 antitorque assembly and engage
wrench lugs with slots at rear of oil tube. See figure 6.
(2) Place torque multiplier 0-10,000 lb ft (0-13560 N·m) over oil tube wrench. Secure
torque multiplier to antitorque assembly using thumbscrews provided.
(3) Break torque and unscrew oil tube using torque multiplier. Be certain that oil tube
threads are disengaged from coupling nut threads. Remove torque multiplier.
(4) Install and engage the three puller pins of 2C6058 wrench in holes of oil tube. Pull
oil tube from rotor.
(5) Remove 2C6084 antitorque assembly from compressor rear frame flange.
h. Remove damper sleeve as follows:
(1) Loosen locks of 2C6563 removal tool and open tool all the way. See figure 7.
(2) Insert tool into HPT rotor rear shaft. When the non-adjustable leg of tool bottoms on
damper sleeve, rotate tool clockwise until tang of leg engages counterclockwise hook of damper
sleeve.
(3) Push adjustable leg of tool forward until it contacts damper sleeve. Compress tool
until adjustable leg engages clockwise hook on damper sleeve. Continue to compress tool sleeve
assembly and lock in compressed position.
(4) Pull sleeve with tool from rotor rear shaft.
WARNING
PENETRATING OIL WD 40 IS NOT TO BE USED ON GAS
GENERATOR/GAS TURBINES. LIQUID WRENCH NO. 1 IS
RECOMMENDED.
i. Lubricate turbine rotor coupling nut with penetrating oil using oil can or equivalent. Turn
rotor to ensure that oil penetrates the full circumference of the threads.

15
GEK 97310
VOLUME II
WP 202 00
j. Install 1C6950 coupling nut wrench onto aft end of turbine rotor as follows. See figure 8:
(1) Make certain jackscrews (10, figure 8) in outer flange of coupling nut wrench are
retracted and adjust locking tabs (2) out and away from gas generator.
WARNING
(2) Install lift nut (13) into 1C6950 coupling nut wrench (1) and using a hoist, position
coupling nut wrench above aft end of turbine rotor.
(3) Mark center of 24 scalloped slots on rotor aft shaft. Mark center of locking lugs on
1C6950 coupling nut wrench.
CAUTION
CLAMPS MUST ENGAGE STAGE 2 NOZZLE ASSEMBLY
FLANGE ONLY. DO NOT INSTALL OVER CRF AFT
FLANGE. SEE FIGURE 9.
NOTE
Make certain lugs on coupling wrench engage slots on aft face of
rotor.
(4) Install lift nut/wrench assembly on rotor and adjust locking tabs (2, figure 8) to
engage stage 2 nozzle support flange. Tighten locking tabs.
(5) Install T-handle jackscrews (10) in holes provided in housing outer ring and finger-
tighten against shroud support. Remove lift nut (13).

16
GEK 97310
VOLUME II
WP 202 00
CAUTION
z TURBINE ROTOR REAR STUB-SHAFT HAS LEFT HAND
THREADS.
z ENSURE PILOT NUT (5) IS PROPERLY INSTALLED AND
SECURED IN COUPLING NUT WRENCH (1) TO PRE-
VENT SEPARATION OF ROTOR ASSEMBLY AND LIFT
FIXTURE.
NOTE
Prior to use of 1C6950 tooling, clean threads of pilot nut (5) and
locknut (7) with solvent and a rag. Examine threads for damage
and repair as necessary. When installing locknut and pilot nut,
tighten them fingertight only.
(6) Install pilot nut (5), left hand thread, onto rear stub-shaft and tighten securely using
wrench (9).
NOTE
It may be necessary to slowly rotate the torque tube (6) until
engagement of the torque tube splines and HPT coupling nut
splines can be felt.
(7) Carefully install torque tube (6) into rear of rotor and engage coupling
nut (12, figure 3) at front of rotor.
(8) Lock torque tube in place using locknut (7, figure 8), right hand thread. Locknut
must be flush or below surface of wrench. Tighten nut securely using wrench (9).
WARNING
WHEN A TORQUE MULTIPLIER IS TO BE USED, IT MUST
HAVE ADEQUATE CAPACITY TO MEET THE SPECIFIED
TORQUE REQUIREMENTS OF THE OPERATION. THE
TORQUE MULTIPLIER MANUFACTURER’S INSTRUCTIONS
AND THE INSTRUCTIONS CONTAINED HEREIN MUST BE
FOLLOWED EXACTLY TO GUARD AGAINST THE POSSI-
BLE HAZARDOUS RESULTS OF TOOL MISUSE.
NOTE
When using a Sweeney model 8111 torque multiplier, an adapter,
PN 194495, provided by Sweeney Co. is required.
k. Install torque multiplier (8) 0-50,000 lb ft (0-67,800 N·m) to rear of coupling nut wrench
and secure with thumbscrews. Use a hoist to support torque multiplier (if required). Refer to
WP 001 00, table 1.

17
GEK 97310
VOLUME II
WP 202 00
CAUTION
GUIDE PINS SHALL BE USED WHEN REMOVING NOZZLE
ASSEMBLY TO LESSEN POSSIBILITY OF DAMAGE TO AIR
SEALS. GUIDE PINS MAY BE LOCALLY FABRICATED PER
FIGURE 10.
l. Install eight 2C6610 guide pins (see figure 10) through the larger boltholes in the coupling
wrench using alternating boltholes. Secure guide pins to compressor rear frame flange using nuts.
Ensure guide pins are seated against CRF flange prior to removing nozzle assembly.
m. Install four jackscrews from 1C6804 tool set (figure 9), from forward side to threaded
holes in compressor rear frame rear flange. Thread the jackscrews into holes until they just touch
stage 2 nozzle support.
WARNING
n. Install 2C6187 lift fixture to rear of coupling nut wrench using a hoist. Secure using four
lockpins (12, figure 8). Remove slack from hoist cable.
o. Carefully raise hoist attached to lift fixture until a gap of approximately 0.25 inch
(6.4 mm) exists between spring loaded parts. See figure 1. This will exert an upward force on
turbine rotor and prevent excessive pressure on coupling nut threads.

18
GEK 97310
VOLUME II
WP 202 00
WARNING
PERSONNEL SHALL STAND CLEAR OF SIDE OF ENGINE
WHEN USING TORQUE MULTIPLIER. TORQUE IN EXCESS
OF 30,000 LB FT (40,680 N·M) MAY BE REQUIRED TO
BREAK LOOSE COUPLING NUT. IF PARTS SHOULD FAIL,
THEY WILL DO SO WITH EXPLOSIVE FORCE AND COULD
CAUSE SERIOUS INJURY.
CAUTION
THE FOLLOWING TASK IS CRITICAL AND MUST BE PER-
FORMED WITH EXTREME CARE TO PREVENT DAMAGE
TO SHAFT THREADS, ROTOR BLADES, VANES, AND
SEALS. AS COUPLING NUT IS LOOSENED AND ROTOR
MOVES TO THE REAR (UP), THE HOIST MUST BE RAISED
SUFFICIENTLY TO APPROXIMATELY 0.25 INCH (6.4 MM)
GAP IN LIFT FIXTURE TO PREVENT EXCESSIVE PRES-
SURE ON COUPLING NUT THREADS.
NOTE
HPT rotor coupling nut threads are standard (right hand) threads.
p. Break torque on coupling nut (counterclockwise direction) by applying force through

torque multiplier. Slowly and carefully loosen coupling nut, approximately two turns, while using
jackscrews in compressor rear frame to move stage 2 nozzle upward with the rotor. Raise hoist
upward with rotor to prevent excessive pressure on shaft threads.
q. If same rotor/stage 2 nozzle EMU is to be reinstalled, matchmark one rotor blade to

stage 2 nozzle flange to compressor rear frame flange.
CAUTION
GREASE PENCILS OR LEAD (GRAPHITE) MUST NOT BE
USED TO MARK COMBUSTION SECTION OR HOT SECTION
PARTS. THESE MATERIALS PLUS HEAT CAN CAUSE PART
MATERIAL DAMAGE.
r. Remove torque multiplier.

19
GEK 97310
VOLUME II
WP 202 00
NOTE
Keep hoist raised, as necessary, during entire loosening operation to
maintain 0.25 inch (6.4 mm) gap in lift fixture.
s. Continue to loosen coupling nut using 2C6341 spline wrench (14, figure 8), positioned
over torque tube (6) aft spline teeth, until threads are completely disengaged and turbine rotor for-
ward shaft is free of the compressor shaft.
CAUTION
USE CARE TO PREVENT DAMAGING AIR FILTER; FILTER
LIP MAY HANG UP ON BORESCOPE PORT. IF THIS
OCCURS, MOVE NOZZLE FORWARD AND ATTEMPT TO
MOVE IT SIDEWAYS OR SLIGHTLY TILT IT TO PROVIDE
CLEARANCE.
t. When turbine rotor is free of compressor rotor and stage 2 nozzle is free of compressor
rear frame, carefully lift assembly clear of gas generator.
u. If same HPT rotor/stage 2 nozzle EMU is to be reinstalled, mark compressor rotor shaft at
12 o’clock position using Dykem.
v. Transfer the rotor/nozzle assembly to 1C8059 turbine rotor vertical stand

(figures 1 and 11).

20
GEK 97310
VOLUME II
WP 202 00
w. Remove 1C6950 coupling nut wrench and 2C6187 lift fixture from rear of turbine rotor as
follows:
CAUTION
EXERCISE CARE WHEN HANDLING TURBINE ROTOR
AFTER COUPLING WRENCH/LIFT FIXTURE ASSEMBLY IS
REMOVED. THE STAGE 2 NOZZLE ASSEMBLY WILL BE
LOOSE ON ROTOR AND SUBJECT TO DAMAGE.
(1) Remove lockpins (12, figure 8) and remove lift fixture 2C6187.
(2) Remove torque multiplier (and adapter) if used.
(3) Remove locknut (7), using wrench (9). Locknut has right hand threads.
(4) Remove torque tube (6) using a hoist.
(5) Remove pilot nut (5) using wrench (9). Pilot nut has left hand threads.
(6) Retract T-handle jackscrews (10).
(7) Install lift nut (13) to coupling nut wrench (1) and remove lift fixture (3) and cou-
pling nut wrench (1) from rotor, using a hoist attached to lift eye.
x. Remove jackscrews from compressor rear frame. Remove guide pins.
y. If required remove pressure lock seal (13, figure 3) from aft end of compressor rotor rear
shaft.

21
GEK 97310
VOLUME II
WP 202 00
5. REMOVAL OF STAGE 2 HPT NOZZLE ASSEMBLY FROM HPT TWIN SHANK
ROTOR.
a. Remove the stage 2 high pressure turbine nozzle assembly from the high pressure turbine
rotor (if required) as follows:
CAUTION
HIGH PRESSURE TURBINE ROTOR AND STAGE 2 HIGH
PRESSURE TURBINE NOZZLE ASSEMBLIES ARE
MACHINED AS A MATCHED SET. MAKE CERTAIN ASSEM-
BLIES ARE TAGGED AND IDENTIFIED AS A SET WHEN-
EVER EITHER MUST BE REMOVED. ALL PARTS MUST BE
MATCHMARKED AS THEY ARE REMOVED TO ENSURE
ASSEMBLY IN SAME RELATIVE POSITION. SHROUDS
AND INTERSTAGE SEALS CANNOT BE REPLACED AT
LEVEL 2 AND MUST BE ASSEMBLED TO SAME RELATIVE
POSITION TO MAINTAIN PROPER CLEARANCES
BETWEEN ROTATING AND STATIONARY PARTS.
(1) Place high pressure turbine rotor, with stage 2 nozzle installed, into stand. Adjust
stand as necessary to support stage 2 nozzle assembly.
(2) If stage 2 rotor blades are to be removed, proceed as follows:
(a) Matchmark stage 2 blade retainer to turbine rotor.
(b) Number stage 2 blade pairs starting at 1-1 mark on rotor disk dovetail tangs.
Number blade pairs working in clockwise direction (aft looking forward). Fifth blade pair should
be between 5-5 mark on disk.
(c) Number all damper seals in clockwise direction. No. 1 seal will be just right of
blade pair No. 1.
(d) Loosen all bolts securing blade retainer but do not remove bolts.
(e) Place masking tape over boltheads to hold bolts in retainer.
(f) Remove blade retainer and bolts as a unit.
(g) Remove air seal from forward side of retainer.
(h) Remove blade pairs by pulling them out of rear of disk. Place blade pairs in
container and install cover on container.

22
GEK 97310
VOLUME II
WP 202 00
(i) Remove damper seals.
WARNING
(3) Using 1C5964 lift sling, remove stage 2 nozzle assembly from high pressure turbine
rotor and use two persons to carefully turn nozzle assembly over and set aft side down on flat sur-
face.
6. INSTALLATION OF STAGE 2 HPT NOZZLE ASSEMBLY ON HPT ROTOR.
a. Install the stage 2 high pressure turbine nozzle assembly on the high pressure turbine rotor
(if required) as follows:
(1) Place high pressure turbine rotor in 1C8059 vertical stand.
(2) Place stage 2 nozzle assembly forward end (air screen end) down over rotor.
(3) Install stage 2 high pressure turbine rotor blades according to position numbers made
during disassembly (or during preparation for shipment) as follows:
(a) Install blade pair position marked No. 1 into dovetail slot between 1-1 marks
stamped on rear of dovetail tangs.
CAUTION
MAKE SURE THAT F MARK ON DAMPER SEAL FACES
FORWARD. IMPROPER INSTALLATION CAN RESULT IN
LOSS OF DAMPER SEAL AND GAS GENERATOR DAMAGE.
(b) Install damper seal position marked No. 1 immediately to right (aft looking for-
ward) of blade pair No. 1.
(c) Continue installing blade pairs and damper seals, according to position marks,
working in a clockwise (aft looking forward) manner. Blade pair No. 5 shall be between
5-5 marks on dovetail tangs.

23
GEK 97310
VOLUME II
WP 202 00
(d) Install all blade pairs and damper seals.
CAUTION
MAJOR GAS GENERATOR DAMAGE CAN RESULT FROM
IMPROPERLY INSTALLED DAMPER SEALS.
(e) Apply hand pressure against aft face of damper seal. If damper seal can be dis-
lodged by hand pressure, re-install or replace damper seals or blade pairs as required.
CAUTION
RETAINER BOLTS FOR STAGE 2 RETAINER SHALL BE
INSTALLED IN THE SAME POSITION FROM WHICH THEY
WERE REMOVED. RETAINER BOLTS MUST MAINTAIN A
MINIMUM RUNNING TORQUE OF 3.5 LB IN. (0.4 N·M).
(f) Install stage 2 blade retainer and seal according to matchmark made during
removal just prior to rotor installation. Do not allow bolts to become dislodged during installa-
tion. Bolts must maintain a running torque of 3.5 lb in. (0.4 N·m). Tighten bolts to 110-120 lb in.
(12.5-13.6 N·m) of torque, loosen one-half turn and retighten to 110-120 lb in. (12.5-13.6 N·m) of
torque.
(g) Visually inspect to make certain seal has remained in place.
(h) Check for clearance between blade retainer and disk using a 0.001 inch
(0.03 mm) feeler stock to make sure seal has been crushed. If clearance is 0.001 inch (0.03 mm)
or greater, seal is not properly installed.
(i) If clearance between retainer and disk is greater than 0.001 inch (0.026 mm),
remove retainer. Check to ensure that seal has remained in place. Install retainer and check clear-
ance again. If clearance limit cannot be met, replace retainer.

24
GEK 97310
VOLUME II
WP 202 00
7. INSTALLATION OF HPT TWIN SHANK ROTOR AND STAGE 2 NOZZLE
ASSEMBLY.
WARNING
NOTE
The HPT rotor/stage 2 nozzle EMU is assumed to be in 1C8059
vertical stand (figure 11).
a. Install lift nut (13, figure 8) into 1C6950 coupling nut wrench (1). Using a hoist, lift
wrench onto aft end of turbine rotor as follows:
(1) Make certain T-head jackscrews (10) in outer flange of coupling nut wrench are
installed and retracted and adjust locking tabs (2) out and away from coupling nut wrench.
NOTE
z No. 5 bearing inner race must be in place before coupling nut
wrench can be installed. If bearing is not in place refer to
WP 221 00, bearings and seals.
z The 1C6950 spanner wrench has 24 lugs which engage the scal-
lops on the rear shaft for antitorque purposes. Make sure that
these lugs are fully engaged with the shaft and not seated at an
angle.
(2) Install lift nut wrench assembly on rotor rear stub-shaft.
CAUTION
(3) Adjust locking tabs (2, figure 8) to engaged stage 2 nozzle support flange. Tighten
tabs.
(4) Adjust jackscrews (10) in coupling wrench outer ring and finger-tighten against
shroud support.
(5) Remove hoist and lift nut (13).

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GEK 97310
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CAUTION
THREADS.
FIXTURE.
NOTE
and repair as necessary. When installing locknut, tighten finger-
tight only.
wrench (9).
(7) Carefully install torque tube (6), into rear of rotor and engage coupling
nut (12, figure 3) at front of rotor.
(8) Lock torque tube in place using locknut (7, figure 8), right hand threads. Locknut
must be flush or below surface of coupling wrench. Tighten nut securely using wrench (9).
WARNING
NOTE
If Sweeney model 8111 torque multiplier is used, an adapter,
PN 194495, provided by Sweeney Co., is required.
(9) Install torque multiplier, 0-15,000 lb ft (0-20,340 N·m), on aft end of coupling nut
wrench (1). Refer to WP 001 00, table 1.
(10) Attach hoist to 2C6187 lift fixture (3, figure 8) and install lift fixture to coupling nut
wrench (1). Secure with four lockpins (12).

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GEK 97310
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WARNING
SOLVENT IS FLAMMABLE AND IRRITATING TO THE
SKIN, EYES, AND RESPIRATORY TRACT. USE GOGGLES
OR FACE SHIELD AND PROTECTIVE CLOTHING AS NEC-
ESSARY. USE IN WELL-VENTILATED AREA OR AN
APPROVED CLEANING CABINET. KEEP AWAY FROM
HEAT, SPARKS, AND OPEN FLAME.
CAUTION
z DO NOT SUBSTITUTE ANY ANTISEIZE COMPOUND
FOR A50TF201 LUBRICANT. USE OF UNAUTHORIZED
LUBRICANT ON BOLT/NUT THREADS CAN CAUSE
z USE ONLY SPECIFIED LUBRICANTS ON SILVER
PLATED THREADS. LUBRICANTS CONTAINING COP-
PER MUST NOT BE USED. HEAT WITHIN A GAS GEN-
ERATOR MAY CAUSE CHEMICAL REACTION
BETWEEN COPPER, IN THE LUBRICANT, AND SILVER.
THE REACTION CAN CAUSE THREADS TO SEIZE TO A
POINT THAT DESTRUCTIVE FORCE IS REQUIRED TO
SEPARATE PARTS.
b. Clean the threads and mate face of the compressor rotor rear shaft with solvent (P-D-680).
Check threads for burrs. Remove any burrs, using a fine stone and fiber wheel. Thoroughly clean
threads and dry. Coat the aft two to three threads with antiseize compound, A50TF201. Do not
over coat.
CAUTION
PRESSURE LOCK SEAL (13, FIGURE 3) MUST BE
INSTALLED IN AFT ID OF COMPRESSOR ROTOR SHAFT TO
PREVENT AIR LEAKAGE.
c. Visually inspect the pressure lock seal (13, figure 3) at aft end of compressor rotor rear
shaft, for damage. Replace seal if necessary.
WARNING
d. Raise HPT rotor/stage 2 nozzle assembly from vertical stand and position the assembly
above the gas generator.

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e. Clean the threads and forward face of the HPT rotor coupling nut, and the mate face and
coupling nut seating surface of the HPT rotor forward shaft with solvent (P-D-680). Check
threads for burrs. Remove any burrs, using a fine stone and fiber wheel. Thoroughly clean
threads and dry. Thoroughly coat the forward face of the coupling nut and all coupling nut
threads with antiseize compound, A50TF201. Overall thread coverage required. Remove excess
thread lubricant.
f. Inspect in and around No. 4 bearing sump area for foreign material and verify that the
No. 4 bearing split nut lockring is engaging both the nut and compressor rotor shaft splines.
g. If same EMU is being installed, ensure that previously made matchmarks (at disassembly)
are aligned.
NOTE
The Z mark on high pressure turbine rotor front shaft shall be
aligned to O or LO mark on compressor rotor rear shaft.
h. If a different EMU is being installed, the Z mark on high pressure turbine rotor front shaft
shall be aligned to O or LO mark on compressor rotor rear shaft as follows:
(1) Locate Z mark on HPTR and O or LO mark on compressor rotor. Turn both rotors so
marks are aligned and at 12 o’clock position.
CAUTION
GREASE PENCILS OR LEAD (GRAPHITE) PENCILS MUST
NOT BE USED TO MARK COMBUSTION SECTION OR HOT
SECTION PARTS. THESE MATERIALS PLUS HEAT CAN
CAUSE PARTS MATERIAL DAMAGE.
(2) Mark Z on aft face of HPTR stage 2 disk in line with Z mark on rotor front shaft
using Dykem.

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GEK 97310
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CAUTION
EXERCISE EXTREME CARE DURING INSTALLATION OF
TURBINE ROTOR TO PREVENT DAMAGE TO SEALS AND
COUPLING NUT THREADS. ENSURE BORESCOPE HOLE IN
STAGE 2 NOZZLE ASSEMBLY IS ALIGNED WITH BORES-
COPE HOLE NEAR REAR OF COMPRESSOR REAR FRAME.
NOTE
z Make certain that a stage 1 borescope hole in air filter of stage 2
nozzle assembly is about 4-1/2 inches (114 mm) from stage 2
borescope hole.
z To aid in aligning HPT EMU, install 2C6610 guide pins in com-
pressor rear frame. Location of guide pins should coincide with
larger bolthole location in coupling nut wrench outer ring.
i. Visually align turbine rotor front shaft with rear shaft of compressor rotor. Carefully
lower turbine rotor over compressor rear shaft until splines start to engage and the coupling nut
threads are almost touching the compressor rotor rear shaft threads. Adjust the stage 2 nozzle
assembly as necessary to align borescope holes. Push down on the aft end of the turbine rotor
(2C6187 spring-loaded lift fixture will allow downward movement) and engage coupling nut
threads by applying force (clockwise) through torque multiplier.
j. Continue moving turbine rotor downward and turning torque multiplier until coupling nut
is tight.
CAUTION
RUNNING TORQUE OF COUPLING NUT SHALL NOT
EXCEED 200 LB FT (271.2 N·M) DURING TIGHTENING
OPERATION. IF TORQUE SHOULD INCREASE SIGNIFI-
CANTLY PRIOR TO SEATING, REMOVE ROTOR AND
INSPECT FOR CAUSE OF TORQUE INCREASE.
(1) Tighten coupling nut to 7500 lb ft (10170 N·m) of torque and untighten to
500-1500 lb ft (675-2034 N·m) of torque.
k. Retighten coupling nut to 2000 lb ft (2712 N·m) of torque by applying force through
torque multiplier. Record the wrench angle at 2000 lb ft (2712 N·m). Lower the hoist as the cou-
pling nut is tightened but always keep an upward spring force (from lift fixture 2C6187) applied.
Maintain a gap of approximately 1/4 inch between the spring loaded parts of the lift fixture (see
figure 1) as coupling nut is tightened. When gap is correct, the coupling nut will turn relatively
easy.

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NOTE
If torque multiplier has no protractor, matchmark the angular rela-
tionship of the wrench torque tube to the wrench housing using
marking ink.
l. Increase the torque until the wrench angle is 28-30 degrees greater than that recorded at
2000 lb ft (2712 N·m) or until the torque reaches a maximum of 10,000 lb ft (13,560 N·m), which-
ever occurs first.
m. If the wrench angle is 28-30 degrees greater than that recorded at 2000 lb ft (2712 N·m)
and the torque is less than 10,000 lb ft (13,560 N·m), the coupling nut installation is acceptable.
n. If the above requirements are not met, remove, clean, recoat, and reinstall HPT coupling
nut. Do not exceed the maximum allowable torque of 10,000 lb ft (13,560 N·m) or a total of six
complete torquing cycles of the HPT coupling nut. If these limits are exceeded, replate the HPT
coupling nut silver coating or replace coupling nut.
NOTE
New or replated coupling nuts will achieve the angle of
28-30 degrees at a lower torque value, usually less than 8,000 lb ft
(10848 N·m). Reuse of the coupling nut increases the torque
requirement over the maximum allowable 10,000 lb ft
(13,560 N·m) limit. Torquing, then loosening the coupling nut con-
stitutes one use or torquing cycle.
o. Remove 2C6187 lift fixture (3, figure 8) and torque multiplier. Remove locknut (7) and
pull torque tube (6) out the rear. Remove pilot nut (5). Pilot nut has left hand threads. Remove
coupling nut wrench and lift fixture (1 and 3) as a unit. Remove 2C6610 guide pins.
p. Measure concentricity of No. 5 bearing inner race on turbine rotor rear stub-shaft using
1C5937 concentricity fixture. Install support slightly aft of rotor and adjust indicator against
6 o’clock position of bearing race. Maximum runout is 0.010 inch (0.25 mm) FIR. Measure at
approximately 12 equal points allowing rotor to stabilize before each reading. If not within limits,
remove rotor and reinstall in a different circumferential position to obtain required concentricity.
Remove concentricity gage and support.
q. Install the HPT pressure tube damper sleeve (figure 7) into the aft end of the high pressure
turbine rotor. Compress the damper sleeve to insert and seat against ID of the pressure tube.

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GEK 97310
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WARNING
TOUCH YOU. IRRITANT. PERSONAL PROTECTIVE EQUIP-
MENT REQUIRED. USE MECHANICAL EXHAUST VENTI-
LATION - IF NOT AVAILABLE, USE AN APPROVED
RESPIRATOR.
r. Install flexible oil seals (4, figure 3) in two larger grooves near aft end of oil tube (11).
Lubricate O-ring (5) with gas turbine lube oil and install in smaller groove near aft end of oil tube.
s. Apply a light coating of prussian blue to forward end of oil tube.
t. Visually inspect using strong light to make certain that pressure lock seal (13) is properly
installed in aft end of compressor rotor rear shaft.
CAUTION
ANTISEIZE COMPOUND, A50TF201. USE OF UNAUTHO-
u. Coat threads of oil tube (11) with antiseize compound, A50TF201 and install into aft end
of high pressure turbine rotor. Tighten as far as possible by hand.
v. Install 2C6084 antitorque assembly to aft end of high pressure turbine rotor. Make certain
lugs on antitorque assembly engage slots on turbine rotor. Secure assembly to compressor rear
frame with the six clamps provided. Tighten securely.
CAUTION
ENSURE THAT 2C6058 WRENCH ENGAGES OIL TUBE
TANGS FULLY AND THE THREE PULLER PINS ARE IN THE
RADIALLY OUTWARD POSITION.
w. Install 2C6058 oil tube wrench (figure 6).
NOTE
Make certain that torque multiplier is fully seated against wrench
support.
x. Install torque multiplier 0-10,000 lb ft (0-13,560 N·m). Engage antitorque lugs on torque
multiplier in bosses on 2C6084. Refer to WP 001 00, table 1.
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y. Tighten oil tube 600-800 lb ft (813.6-1084.8 N·m) of torque.
z. Measure and record drop dimension (X, detail C, figure 3) from aft end of oil tube to aft
end of rotor rear shaft. Mark point of measurement of shaft only.
aa. Remove oil tube. Inspect oil tube and seating surface inside compressor rotor rear shaft
for continuous prussian blue pattern to ensure oil tube has seated.
ab. Remove marking compound from oil tube.
ac. Reinstall the oil tube and tighten to 1000 lb ft (1356 N·m) of torque. Break torque and
retorque to 1000 lb ft (1356 N·m). Visually check to ensure that one slot in rotor shaft aligns to a
slot in oil tube to allow installation of key retaining ring (10). If necessary, increase torque on oil
tube to align slots. Do not exceed 1200 lb ft (1627.2 N·m).
ad. Remove torque multiplier and 2C6058 wrench. Trial fit keyed retaining ring. Increase
torque slightly if necessary to align retaining ring, but do not exceed 1200 lb ft (1627.2 N·m).
ae. Measure drop dimension (X, detail C, figure 3) from aft end of oil tube to aft end of rotor
rear shaft at same point marked earlier. Measurement shall be equal to or less than measurement
made in step z.
CAUTION
KEYED RETAINING RING MUST BE INSTALLED WITH
OUTER KEY TO REAR, TO ALLOW PROPER THREAD
ENGAGEMENT BETWEEN SPANNER NUT AND SHAFT.
af. Install keyed retaining ring (outer keys to rear) to lock oil tube to rotor rear shaft. See
detail A, figure 3.
CAUTION
z NO. 5 BEARING SPANNER NUT HAS LEFT HAND
THREADS.
z DO NOT SUBSTITUTE ANY THREAD LUBRICANT FOR
RIZED LUBRICANT ON BOLT/NUT THREADS CAN
CAUSE SULFIDATION ATTACK AND PREMATURE
FAILURES.
ag. Coat threads of No. 5 bearing spanner nut (7, figure 3) with antiseize compound,
A50TF201 and install on rear of high pressure turbine rotor. Tighten to 450 lb ft (610.2 N·m) of
torque using 2C6084P25 torque tube and torque multiplier 0-10,000 lb ft (0-13560 N·m). Refer to
WP 001 00, table 1.

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ah. Check with 0.001 inch (0.025 mm) feeler gage to make sure that bearing race is seated.
ai. Remove torque multiplier and torque tube.
CAUTION
USE ONLY APPROVED MARKING MATERIAL TO PREVENT
PART DAMAGE.
aj. Inspect for alignment at a pin hole in spanner nut to a pin hole in rotor rear shaft. If not
already aligned, select holes nearest alignment by counterclockwise rotation of spanner nut. Put a
thin line mark on No. 5 bearing inner race to represent edge of hole in rear shaft. Put a thin line
mark on spanner nut, clockwise from mark on race. The distance between marks is equal to mis-
alignment at pin holes.
NOTE
As an alternate method in aligning pin holes, use 2C6084P25 and
P26 tubes by aligning one of the lines scribed on the P25 torque
tube with a scribed line on the P26 (inner) tube. Do not exceed
specified torque while attempting to align the lockpin holes.
ak. Install wrench and torque multiplier. Increase torque to spanner nut (left hand threads) to
align marks on nut and race. Do not exceed 500 lb ft (678 N·m) of torque.
al. Remove torque multiplier, spanner nut torque tube, and 2C6084 antitorque assembly.
am.Measure and record clearance C60 (see WP 400 00, assembly clearances and drawings)
using a feeler gage.
CAUTION
LOCKING PIN MUST BE PROPERLY INSTALLED AND
SECURED BY RETAINING RING TO PREVENT SPANNER
NUT FROM COMING LOOSE DURING GAS GENERATOR
OPERATION.
an. Secure spanner nut with locking pin (9, figure 3). Install locking pin with grooved end
facing aft. See detail A, figure 3. Secure locking pin with retaining ring (8). Make certain
retaining ring is fully seated in retaining ring groove.
ao. Install stage 1 and 2 nozzle borescope plugs and washers in compressor rear frame. Plugs
are located at approximately 3 o’clock position near rear of frame (aft looking forward).
ap. Install four setscrews in forward face of compressor rear frame rear flange at 2, 4, 8, and
10 o’clock positions. See figure 2.
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GEK 97310
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aq. Perform installation portions of the following work packages:
WP 220 00 Removal/Installation of Power Turbine Assembly
WP 208 00/SWP 208 01 Replacement of Turbine Mid Frame
WP 221 00 Inspection and Replacement of Miscellaneous Sump Components
WP 400 00/SWP 400 01 Assembly Clearances and Drawings
8. INSPECTION OF HPT TWIN SHANK ROTOR AND STAGE 2 NOZZLE

ASSEMBLY.
a. Stage 2 High Pressure Turbine Nozzle Assembly. See figure 12 for hardware description
and refer to table 1 for inspection limits.
b. High Pressure Turbine Rotor Inspection. See figures 13 and 14 for hardware description.
Refer to table 2 for inspection limits.
c. High Pressure Turbine Twin Shank Rotor Blades. See figure 15 for hardware description.
Refer to table 3 for inspection limits.
d. High Pressure Turbine Oil Tube and Damper Sleeve. See figures 16 and 17. Refer to
table 4 for inspection limits.
e. High Pressure Turbine Nozzles. See figure 18. Refer to table 5 for inspection limits.

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GEK 97310
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Figure 12. Assembly of Stage 2 High Pressure Turbine Nozzle Assembly

Twin Shank Rotor Configuration
35
GEK 97310
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Table 1. STAGE 2 HIGH PRESSURE TURBINE NOZZLE ASSEMBLY
On-Site On-Site
SCREEN ASSEMBLY
1. Screen for:
a. Obstruction Not serviceable Any amount Clean
screen
b. Cracks, tears, Not serviceable
etc.
2. Front Air Seal for:
a. Cracks 12 per segment,
0.25 in (6.4 mm) long
b. Distortion Up to 0.03 in Any amount Re-form seal strips
(0.8 mm) out-of-line with hand tools
provided edges con-
tact seal land after
assembly
3. Borescope Hole Washer for:
a. Wear 0.005 in (0.13 mm)
deep
b. Distortion Not serviceable
4. Backing Strip for:
a. Cracks at Two cracks, 0.25 in Not repairable Replace screen
cooling holes (6.4 mm) long at each assembly**
brace
and
at four braces, cracks
to maximum length of
0.13 in (3.3 mm) long
provided crack does
not connect three
cooling holes

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Table 1. STAGE 2 HIGH PRESSURE TURBINE NOZZLE ASSEMBLY - Continued
On-Site On-Site
NOZZLE COOLING FEED AIR TUBES

1. All Areas for:
a. Cracks Not serviceable Not repairable Replace tube**
b. Wear Not serviceable Not repairable Replace tube**
NOZZLE SUPPORT. See figure 13.
1. All Body Surface Area for:
a. Cracks Not serviceable Not repairable Replace**
b. Nicks and Any number, and Not repairable Replace**
scratches length 0.016 in
(0.41 mm) deep.
Remove high metal
from mating surfaces
c. Bulges and Three bulges or dents, Any amount that will Bench high metal
dents 0.50 in (12.7 mm) not affect assembly on mating flanges
diameter, 0.19 in and mating surfaces
(4.8 mm) deep. No only, or replace
high metal allowed on part**
mating surfaces
d. Plugged Not serviceable Any number Clear holes
cooling air
holes
2. Stage 2 Nozzle Mounting Flange for:
a. Circumferen- Not serviceable Not repairable
tial cracks
b. Radial cracks Two radial cracks
from bolt holes
inward, provided they
are separated by a
minimum of five
boltholes

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GEK 97310
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On-Site On-Site
c. Nicks and Any number, any

from mating surface
d. Missing or 10 percent may be
chipped ther- missing
mal sprayed
coating
3. Rear Mounting Flange for:
a. Cracks extend- Two radial cracks,
ing from bolt provided they are sep-
holes to edge arated by a minimum
of flange of five boltholes
b. Nicks, scores, Any number, 0.020 in
and scratches (0.50 mm) deep, after
removal of high
metal. Must not
extend more than
75 percent across
surface
4. Nozzle Support Seal for:
a. Circumferen- Not serviceable Not repairable Replace support**
tial cracks
b. Axial cracks at One per sawcut, Not repairable Replace support**
sawcuts 0.13 in (3.3 mm) long
c. Distortion of Any amount provided Any amount Mechanically
air seal OD is not less than straighten. Inspect
36.446 in for cracks
(925.728 mm)
diameter

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GEK 97310
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On-Site On-Site
d. Wear on wear 0.010 in (0.26 mm) Not repairable Replace support**

band deep, provided OD is
not less than 36.446 in
(925.728 mm)
diameter
e. Spot weld at 50 percent of spot
cover to seal weld may be loose
STAGE 2 FORWARD SHROUD SUPPORT
1. All Areas for:
a. Circumferen- Not serviceable Not repairable Replace segment**
tial cracks
b. Radial cracks Two cracks from bolt- Not repairable Replace segment**
hole to OD of support.
One crack at slot,
0.38 in (0.5 mm) long
c. Wear on Any amount, 0.010 in Not repairable Replace segment**
mounting (0.26 mm) deep up to
support one in (25 mm) from
ends, 0.030 in
(0.78 mm) deep
d. Distortion Not serviceable Any amount, provided Mechanically
there are no resulting straighten. Inspect
cracks from rework for cracks
STAGE 2 REAR SHROUD SUPPORT
1. Flange Area for:
a. Cracks from Any number, provided Not repairable Replace segment**
boltholes to they are separated by
OD a minimum of five
boltholes that are not
cracked

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GEK 97310
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On-Site On-Site
b. Cracks from Six cracks, 0.15 in

slot hole (0.39 mm) long pro-
vided none in adjacent
slots
2. Disk Area for:
a. Cracks Not serviceable
3. Mounting Supports for:
a. Cracks Three axial cracks,
0.25 in (6.35 mm)
long separated by at
least two in (51 mm).
No circumferential
cracks allowed
b. Wear on Any amount, 0.010 in
shroud track (0.26 mm) deep after
mating surface removal of high metal
c. Corrosion or 0.020 in (0.52 mm)
burning deep in area not
greater than 0.25 in
(0.65 mm) by 0.25 in
(0.65 mm), 11 areas
maximum
4. Retainers for:
a. Loose or miss- Not serviceable
ing seal strips
b. Loose or miss- Not serviceable
ing retainer
clips
c. Cracks in weld Not serviceable
or retainer

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GEK 97310
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On-Site On-Site
INTERSTAGE AIR SEAL

NOTE
If any one or all of the HPT interstage air seals must be replaced,
the complete HPT stage 2 nozzle assembly and HPT rotor assem-
bly must be replaced with a matched set.
1. Rear Baffle for:
a. Circumferen- Not serviceable
tial cracks
b. Radial cracks Two cracks if between Every other bolthole
boltholes and OD of
baffle, provided they
are separated by a
minimum of three
boltholes that are not
cracked
c. Distortion Any amount, provided Any amount Mechanically
proper assembly can straighten so it can
be accomplished and be assembled and
the required mini- minimum clear-
mum clearance can be ance maintained
maintained
2. Honeycomb for:
a. Annular wear One per step, 0.25 in Not repairable
groove (6.4 mm) wide, not to
exceed 0.13 in
(3.3 mm) deep
b. Corner cell A section of first cell Not repairable
ribs dented or rib may be dented
bent 1.00 in (25.4 mm)
long, second cell rib
0.75 in (19.1 mm)
long

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On-Site On-Site
c. Cell damage/ Any number of iso- Not repairable

erosion lated cell areas of
0.50 in (12.7 mm)
square
3. Housing for:
a. Axial cracks Two axial cracks
1.00 in (25.4 mm)
long, not within
2.00 in (50.8 mm) of
end
b. Circumferen- Not serviceable Not repairable
tial cracks
c. Wear except Wall thickness not to Not repairable
on area W be less than 0.030 in
(0.78 mm). Local-
ized area 0.50 square
in (3.2 cm2) may be
0.024 in (0.61 mm)
thick
d. Wear on Loss up to 50% of Not repairable
area W coating area. Mini-
mum thickness in
localized areas
0.50 square in
(3.2 cm2) not less than
0.024 in (0.609 mm)
thick
e. Distortion at Any amount radially
boltholes
f. Cracks at One crack per hole
boltholes extending outward to
flange OD

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On-Site On-Site
4. Channel Nuts for:

a. Thread Not serviceable
damage
b. Cracked Three per segment,
channel 0.25 in (6.4 mm) long
5. Seal Strips and Clips for:
a. Distortion Not serviceable
b. Wear 0.010 in (0.26 mm) on
strips and 0.015 in
(0.39 mm) on clips
c. Cracks in weld Not serviceable
or seal/clip
parent metal
6. Stiffener for:
a. Distortion Not serviceable
b. Cracked or Not serviceable
broken

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GEK 97310
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On-Site On-Site
STAGES 1 AND 2 TURBINE SHROUDS

NOTE*
If any one or all of the HPT shrouds must be replaced, the com-
plete HPT stage 2 nozzle assembly and HPT rotor assembly must
be replaced with a matched set.
a. Cracks Accept axial cracks Not repairable See NOTE*
provided they are
spaced 6.00 in
(152.4 mm) apart and
do not extend into
radial rib
b. Wear on mat- Any length 0.005 in Not repairable See NOTE*
ing surface (0.13 mm) deep,
0.010 in (0.26 mm)
deep for total length
of 1.00 in (25.4 mm)
c. Bent edge on Not serviceable 0.06 in (1.6 mm) from Mechanically
support original contour straighten. Inspect
for cracks
d. Dents 0.020 in (0.52 mm) Dents up to 1.00 in Remove protrusion
deep, provided it can (25.4 mm) long are by blending
be assembled acceptable, if removal
does not thin flange to
less than 50% of orig-
inal flange thickness
e. Nicks and Any number, 0.010 in Any number, 0.020 in Blend to remove
scores (0.26 mm) deep after (0.52 mm) deep damage
f. Distortion and/ Acceptable if proper Not repairable See NOTE*
or waviness assembly can be
accomplished

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GEK 97310
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On-Site On-Site

a. Circumferen- Not serviceable Not repairable See NOTE*
tial cracks
b. Axial cracks One crack per seg- Not repairable See NOTE*
in backing ment 0.50 in
strip (12.7 mm) long; four
cracks per segment
0.25 in (6.4 mm) long
c. Nicks, dents, Any number, 0.03 in Not repairable See NOTE*
3. Filled Honeycomb for:
a. Wear track in 0.016 in (0.41 mm) Not repairable See NOTE*
honeycomb deep, full length of
segment; or 0.03 in
(0.8 mm) deep,
4.00 in (102 mm) long
per segment
b. Pickup or high Not serviceable Any amount Remove pickup or
metal high metal by
blending/grinding
to original contour.
Polish to a smooth
surface

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GEK 97310
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On-Site On-Site
NOTE
The cumulative total of all axial and circumferential areas of
damage and/or removal of unbonded cells shall not exceed
0.50 square in. (3.2 cm2) per shroud segment.
c. Axial damage Any number of axial Not repairable See NOTE*
scores not extending
into backing strip,
provided that the
cumulative total of all
axial and circumferen-
tial areas of damage
does not exceed
0.50 square inch
(3.2 cm2) per shroud
segment
d. Circumferen- Any amount provided Not repairable See NOTE*
tial damage no one area of damage
exceeds 0.25 in
(6.4 mm) wide for
entire length of
shroud segment or
0.38 in (9.8 mm) wide
by 4.00 in (102 mm)
long per shroud
segment. (Refer to
preceding NOTE)
e. Loose or Not serviceable Cumulative total Pry out loose or
unbonded cells equal to 0.50 in unbonded cells and
(12.7 mm) diameter cut off at point
circle per segment. where cells are
(Refer to preceding firmly bonded.
NOTE) Blend to remove
rough edges

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f. Erosion on 0.050 in (1.30 mm)

honeycomb deep, 1 sq in (6.5 cm2)
filler material cumulative area
NOZZLES
Refer to paragraph 8.e., High Pressure Turbine Nozzles and figure 18
** May be repairable, consult GE for disposition of replaced part.
Figure 13. Blend Repair of Front Shaft Air Seals and Thermal Shield Seal Serrations

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Figure 14. High Pressure Turbine Twin Shank Rotor Including Air Seal Diameter Limits

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Table 2. HIGH PRESSURE TURBINE TWIN SHANK ROTOR
On-Site On-Site
NOTE*
If HPT rotor must be replaced, the complete HPT stage 2 nozzle
assembly and HPT rotor assembly must be replaced with a
matched set.
FRONT SHAFT ROTATING AIR SEALS (1)
1. All Areas (except serrations) for:
a. Cracks Not serviceable Not repairable Replace turbine rotor
per NOTE* at begin-
ning of this table**
b. Nicks, dents, Any number, 0.015 in Not repairable Replace turbine rotor
and scratches (0.39 mm) deep after per NOTE* at begin-
removal of high metal ning of this table**
2. Seal Serrations for:

a. Wear on OD Within minimum OD Not repairable Replace turbine rotor
limits of figure 8 per NOTE* at begin-
b. Turned metal Not serviceable Any amount provided Remove turned metal
minimum OD is
within wear limit of
figure 14

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Table 2. HIGH PRESSURE TURBINE TWIN SHANK ROTOR - Continued
On-Site On-Site
NOTE
Maximum individual or cumulative length of blends on any one
tooth shall not exceed 5 in. (127 mm); total cumulative length of
all blends on the six serrations per seal shall not exceed 16 in.
(406 mm), or forward tooth on forward seal may be removed
100 percent provided cumulative length of all blends on remain-
ing seal teeth do not exceed 8 in. (203 mm). Measurements to be
made at outside diameter of serrations (including blend radius).
Do not leave serration sections less than one in. (25 mm) long
between blends.
c. Cracked or Not serviceable Any number may be Blend. Inspect for
cracked out blended out if they can cracks
serrations be completely
removed within limits
of preceding NOTE
and figure 13
d. Nicks and Any number, 0.03 in Any number may be Blend. Inspect for
dents (0.8 mm) deep after blended out if they can cracks
removal of high metal be completely
of preceding NOTE*
and figure 13
e. Scratches Any number, 0.010 in Any number may be Blend. Inspect for
(0.26 mm) deep after blended out if they can cracks
removal of high metal be completely
of preceding NOTE*
and figure 13
f. Bending Not serviceable Any lenght may be Straighten with hand
straightened a maxi- tools. Shall not be
mum of 0.13 in overbent and rebent.
(3.3 mm) axially Inspect for cracks

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On-Site On-Site
FORWARD SHAFT
NOTE
Limits for areas aft of 13 in. (330 mm) from shaft front face.
1. All Areas for:
per NOTE* at begin-
2. Splines for:
a. High metal Not servicable Any amount Remove high metal
b. Nicks and Any number 0.03 in Not repairable Replace turbine rotor
dents (0.8 mm) deep, 0.03 in per NOTE* at begin-
(0.8 mm) wide by ning of this table**
0.25 in (6.4 mm) long
metal. None allowed
in root radii. Total
area of nicks and dents
on each tooth not to
exceed 15 percent of
that tooth area
c. Scratches Any number, 0.020 in Not repairable Replace turbine rotor
(0.52 mm) deep, per NOTE* at begin-
0.06 in (1.6 mm) ning of this table**
wide, 0.63 in (16 mm)
long after removal of
high metal. None
allowed in root radii.
Total area of scratches
on each tooth not to
that tooth area

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On-Site On-Site
3. Pilot for:
a. Nicks and Any number, 0.06 in Not repairable Replace turbine rotor
dents (1.6 mm) deep after per NOTE* at begin-
b. Pickup and Not serviceable Any amount Remove high metal
high metal
c. Scratches Any number, 0.010 in Any number provided Blend to remove
(0.26 mm) deep, any not more than 13 per- damage
length cent of surface is
affected
4. External Surfaces for:
a. Nicks Any number, 0.010 in Any number, 0.016 in Blend to remove dam-
(0.26 mm) deep after (0.4 mm) deep age and inspect for
removal of high metal cracks
b. Dents Any number, 0.016 in Not repairable Replace turbine rotor
(0.4 mm) deep per NOTE* at begin-
c. Scratches Any number, any Any number, 0.010 in Blend to remove
length 0.005 in (0.26 mm) deep damage
5. Cooling Air Holes for:
a. Nicks and Not servicable Any number that can Blend to remove
scratches be removed by blend- damage
ing to a maximum of
0.03 in (0.8 mm) deep.
Holes can be
increased in diameter
by 0.13 in (3.3 mm)
and edge radius
increased to 0.13 in
(3.3 mm) maximum
(true radius not
required) to remove
damage

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On-Site On-Site
STAGES 1 AND 2 BLADE RETAINERS (3), (9)
1. All Areas for:
a. Cracks Not serviceable Not repairable Replace blade
retainer; however,
engine vibration levels
must not be exceeded
during engine
operation
b. Nicks and Any number, 0.010 in Any number, 0.016 in Blend to remove
dents (0.26 mm) deep (0.4 mm) deep damage
length, 0.010 in (0.4 mm) deep damage
(0.26 mm) deep
STAGES 1 AND 2 DISKS (4), (10)
1. All Areas for:
per NOTE* at begin-
2. Dovetail Serrations for:
a. Nicks and Three per dovetail ser- Corner radii of dove- Blend to remove
dents rations, 0.010 in tail and posts can be damage
(0.26 mm) deep after locally increased to
removal of high metal 0.08 in (2 mm) radius
to remove nicks and
dents

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On-Site On-Site
b. Scratches Any number, any Not repairable Replace turbine rotor
length, 0.003 in per NOTE* at begin-
(0.078 mm) deep, ning of this table**
metal, provided they
are not located on root
radii or pressure faces.
Root radii or pressure
face scratches not
serviceable
c. Fretting Not serviceable Not repairable Replace turbine rotor
per NOTE* at begin-
3. Rim (OD of Disks) for:
a. Nicks Any number, 0.016 in Any number that can Blend to remove
(0.4 mm) deep after be removed by blend- damage
removal of high metal ing to a maximum
depth of 0.05 in
(1.2 mm)
(1.2 mm) deep after per NOTE* at begin-
c. Scratches Any number, any Any number that can Blend to remove
length, 0.016 in be removed by blend- damage
(0.4 mm) deep after ing to a maximum
removal of high metal depth of 0.05 in
(1.2 mm) and 0.25 in
(6.4 mm) long
d. Galling Any amount, 0.010 in Not repairable Replace turbine rotor
(0.26 mm) deep, per NOTE* at begin-
0.50 in (12.7 mm) ning of this table**
long after removal of
high metal and sharp
edges

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4. Disk Web (Stage 2 Disk Only) for:
a. Nicks and Any number, any Any number that can Blend to remove
scratches length, 0.016 in be removed by blend- damage
(0.4 mm) deep after ing to a maximum of
removal of high metal 0.03 in (0.8 mm) deep
and 0.50 in (12.7 mm)
long. Polish to same
finish as adjacent area
STAGES 1 AND 2 DAMPER SEALS (5), (8)
1. All Areas for:
a. Cracks Not servicable Not repairable Replace damper seal
b. Galling 0.005 in (0.13 mm) Not repairable Replace damper seal
high metal
2. End Faces for:
a. Nicks, dents, 0.020 in (0.52 mm) Not repairable Replace damper seal
scratches deep after removal of
high metal
THERMAL SHIELD (7)
1. All Areas Except Seal Serrations for:
per NOTE* at begin-
b. Scratches Any number, 0.005 in Any number, 0.010 in Blend to remove
(0.13 mm) deep, (0.26 mm) deep damage
0.50 in (12.7 mm)
long
c. Nicks Any number, 0.010 in Any number, 0.016 in Remove high metal
(0.26 mm) deep (0.4 mm) deep

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d. Dents Any number, 0.03 in Not repairable Replace turbine rotor
2. External Seal Serrations for:
a. Turned metal Not servicable Any amount provided Remove turned metal
minimum OD is
within wear limits of
figure 14
NOTE
Maximum cumulative blend length on any one tooth shall not
exceed 5 in. (127 mm). Total cumulative length of all blends on
the four serrations shall not exceed 10 in. (254 mm). Measure-
ment to be made at OD of serrations (including blend radius). Do
not leave sections of seal tooth shorter than one in. (25 mm) long
between blends.
b. Cracks or Not serviceable Any number may be Blend. Inspect for
cracked out blended out if they can cracks
serrations be completely
of preceding NOTE*
and minimum OD
limits of figure 14
c. Nicks Any number, 0.03 in Any number may be Blend. Inspect for
(0.8 mm) deep pro- blended out if they can cracks
vided there is no crack be completely
and high metal is removed within limits
removed of preceding NOTE*
and figure 13
d. Dents Any number, 0.03 in Any number may be Blend. Inspect for
(0.8 mm) deep blended out if they can cracks
be completely
of preceding NOTE*
and figure 13

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e. Bending Not serviceable Any length may be Straighten; may not be
straightened a maxi- overbent and rebent.
mum of 0.13 in Inspect straightened
(3.3 mm) axially area for cracks
f. Wear on OD Within limits of Not repairable Replace turbine rotor
figure 14 per NOTE* at begin-
REAR SHAFT (11)
1. All Areas Except Seal Serrations for:
per NOTE* at begin-
2. Threads for:
a. Damage Accept nicks and Total removal of first Remove all thread
(nicks, dents, dents 0.06 in (1.6 mm) half of entrance thread pickup and high
pickup, or high deep after removal of is permissible if
metal) high metal remainder of threads
are free of damage. If
entrance thread is free
of damage, the cumu-
lative length of dam-
age in other areas
must not exceed
50 percent of one
complete thread
3. No. 5 Bearing Journal for:
a. Pickup and Not serviceable Any amount Remove high metal
high metal
b. Nicks, dents, Any number, 0.010 in Not repairable Replace turbine rotor
scores, and (0.26 mm) deep after per NOTE* at begin-
scratches removal of high metal ning of this table**
provided not more
than 5 percent of jour-
nal OD is affected in
any 90 degree sector

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On-Site On-Site
4. No. 5 Bearing Air and Oil Seal Serrations for:
a. Wear on OD Acceptable provided Not repairable Replace turbine rotor
average reading of an per NOTE* at begin-
8-point diametral ning of this table**
check is within limits
of figure 14
NOTE
Total cumulative length of all blends on serrations A shall not
exceed 7 in. (178 mm). Total cumulative length on serrations B,
C, or D shall not exceed 3 in. (76 mm). Measurements to be made
at outside diameter of the serrations (including blend radius).
Minimum blend radius to be 0.06 in. (1.6 mm). Do not leave ser-
ration sections less than 0.50 in. (12.7 mm) long between blends.
b. Cracked or Not serviceable Any number may be Blend. Inspect for
cracked out blended out if the cracks after blending
serrations crack can be com- per figure 13
pletely removed by
blending a maximum
of 0.100 in (2.6 mm)
deep, one in (25 mm)
long and within limits
of preceding NOTE*
c. Nicks and Any number, 0.03 in Any number may be Blend. Inspect for
dents (0.8 mm) deep pro- blended out if they can cracks after blending
vided there is no crack be completely per figure 13
and high metal is removed by blending
removed a maximum of
0.100 in (2.6 mm)
deep, one in (25 mm)
long and within limits
of preceding NOTE*
d. Bending Not serviceable Any length may be Straighten with hand
straightened a maxi- tools. Shall not be
mum of 0.06 in overbent and rebent.
(1.6 mm) axially Inspect straightened
area for cracks

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5. Flanges for:
(0.4 mm) deep be removed by blend- damage
ing a maximum of
0.03 in (0.8 mm) deep
(0.26 mm) deep after ing a maximum of
removal of high metal 0.02 in (0.4 mm) deep
d. High metal Not serviceable Remove high metal
e. Damaged 0.03 in (0.8 mm) Not repairable Replace turbine rotor
wrenching deformation after per NOTE* at begin-
slots removal of high metal ning of this table**
6. All Other Areas for:
(0.26 mm) deep after be removed by blend- damage
removal of high metal ing a maximum of
0.016 in (0.4 mm)
deep
(0.13 mm) deep ing a maximum of
0.010 in (0.26 mm)
deep

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PRESSURE TUBE
1. Internal Surfaces for:
per NOTE* at begin-
b. Buckling Not serviceable Not repairable Replace turbine rotor
per NOTE* at begin-
COUPLING NUT
1. Threads for:
a. Damage Not serviceable Threads may be Blend to remove dam-
blended a maximum age. Repaired threads
of one half thread must have finish at
height, 0.13 in adjacent area
(3.3 mm) long to
remove damage. A
maximum of 4 such
repairs spaced at least
0.50 in (12.7 mm)
apart
b. Pickup and Not serviceable Any amount Remove pickup and
high metal high metal
2. Splines for:
a. Nicks and Any number, 0.06 in
dents (1.6 mm) deep after
b. Cracks Not serviceable Not repairable Replace turbine rotor
per NOTE* at begin-
** May be repairable, consult GE for disposition of replace part.

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Figure 15. High Pressure Turbine Twin Shank Rotor Blades

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Table 3. HIGH PRESSURE TURBINE TWIN SHANK ROTOR BLADES
On-Site
Max Serviceable On-Site On-Site
Inspect Limits Max Repairable Limits Corrective Action
NOTE*
If HPT rotor must be replaced, the complete HPT stage 2 nozzle
matched set.
STAGE 1 BLADES ONLY. See figure 15.
1. Leading Edge for:
a. Cracks Any number, 5.32 in Not repairable Replace blade per
(3.969 mm) long pro- paragraph 10 or
vided they do not inter- replace turbine rotor
sect adjacent holes. per NOTE* at
None allowed in beginning of this
area B table**
b. Blocked holes Total of three holes, Not repairable Replace blade per
one only in area B, paragraph 10 or
separated by one replace turbine rotor
per NOTE* at
beginning of this
table**
c. Erosion/ Any amount in area A, Not repairable Replace blade per
corrosion provided wall is not paragraph 10 or
penetrated. Any replace turbine rotor
amount in area B, proper NOTE* at
vided it is not through beginning of this
coating. If coating in table**
area B is penetrated,
gas generator must be
replaced within
1800 hours and bores-
cope inspected at
600 hour intervals

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Table 3. HIGH PRESSURE TURBINE TWIN SHANK ROTOR BLADES - Continued
On-Site
2. Trailing Edge for:
a. Cracks Not serviceable Not repairable Replace blade per
paragraph 10 or
replace turbine rotor
per NOTE* at
beginning of this
table**
b. Clogged air Top hole plus three Not repairable Replace blade per
passages additional holes in any paragraph 10 or
above the bottom eight replace turbine rotor
holes provided no two per NOTE* at
are adjacent. None beginning of this
allowed in bottom table**
eight holes
c. Erosion/ Any amount in area A Not repairable Replace blade per
corrosion provided cooling holes paragraph 10 or
are not penetrated replace turbine rotor
from either concave or per NOTE* at
convex walls. If coat- beginning of this
ing in area B is pene- table**
trated, gas generator
must be replaced
within 1800 hours and
borescope inspected at
600 hour intervals
3. Concave and Convex Surfaces for:
a. Cracks at gill Not serviceable Not repairable Replace blade per
holes or airfoil paragraph 10 or
per NOTE* at
beginning of this
table**

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b. Blocked gill Top gill hole plus one Not repairable Replace blade per
holes additional hole per row paragraph 10 or
not within 0.25 in replace turbine rotor
(6.35 mm) of root per NOTE* at
beginning of this
table**
c. Distortion or Not serviceable Not repairable Replace blade per
evidence of paragraph 10 or
burning or replace turbine rotor
melting per NOTE* at
beginning of this
table**
STAGE 2 BLADES ONLY. See figure 15.
1. All Areas for:
a. Cracks Not serviceable Not repairable Replace blade per
paragraph 11 or
per NOTE* at
beginning of this
table**
STAGE 1 AND 2 BLADES
a. Nicks and Any amount provided Not repairable Replace blade per
dents there is no torn metal paragraph 10 and 11
or cracks or replace turbine
rotor per NOTE* at
beginning of this
table**
b. Tears Not serviceable Not repairable Replace blade per
paragraph 10 and 11
or replace turbine
rotor per NOTE* at
beginning of this
table**

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On-Site
a. Nicks and Any amount provided Not repairable Replace blade per
dents there is no torn metal paragraph 10 and 11
or cracks or replace turbine
rotor per NOTE* at
beginning of this
table**
a. Nicks and Not serviceable Not repairable Replace blade per
dents paragraph 10 and 11
or replace turbine
rotor per NOTE* at
beginning of this
table**
4. Blade Tips for:
NOTE
Blade tip is the area from the blade tip down to the top of the
metering cap for stages 1 and 2 blades (reference: 0.100 in.
(2.54 mm) above the top gill hole for stage 1).
a. Cracks in Any number of radial Not repairable Replace blade per
stages 1 and 2 cracks 0.300 in long paragraph 10 and 11
blade tips or replace turbine
rotor per NOTE* at
beginning of this
table**
One axial crack Not repairable Replace blade per
allowed provided it is paragraph 10 and 11
no longer than 0.50 in or replace turbine
(12.7 mm) and 0.10 in rotor per NOTE* at
(2.5 mm) above the top beginning of this
gill hole for stage 1 or table**
in the area from the
blade tip down to the
top of the tip metering
cap for stage 2

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On-Site
b. Bent or curled Any amount
blade tips
c. Dents in lead- Any depth if metal is Not repairable Replace blade per
ing edge of not torn paragraph 10 and 11
stage 1 blade or replace turbine
rotor per NOTE* at
beginning of this
table**
d. Missing pieces Any amount above
blade tip metering cap
** May be repairable, consult GE for disposition of replaced parts.
Figure 16. High Pressure Turbine Oil Tube

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Figure 17. High Pressure Turbine Twin Shank Rotor Damper Sleeve

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Table 4. HIGH PRESSURE TURBINE OIL TUBE AND DAMPER SLEEVE
On-Site On-Site
OIL TUBE. See figure 16.

1. All Areas Except Threads for:
a. Cracks Not serviceable Not repairable Replace oil tube*
b. Distortion or Not serviceable Not repairable Replace oil tube*
buckling
c. Nicks and Any number, any Not repairable Replace oil tube*
(0.4 mm) deep after
except 0.005 in
(0.13 mm) deep on
inner tube
d. Dents Any number, 0.03 in Not repairable Replace oil tube*
(0.8 mm) deep, pro-
vided tube is not bent
2. Threads for:
a. Damage Accept nicks and Total removal of Remove all thread
(nicks, dents, dents 0.06 in entrance thread is per- pickup and high
pickup, or (1.6 mm) deep after missible provided metal. If entrance
high metal) removal of high metal remainder of threads thread is removed,
are free of damage. If lead-in radii must
entrance thread is free be contoured same
of damage, the cumu- as original
lative length of dam-
age to other threads
must not exceed 1/2
of one complete
thread

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Table 4. HIGH PRESSURE TURBINE OIL TUBE AND DAMPER SLEEVE - Continued
On-Site On-Site
DAMPER SLEEVE. See figure 17.

1. All Areas for:
a. Nicks and Not serviceable Any amount to 0.05 in Remove high metal
scratches (0.13 mm) deep
b. Buckling Not serviceable Not repairable Replace sleeve*
c. Cracks Not serviceable Not repairable Replace sleeve*
2. Sleeve Outside Diameter (Both Ends) for:
a. Free-state Six point average of Any amount Re-form as neces-
dimension 5.87-6.50 in sary to within ser-
(149.1-165.1 mm) viceable limits. No
gaps permitted at
step after reforming
3. Area J for:
a. Fretting Any amount to Any amount to
0.003 in (0.076 mm) 0.006 in (0.16 mm)
deep. No fretting per- deep
mitted in fillet at aft
area J
* May be repairable, consult GE for disposition of replaced part.

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.
Figure 18. High Pressure Turbine Nozzles
Table 5. HIGH PRESSURE TURBINE NOZZLES
On-Site On-Site
STAGE 2 HIGH PRESSURE TURBINE NOZZLE. See figure 18.

a. Axial cracks Any number, 0.09 in Not repairable Replace nozzle or
in trailing (2.4 mm) long, two segment*
edge per vane, 0.50 in
(12.7 mm) long, pro-
vided they are 0.25 in
(6.4 mm) apart
b. Axial cracks Not serviceable Not repairable Replace nozzle or
leading edge segment*
c. Cracks in con- Two cracks 1.50 in Not repairable Replace nozzle or
cave surfaces (38.1 mm) maximum segment*
length

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Table 5. HIGH PRESSURE TURBINE NOZZLES - Continued
On-Site On-Site
d. Craze cracking Any amount

NOTE
Craze cracking is defined as numerous superficial surface cracks
which have no visual width or depth.
e. Buckling of Any number, 0.06 in Not repairable Replace nozzle or
trailing edge (1.6 mm) from origi- segment*
nal contour
f. Burns on air- 1.00 in square Not repairable Replace nozzle or
foil surfaces (4.5 sq. cm) area with segment*
no through metal
thickness
g. Corrosion Any amount provided Not repairable Replace nozzle or
corrosion is not com- segment*
pletely through metal
thickness
h. Nicks, scores, Any number, 0.25 in Not repairable Replace nozzle or
scratches, or (6.4 mm) long, 0.03 in segment*
dents (0.8 mm) deep after
i. Buckling of 0.06 in (1.6 mm) from Not repairable Replace nozzle or
trailing edge original contour segment*
j. Eroded areas Any amount, 0.016 in Not repairable Replace nozzle or
(0.4 mm) deep segment*
a. Cracks Any number, 0.63 in Not repairable Replace nozzle or
between vanes (16 mm) long sepa- segment*
rated by 0.25 in
(6.3 mm)
b. Craze cracking Any amount

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Table 5. HIGH PRESSURE TURBINE NOZZLES - Continued
On-Site On-Site
NOTE
Craze cracking is defined as numerous superficial surface cracks
which have no visual width or depth.
c. Cracks in band Two cracks, 0.38 in Not repairable Replace nozzle or
trailing edge (9.7 mm) long, any segment*
number 0.13 in
(3.3 mm) long
STAGE 1 AND STAGE 2 SHROUD
1. Shroud for:
a. Wear Any amount as long Not repairable Replace shroud*
as backing strip is not
damaged
b. Erosion Total eroded area Not repairable Replace shroud*
missing not to exceed
10 percent provided
missing area is not
completely across
axial width of shroud;
no single area to
exceed 1.00 square in
(6.4 cm2)
c. Axial cracks Two per shroud seg-
ment 0.25 in (6.3 mm)
long; one per shroud
segment 1.00 in
(25 mm) long
d. Distortion Free state distortion Not repairable Replace shroud*
allowable, provided
proper assembly and
blade clearance can be
maintained

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9. PARTS REPAIR. Parts repair is limited to mechanical straightening, benching of parts, re-
forming, blending, cleaning holes, or replacing as noted during inspection operation. (See appli-
cable table.)
10. PARTS REPLACEMENT - HPT TWIN SHANK ROTOR STAGE 1 BLADE PAIRS.
a. Remove stage 1 blade pair as follows:
(1) Matchmark stage 1 blade retainer (7, figure 19) to turbine rotor and matchmark nuts
to blade retainer. All parts shall be installed in same position from which they were removed.
CAUTION
OBSERVE CARE WHEN REMOVING STAGE 1 BLADE
RETAINER TO PREVENT DISLODGING BALANCE
WEIGHTS WHICH ARE ON BOLTHEADS BENEATH
RETAINER.
(2) Remove stage 1 blade retainer (7) by removing 27 nuts. If necessary, use jackscrews
to break retainer loose. Place a protective cover over rotating air seals on front shaft. Slide
retainer down front shaft and allow it to rest behind rotating seals.
(3) Ensure blades are position-marked so that they can be re-installed in the positions
from which they are removed, and remove the stage 1 blade pairs (9) by moving them forward.
CAUTION
BLADES MUST BE PROTECTED FROM CONTAMINATION
AT ALL TIMES WHEN REMOVED FROM ROTOR TO PRE-
VENT CLOGGING OF AIRHOLES.
(4) Place blade pairs in container and cover with lid.

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Figure 19. High Pressure Turbine Twin Shank Rotor Assembly

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(5) Ensure damper seals are position-marked so that they can be re-installed in the posi-
tions from which they are removed. Remove the damper seals (18) from the disk between blade
pairs.
(6) Remove stage 1 blade retainer from front shaft.
(7) Remove air seal (8) from groove in rear side of stage 1 blade retainer.
b. Select replacement stage 1 blade pairs as follows:
NOTE
If individual blades are being replaced, select blades per step (1). If
all stage 1 blades are being replaced, calculate blade position per
step (3).
(1) Replacement blade pairs shall be of equal weight within two grams of blade pairs
which they replace (figures 20 and 21).
(2) Six blade pairs may be replaced provided replacement blade weight does not differ
from original blade weight by three grams in any one quadrant. If this is not possible see blade
replacement guide, figure 21, for acceptable replacement limits of typical blade pair
combinations.
(3) If all stage 1 blades are being replaced, calculate blade position using GE computer-
ized balance program, 9470M55G01.
c. Install replacement stage 1 blade pairs as follows:
CAUTION
ENSURE ALL BLADES BEING RE-INSTALLED ARE
INSTALLED IN THE POSITIONS FROM WHICH THEY WERE
REMOVED.
(1) Install a stage 1 blade pair (4, figure 22) from the front side of the disk. Ensure blade
pairs and damper seals being re-installed are installed according to position marks made during
removal. Make certain damper seals are installed with F mark facing forward. Continue until all
blades and damper seals are installed.

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Figure 20. High Pressure Turbine Twin Shank Rotor Blade Comparison

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Figure 21. High Pressure Turbine Twin Shank Rotor Blade Replacement Guide

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Figure 22. High Pressure Turbine Twin Shank Rotor Blade Installation

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(2) Measure dimension AL between damper seal and blade pair using feeler stock. Hold
blade pairs together so there is no gap at AC between blade side rails. Blades must be held radi-
ally outward and damper seal radially inward while checking dimensions AL. Minimum
0.002 inch (0.05 mm) clearance, maximum 0.025 inch (0.64 mm) clearance. If clearance is
exceeded, replace damper seal. If clearance is 0.016-0.025 inch (0.41-0.64 mm) the force test of
(3) is required.
NOTE
With blades extended radially outward and separated to maximum
opening at AC, damper seals must not be dislodged with a hand
pressure force at outer forward surface. Force test is not required if
clearance is less than 0.015 inch (0.38 mm) at AL as measured in
substep (2).
(3) Apply hand pressure against forward face of damper seal while holding blade pairs
radially outward and separated. If damper seals are dislodged by hand pressure, replace damper
seals or blade pairs as required.
(4) Check clearance AK. Hold damper seal radially outward so it is seated at AD and
AE. Hold blade pairs together so there is no gap at AC. Move inner end of damper seal from side
to side. A slight movement must be felt. If no movement is felt, replace damper seal.
(5) Measure dimension M, between forward leg of damper seal and rotor disk using
feeler stock. Hold damper seal fully forward while measuring dimension M. Dimension M must
be slip fit to 0.0065 inch (0.165 mm) minimum. This may be determined as follows:
(6) Accumulative platform gap (AC) shall be 0.820 inch (20.83 mm) minimum. This
may be determined as follows:
(a) Separate a group of four to six blade pairs from adjacent blade pairs by pushing
blades circumferentially so that blade bases are tight together within the group.
(b) Measure the gap between groups by inserting feeler stock between groups.
Leave feeler stock in place. Feeler stock shall be 0.150 inch (3.81 mm) minimum inward radially
from blade platform.
(c) Repeat substeps (a) and (b) for another group of four to six blade pairs adjacent
to first group.
(d) Continue separating blade pair groups and inserting feeler stock until all circum-
ferential gaps are filed.
(e) Add up the total amount of feeler stock used in measuring gaps between blade
groups. Sum is total accumulative platform gap.

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(f) If limits are exceeded, replace damper seals or blade pairs as necessary. Refer to
blade replacement guide for replacing blade pairs to maintain rotor balance.
(7) If stage 1 blade retainer is replaced, proper fit of replacement retainer to disk shall be
ensured according to the following substeps.
(a) Install shims of equal thickness as slave parts on 27 stud heads where stage 1
blade retainer will seat. Shims shall be thick enough so that retainer, when installed for trial fit,
will have a gap at disk rim. Record thickness of shims as dimension D.
(b) Install stage 1 retainer, for trial fit, so that it seats on shims installed in
substep (a). Secure retainer with 27 free running nuts tightened handtight.
(c) Measure gap, using feeler stock, between retainer and stage 1 disk rim at each
stud location. Record as dimension E.
(d) Subtract dimension D, substep (a) from dimension E, substep (c) to determine
actual maximum clearance (or minimum interference) between stage 1 blade retainer and stage 1
disk.
(e) Remove shims.
(8) Install all balance weights, if removed during disassembly, at the position from which
they were removed. Lockwire balance weights in place.
(9) Install air seal in groove in rear side of stage 1 blade retainer. Use adhesive No. 77 or
No. 1870 (3M Co.) to hold seal in position.
(10) Install stage 1 blade retainer according to the matchmark to stage 1 disk. Secure
retainer with 27 nuts, coated with antiseize compound, A50TF201 and tighten to 35-45 lb in.
(4.0-5.1 N·m) of torque. Loosen nuts one-half turn, then retighten to 35-45 lb in. (4.0-5.1 N·m) of
torque.
CAUTION
GAP SHALL NOT EXCEED 0.010 INCH (0.25 MM) CLEAR-
ANCE AND INTERFERENCE SHALL NOT EXCEED
0.009 INCH (0.23 MM).
(11) Surface of blade retainer which mates to face of disk may be ground to a fit of
0.009 inch (0.23 mm) maximum interference to 0.003 inch (0.08 mm) gap. Grinding shall be
done at point of maximum interference.

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(12) Visually check that no gap exists at any point between retainer and stage 1 disk. If a
blade has an axial length greater than the disk thickness, a maximum gap of 0.003 inch (0.08 mm)
may exist at that blade only between disk and blade retainer.
(13) Ensure that there is a radial clearance between stage 1 blade retainer and front shaft
of rotor after bolts have been tightened. Use feeler gage if visual inspection is in doubt.
(14) Check blade tip shake. Minimum 0.010 inch (0.25 mm) is a circumferential direc-
tion. If in doubt, use a dial indicator. Replace blade or damper seal if minimum tip shake is not
met.
11. PARTS REPLACEMENT - HPT TWIN SHANK ROTOR STAGE 2 BLADE PAIRS.
a. Remove stage 2 blade pairs as follows:
(1) Matchmark stage 2 blade retainer (13, figure 19) to turbine rotor.
(2) Number stage 2 blade pairs (11) starting at 1-1 mark on disk dovetail tangs. Work in
clockwise direction (aft looking forward), fifth blade pair should be between 5-5 mark on disk
dovetail tangs.
(3) Number damper seals (14) in clockwise direction. No. 1 seal shall be just to right of
No. 1 blade pair.
(4) Loosen all bolts securing blade retainer (13), but do not remove bolts.
(5) Place masking tape over boltheads to hold bolts in retainer.
(6) Remove blade retainer with bolts in retainer.
(7) Remove air seal (12) from forward side of retainer.
(8) Remove blade pairs (11) by pulling them out rear of disk. Place blade pairs in con-
tainer and install cover on container.
(9) Remove damper seals (14).
b. Select replacement stage 2 blade pairs as follows:
NOTE
If individual blades are being replaced, select blades per step (1). If
all stage 2 blades are being replaced, calculate blade position per
step (3).
(1) Replacement blade pairs shall be of equal weight within two grams of blade pairs
which they replace (figures 20 and 21).

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(2) Six blade pairs may be replaced provided replacement blade weight does not differ
from original blade weight by three grams in any one quadrant. If this is not possible see blade
replacement guide, figure 21, for acceptable replacement limits of typical blade pair
combinations.
(3) If all stage 2 blades are being replaced, calculate blade position using GE computer-
ized balance program, 9470M55G01.
c. Install replacement stage 2 blade pairs as follows:
CAUTION
ENSURE ALL BLADES BEING RE-INSTALLED ARE
INSTALLED IN THE POSITIONS FROM WHICH THEY WERE
REMOVED.
(1) Install a stage 2 blade pair (figure 22) from rear side of disk. Install a damper seal
then another blade pair. Ensure blade pairs and damper seals being re-installed are installed
according to position marks made during disassembly to maintain rotor balance and clearances.
Make certain damper seals are installed with F mark facing forward.
(2) Measure dimension AN using feeler stock. Hold blade pairs together so there is no
gap at AF between blade side rails. Blades must be held radially outward and damper seal radi-
ally inward while checking dimension AN. Minimum clearance 0.002 inch (0.05 mm); maximum
clearance 0.025 inch (0.64 mm).
NOTE
With blades extended radially outward and separated to maximum
opening at AF, damper seals must not be dislodged by hand pres-
sure force at outer aft surface. Force test is not required if clearance
is less than 0.015 inch (0.38 mm) at AN as measured in substep (2).
(3) Apply hand pressure against aft face of damper seal while holding blade pairs radi-
ally outward and separated. If damper seals are dislodged by hand pressure, replace damper seals
or blade pairs as required.
(4) Check for clearance at AM. Hold damper seal radially outward so it is seated at AG
and AH. Hold blade pairs together so there is no gap at AF. Move inner end of damper seal from
side to side. A slight movement must be felt. If no movement is felt, replace damper seal.
(5) Measure dimension M, between rear leg of damper seal and disk. Hold damper seal
fully to rear while measuring. Dimension M must be slip fit to 0.0065 inch (0.165 mm). If limits
are exceeded, replace seal.

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(6) Accumulated platform gap (AF) shall be 0.530 inch (13.46 mm) minimum. This may
be determined as follows:
(a) Separate a group of four to six blade pairs from adjacent blade pairs by pushing
blades circumferentially so that blade bases are tight together within the group.
(b) Insert feeler stock to fill the gap between groups of blades. Leave feeler stock in
place. Feeler stock shall be 0.150 inch (3.81 mm) minimum inward radially from blade platform.
(c) Repeat substeps (a) and (b) separating another group of four to six blade pairs
adjacent to first group.
(d) Continue separating blade pairs into groups and inserting feeler stock between
groups until all gaps are filled.
(e) Add up the total amount of feeler stock used to fill gaps between groups. Sum is
total accumulated platform gap.
(f) If limits are exceeded, replace damper seals or blade pairs as required. Refer to
blade replacement guide for replacing blade pairs to maintain rotor balance.
(7) Install seal into groove in forward face of stage 2 blade retainer. Use adhesive No. 77
or No. 1870 (3M Co.) to hold seal in position.
CAUTION
RETAINER BOLTS FOR STAGE 2 BLADE RETAINER SHALL
BE REINSTALLED IN SAME POSITION FROM WHICH THEY
WERE REMOVED.
(8) Install stage 2 blade retainer and seal according to the matchmark made during
removal. Do not allow bolts to become dislodged during installation. Coat bolt threads and seat-
ing surface using antiseize compound, A50TF201. Bolts must maintain a running torque of
3.5 lb in. (0.4 N·m). Tighten bolts to 110-120 lb in. (12.4-13.6 N·m) of torque, loosen one half
turn, then retighten to 110-120 lb in. (12.4-13.6 N·m) of torque.
(9) Visually inspect to make certain that seal has remained in place. Visually inspect to
ensure there is no gap between retainer and disk. A local gap, up to 0.010 inch (0.25 mm) is
allowed at a blade, if blade base is thicker than disk rim at that place.
(10) Check blade tip shake. Minimum 0.010 inch (0.3 mm) in a circumferential direction.
If in doubt, use a dial indicator. Replace blade or damper seal if minimum tip shake is not met.

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12. PARTS REPLACEMENT - STAGE 2 HPT NOZZLE SEGMENTS.
CAUTION
MACHINED AS A MATCHED SET. ENSURE ASSEMBLIES
ARE TAGGED AND IDENTIFIED AS A SET WHEN EITHER
MUST BE REMOVED. ALL PARTS MUST BE MATCH-
MARKED AS THEY ARE REMOVED TO ENSURE ASSEM-
BLY IN SAME RELATIVE POSITION. SHROUDS AND
INTERSTAGE SEALS CANNOT BE REPLACED AT LEVEL 2
AND MUST BE ASSEMBLED TO SAME RELATIVE POSI-
TION TO MAINTAIN PROPER CLEARANCES BETWEEN
ROTATING AND STATIONARY PARTS.
a. Remove stage 2 turbine nozzle segments as follows:
(2) Remove stage 2 rotor blades as follow: See figure 23.
(b) Number stage 2 blade pairs starting at 1-1 mark on rotor disk dovetail tangs.
Number blade pairs working in clockwise direction (aft looking forward). Fifth blade pair should
be between 5-5 mark on disk.
blade pair No. 1.
(d) Loosen all bolts securing blade retainer, but do not remove bolts.
(h) Remove blade pairs by pulling them out from rear of disk. Place blade pairs in
container and install cover on container.
(3) Remove stage 2 nozzle assembly from high pressure turbine rotor and place it aft side
down on a flat surface.

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Figure 23. Stage 2 High Pressure Turbine Nozzle Assembly

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(4) Remove the 24 nuts and clips (2) from filter screen assembly. Remove filter screen
assembly.
(5) Remove ring retainer (6) from cooling tube at outer end of each nozzle segment. Use
a pointed tool to compress the retaining ring. Remove retaining ring, using needle nose pliers.
Discard retaining ring.
(6) Lift the spring washer (7) from the port and discard.
(7) Use puller (Snap-On CJ93 or alternate 2C6623) to remove the tube (5). Insert the
tool into the tube, spread the legs, and drive out the tube.
(8) Turn nozzle assembly, by hand, forward side down.
(9) Matchmark stage 2 shroud aft support (10) to nozzle support (4) and remove shroud
support by removing 33 bolts and nuts.
(10) The aft flange of the nozzle support (4) has extra holes to use in removing aft shroud
support (10). Using a small drift inserted through the holes against the aft shroud support, gently
tap the drift against the shroud support, moving it away from the nozzle support flange.
(11) Matchmark stage 2 shroud segments (11) to forward shroud support (13).
CAUTION
DO NOT USE ENOUGH FORCE AT ANY ONE POINT TO
DAMAGE THE PARTS.
(12) Insert the tip of a flat screwdriver between the front edge of the stage 2 shroud seg-
ment (11) and the aft edge of the nozzle segment (15) outer web, and with a twisting movement
gently pry the shroud segments back from the nozzle segments. Work around the nozzle assem-
bly, moving the shroud segments back about 0.06 inch (1.6 mm) at a time, until the segments
come loose from the forward support (13) and the aft shroud support (10) comes loose from the
nozzle support (4).
(13) Remove the eleven stage 2 shroud segments (11) from forward shroud support (13).
(14) Remove and discard shroud seals (12) from end grooves in shrouds.
(15) Loosen, but do not remove, the interstage seal mounting bolts (17).
(16) Matchmark stage 2 forward shroud support (13) to nozzle support.
(17) Remove all nuts from slabhead bolts (8) that secure the outer nozzle segment flange
to the nozzle support.

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(18) Lift off the stage 2 shroud forward supports (13).
(19) Carefully lift interstage seal (18) and nozzle segment ring from the nozzle support.
(20) If necessary to replace slabhead bolt, remove slabhead bolts (8) from nozzle
support (4) by pushing bolts out of push nuts (9). Using a punch and a hammer, gently tap the
slabhead bolts (8) from the nozzle support inner mounting flange.
(21) Discard the push nuts (9).
(22) Disassemble the nozzle segment ring and interstage seal as follows:
(a) Put subassembly on a flat work surface.
(b) Remove the interstage seal bolts (17) and slide the nozzle segments (15) from
the interstage seal (18). Discard the nozzle seals (14 and 16). Place nozzle segments in container.
CAUTION
SHROUDS AND INTERSTAGE SEALS CANNOT BE
REPLACED AT LEVEL 2 AND MUST BE ASSEMBLED TO
SAME RELATIVE POSITION TO MAINTAIN PROPER
CLEARANCES BETWEEN ROTATING AND STATIONARY
PARTS.
b. Install stage 2 turbine nozzle segments as follows:
(1) Place stage 2 nozzle support (4, figure 23) on low workbench, aft end up.
(2) Place six interstage air seals (18), forward end down, on a skid or low workbench.
Alternate the 5 and 6 bolthole segments to form a circle. Identify and mark the center point (rivet)
of one 6 bolthole segment as TOP. This mark will be used for orientation during remainder of
assembly. Position mark interstage seal segments.
CAUTION
DO NOT APPLY EXCESSIVE END PRESSURE TO BOLTS/
SCREWS AS NUTS MAY BE PUSHED FROM GANG
CHANNELS.
(3) Install stage 2 nozzle segment (15) marked 1-66 to interstage air seal at TOP mark
made in previous substep. Position bolthole in nozzle segment in line with first bolthole counter-
clockwise from TOP mark on air seal. Secure with a bolt. Tighten but do not torque. Mark trail-
ing edge of vane in line with TOP mark as vane No. 1, if not marked at disassembly. Mark
trailing edge of vane on left as vane No. 66.

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NOTE
Petrolatum may be used to hold nozzle seals in place during
assembly.
(4) Install an inner nozzle seal (16) and an outer nozzle seal (14) to grooves in right side
of installed nozzle segment.
(5) Install a second nozzle segment (15) containing vanes No. 2 and 3, to right side of
first nozzle segment. Slide nozzle segments together, making sure inner and outer nozzle seals
engage grooves in second nozzle segment. Secure with bolt. Tighten but do not torque.
(6) Continue installing nozzle segments, inner nozzle seals, and outer nozzle seals in a
clockwise direction until eight segments (vanes No. 66 and 1 through 15) have been installed.
Secure each with a bolt, but do not torque.
(7) Install borescope nozzle segment into next position (vanes No. 16 and 17). Bores-
cope nozzle will install only at this position. Install inner and outer nozzle seals (14 and 16) to
right hand side of nozzle segment.
(8) Continue installing nozzle segments, inner nozzle seals, and outer nozzle seals until
all segments have been installed. Tighten, but do not torque bolts.
(9) Position mark borescope nozzle segment vanes as 16 and 17, if not already marked.
(10) Loosen the bolts (17) at each end of interstage seal segment. Tie interstage seal seg-
ments together with safety wire fastened around the loosened bolts.
NOTE
Always use new push nuts. The push nuts must be installed with
the inner tabs bent away from the boltheads. If the nuts are improp-
erly installed, the bolts will probably be unseated.
(11) Install replacement (if required) slab head bolts (8) to inner bolt circle of stage 2 noz-
zle support from forward side. Position slab head against mating rabbet to prevent bolt rotating.
Secure with new push nuts (9). Bolts should have no axial movement after push nuts are
installed.

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CAUTION
DO NOT FORCE SLABHEAD BOLTS OUT OF POSITION AS
NOZZLE SEGMENTS ARE SEATED.
(12) Ensure trailing edge of vane No. 1 is aligned with TOP mark on nozzle support aft
flange and that both borescope nozzle bushings are aligned to holes in nozzle support. Trailing
edge of borescope nozzle segment are vanes 16 and 17. Very carefully lift and place stage 2 noz-
zles into nozzle support (4) over bolts (8).
(13) Engage vane forward runners with groove between nozzle support and stage 1 shroud
support. Align boltholes in nozzle segments with bolts in nozzle support and seat subassembly.
(14) If interference between nozzle adapter and nozzle support is encountered, the adapter
may be locally blended per detail A, figure 23.
NOTE
Be careful to keep from pushing bolts out of push nuts.
(15) Place stage 2 shroud forward supports (13), according to matchmarks, on aft face of
vane segment flange, with runner of support facing aft. Secure nozzle support (4), nozzle
vanes (15), and shroud supports (13) together with locknuts. Tighten nuts 90-94 lb in.
(10.2-10.6 N·m).
(16) Remove safety wire from interstage seal bolts. Tighten all interstage seal bolts
24-27 lb in. (2.7-3.1 N·m) of torque.
(17) Install stage 2 shroud segments (11) according to matchmarks, to stage 2 shroud sup-
port (13) so shroud stops enter slots in shroud support, and shroud ends engage each other. Install
shroud seals (12) between shroud segments.
NOTE
Make certain O mark on shroud support aligns with TOP mark on
nozzle support. Make certain boltholes and dowel pin holes are
aligned and that lip on support engages shroud runners.
(18) Install stage 2 rear shroud support (10) according to matchmark. Rear nozzle support
will install in only one position due to locating pin in nozzle support near top vertical centerline.
(19) Install air filter assembly (1), figure 23 as follows:
(a) Locate TOP mark on nozzle support rear flange OD.

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(b) Locate bolts 7 and 8, counterclockwise, forward looking aft (looking down).
Bolt No. 1 is at TOP mark.
(c) Place air filter (1) over bolts (3) in nozzle support so that adjustable borescope
hole is between bolts 7 and 8.
(d) Install clips (2) over bolt ends, with short end of clips up and out.
(e) Tighten nuts 36-40 lb in. (4.1-4.5 N·m) of torque.
(20) Install cooling tube (5) into ferrule of nozzle support and seat in boss of stage 2
nozzle.
(21) Install spring washer (7) in ferrule over cooling tube. Secure with ring retainer (6).
(22) Place high pressure turbine rotor in vertical stand.
(23) Place stage 2 nozzle assembly, forward end (air screen end) down, over rotor.
(24) Install stage 2 high pressure turbine rotor blades, according to position marks made
during disassembly, as follows:
(a) Install blade pair position marked No. 1 into dovetail slot between 1-1 marks
stamped on rear of dovetail tangs.
CAUTION
LOSS OF DAMPER SEAL AND GAS TURBINE DAMAGE.
ward) of blade pair No. 1.
(c) Continue installing blade pairs and damper seals, according to position marks,
working in a clockwise (aft looking forward) manner. Blade pair No. 5 shall be between
5-5 marks on dovetail tangs.
(d) Install all blade pairs and damper seals.

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CAUTION
MAJOR GAS TURBINE DAMAGE CAN RESULT FROM
lodged by hand pressure, reinstall or replace damper seals or blade pairs as required.
CAUTION
BE INSTALLED IN THE POSITION FROM WHICH THEY
(f) Just prior to rotor installation, install stage 2 blade retainer and seal according to
matchmark made during removal. Do not allow bolts to become dislodged during installation.
Bolts must maintain a running torque of 3.5 lb in. (0.4 N·m). Tighten bolts 110-120 lb in.
(12.4-13.6 N·m) of torque, loosen one-half turn and retighten 110-120 lb in. (12.4-13.6 N·m).
remove retainer. Check to ensure that seal has remained in place. Install retainer and check clear-
ance again. If clearance limit cannot be met, replace retainer.

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REPLACEMENT OF HPT SINGLE SHANK ROTOR/

STAGE 2 NOZZLE ASSEMBLY

1 - 112 . . . . . . . . 0
ALPHABETICAL INDEX
Subject Page
Inspection of HPT Single Shank Rotor and Stage 2 Nozzle Assemble. . . . . . . . . . . . . . . . . 32

Installation of HPT Single Shank Rotor and Stage 2 Nozzle Assembly . . . . . . . . . . . . . . . . 22
Installation of Stage 2 HPT Nozzle Assembly on HPT Single Shank Rotor. . . . . . . . . . . . . 21
Parts Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Parts Replacement - HPT Single Shank Rotor Stage 1 Blades . . . . . . . . . . . . . . . . . . . . . . . 94
Parts Replacement - HPT Single Shank Rotor Stage 2 Blades . . . . . . . . . . . . . . . . . . . . . . . 100
Parts Replacement - Stage 2 HPT Nozzle Segments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Removal of HPT Single Shank Rotor and Stage 2 Nozzle Assembly. . . . . . . . . . . . . . . . . . 3
Removal of Stage 2 HPT Nozzle Assembly From HPT Single Shank Rotor . . . . . . . . . . . . 20

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1. INTRODUCTION. This work package contains instructions for the replacement of the HPT
single shank rotor and stage 2 nozzle assembly. Also contained herein are instructions for the
removal, installation, inspection/repair and component replacement where applicable. To
accomplish the tasks described herein, the gas generator must be translated from the horizontal
position to the vertical position per WP 200 00, and the turbine mid frame removed per
WP 201 00 or SWP 201 01.

1C5937 Gage, Concentricity - No. 5 Bearing Inner Race
1C5964 Sling Lift - High Pressure Turbine Stage 2
1C6804 Jackscrews
1C6950 Wrench - Horizontal/Vertical HPT Nut
(Alternate Tool - 2C6062)
1C8059 Stand - Vertical - High Pressure Turbine Rotor EMU
1C6058 Wrench - Spanner - Oil Tube, HPTR
1C6063 Puller - Retaining Ring - No. 5 Bearing
2C6084 Wrench - Spanner Nut, No. 5 Bearing
2C6187 Fixture Lift - HPTR Vertical
2C6341 Wrench Spanner Hand Runup
2C6563 Tool Installation/Removal - Damper Sleeve
2C6610 Guide Pins (or locally manufacture)
(Snap-On CJ93) Puller (or Equivalent) - Stage 2 Nozzle Air Tubes
1C6899 Wrench - Horizontal/Vertical HPTR Nut
2C6141 Eye Lift - HPTR Aft
2C6194 Puller - No. 5 Bearing Inner Race
9470M55G01 Program, Balance - Blade Installation/Replacement

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Commercial Cleaning Solvent
GE Spec A50TF201 Antiseize Compound
MIL-L-23699 Gas Turbine Lube Oil
Prussian Blue
Masking Tape
Safety wire
Adhesive No. 77 or No. 1870 (3M Co.)
Petrolatum
Liquid Wrench No. 1 Penetrating Oil
DX100 Dykem
4. REMOVAL OF HPT SINGLE SHANK ROTOR AND STAGE 2 NOZZLE

ASSEMBLY.
a. The removal portions of the following work packages must be accomplished before
removal of the HPT/Stage 2 nozzle assembly.
(1) WP 201 00 or SWP 201 01 - Replacement of Turbine Mid Frame.
(2) WP 220 00 - Removal/Reinstallation of Power Turbine Assembly.
(3) WP 22100 - Inspection and Replacement of Miscellaneous Components.
(4) WP 400 00 - Assembly Clearances and Drawings.
b. A distance of 5.5 to 6 feet (1.6-1.8 meters) will be needed to remove HPT rotor/stage 2
nozzle assembly.

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NOTE
If same parts are to be reinstalled, matchmark HPT rotor/stage 2
nozzle assembly to compressor rear frame flange and all other parts
before they are removed to ease re-installation.
CAUTION
BOTH STAGE 1 AND STAGE 2 BORESCOPE PLUGS MUST
BE REMOVED PRIOR TO REMOVING STAGE 2 NOZZLE
ASSEMBLY FROM ENGINE. STAGE 1 BORESCOPE PLUG
PASSES THROUGH SCREEN ASSEMBLY ON STAGE 2 NOZ-
ZLE ASSEMBLY. SCREEN ASSEMBLY WILL BE DAMAGED
IF REMOVAL OF NOZZLE ASSEMBLY IS ATTEMPTED
PRIOR TO REMOVAL OF PLUGS.
c. Remove stage 1 and 2 nozzle borescope plugs and washers from compressor rear frame.
Plugs are located at approximately 3 o’clock position near rear of frame (aft looking forward).
d. Using an Allen wrench, remove four setscrews from forward face of compressor rear
frame rear flange at 2, 4, 8, and 10 o’clock positions. See figure 2.
NOTE
Place suitable cover on/around HPT/Stage 2 nozzle assembly to
prevent dropping No. 5 bearing spanner nut pin (2, figure 1) into
gas generator.
e. Remove retaining ring (8, figure 3) and pin (9), which secure No. 5 bearing spanner nut
(7), from inside turbine rotor rear stub-shaft. Use needle nose pliers or screwdriver. Place retain-
ing ring and pin in a plastic bag and identify.
f. Remove No. 5 bearing spanner nut as follows. See figure 4.
(1) Lift 2C6084 antitorque assembly, with a hoist and place on aft flange of compressor
rear frame. Engage antitorque lugs of inner ring with slots in rotor rear shaft.
(2) Secure outer ring of antitorque assembly to compressor rear frame flange with the six
clamps provided.
(3) Place 2C6084P25 torque tube, through antitorque assembly and engage lugs of
wrench to slots in No. 5 bearing spanner nut.
(4) Place torque multiplier (0-10,000 lb ft/0-13,560 N·m) over torque tube. Secure

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Figure 1. Removal/Installation of High Pressure Turbine Single Shank Rotor

and Stage 2 Nozzle Assembly (Sheet 1 of 2)

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Figure 1. Removal/Installation of High Pressure Turbine Single Shank Rotor

and Stage 2 Nozzle Assembly (Sheet 2 of 2)

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Figure 2. Location of Setscrews - Compressor Rear Frame and Turbine Mid Frame
CAUTION
NO. 5 BEARING SPANNER NUT HAS LEFT HAND
THREADS.
(5) Apply torque to turn spanner nut (7, figure 3) clockwise (left hand threads) and
loosen spanner nut.
(6) Remove torque multiplier and 2C6084P25 torque tube.
(7) Remove No. 5 bearing spanner nut.
NOTE
(8) Remove oil tube keyed retainer as follows:

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Figure 3. High Pressure Turbine Single Shank Rotor and Stage 2 Nozzle Installation

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Figure 4. Removal/Installation of No. 5 Bearing Spanner Nut Using 2C6084 Wrench

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CAUTION
THE HPT ROTOR REAR SHAFT THREADS ARE LEFT HAND
THREADS.
(a) Insert 2C6063 oil tube key retainer puller through the antitorque assembly and
thread (counterclockwise) onto the HPT rotor aft shaft until puller seats against aft side of No. 5
bearing inner race. Seat puller hand-tight only. See figure 5.
(b) Loosen the eight knobs, position fingers inward to catch forward side of key
retainer and tighten knobs.
(c) Insert 0.25 inch (6.4 mm) dowel rod in hole provided at OD of puller and rotate
clockwise (aft looking forward) until puller and key retainer are removed.
(d) Remove key retainer from puller. Place spanner nut and keyed retainer in a plas-
tic bag and identify.
g. Remove oil tube (11, figure 3) from inside high pressure turbine rotor as follows:
NOTE
(1) Install 2C6058 oil tube wrench through 2C6084 antitorque assembly and engage
wrench lugs with slots at rear of oil tube. See figure 6.
(2) Place torque multiplier 0-10,000 lb ft (0-13,560 N·m) over oil tube wrench. Secure
(3) Break torque and unscrew oil tube using torque multiplier. Be certain that oil tube
threads are disengaged from coupling nut threads. Remove multiplier.
(4) Install and engage the three puller pins of 2C6058 wrench in holes of oil tube. Pull
oil tube from rotor.
(5) Remove 2C6084 antitorque assembly from compressor rear frame flange.
h. Remove damper sleeve as follows:
(1) Loosen locks of 2C6563 removal tool and open tool all the way. See figure 7.
(2) Insert tool into HPT rotor rear shaft. When the non-adjustable leg of tool bottoms on
damper sleeve, rotate tool clockwise until tang of leg engages counterclockwise hook of damper
sleeve.

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Figure 5. Removal of Keyed Retaining Ring Using 2C6063 Puller
Figure 6. Removal/Installation of HPT Oil Tube Using 2C6058 Wrench

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Figure 7. Removal/Installation of Damper Sleeve Using 2C6563
(3) Push adjustable leg of tool forward until it contacts damper sleeve. Compress tool
until adjustable leg engages clockwise hook on damper sleeve. Continue to compress tool sleeve
assembly and lock in compressed position.
(4) Pull sleeve with tool from rotor rear shaft.
WARNING
PENETRATING OIL WD 40 IS NOT TO BE USED ON GAS
GENERATOR/GAS TURBINES. LIQUID WRENCH NO. 1 IS
RECOMMENDED.
i. Lubricate turbine rotor coupling nut with penetrating oil using can or equivalent. Turn
rotor to ensure that oil penetrates the full circumference of the threads.
j. Install 1C6950 coupling nut wrench onto aft end of turbine rotor (see figure 8) as follows:
(1) Make certain jackscrews (10) in outer flange of coupling nut wrench are retracted
and adjust locking tabs (2) out and away from gas generator.

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Figure 8. High Pressure Turbine Single Shank Rotor Using 2C6187 Lift Fixture
and 1C6950 Coupling Nut Wrench

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(2) Install lift nut (13) into 1C6950 coupling nut wrench (1) and using a hoist, position
coupling nut wrench above aft end of turbine rotor.
(3) Mark center of 24 scalloped slots on rotor aft shaft. Mark center of locking lugs on
1C6950 coupling nut wrench.
NOTE
Make certain lugs on coupling wrench engage slots on aft face of
rotor.
CAUTION
FLANGE ONLY. DO NOT INSTALL OVER CRF AFT
(4) Install lift nut/wrench assembly on rotor and adjust locking tabs (2, figure 8) to
engage stage 2 nozzle support flange. Tighten locking tabs.
(5) Install T-handle jackscrew (10) in holes provided in housing outer ring and finger-
tighten against shroud support. Remove lift nut (13).
CAUTION
THREADS.
FIXTURE.
NOTE
lock nut (7) with solvent and a rag. Examine threads for damage
and repair as necessary. When installing pilot nut and locknut,
tighten finger-tight only.
wrench (9).

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Figure 9. 1C6950 HPT Coupling Nut Spanner Wrench Fixture
NOTE
It may be necessary to slowly rotate the torque tube (6) until
engagement of the torque tube splines and HPT coupling nut
splines can be felt.
(7) Carefully install torque tube (6) into rear of rotor and engage coupling nut (12,
figure 3) at front of rotor.
(8) Lock torque tube in place using locknut (7, figure 8), right hand thread. Locknut
must be flush or below surface of wrench. Tighten nut securely using wrench (9).

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WARNING
NOTE
When using a Sweeney model 8111 torque multiplier, an adapter,
PN 194495, provided by Sweeney Co. is required.
k. Install torque multiplier (8) 0-50,000 lb ft (0-67,800 N·m) to rear of coupling nut wrench
and secure with thumbscrews. Use a hoist to support torque multiplier (if required). Refer to
WP 001 00, table 1.
CAUTION
GUIDE PINS SHALL BE USED WHEN REMOVING NOZZLE
ASSEMBLY TO LESSEN POSSIBILITY OF DAMAGE TO AIR
SEALS. GUIDE PINS MAY BE LOCALLY FABRICATED PER
FIGURE 10.
l. Install eight 2C6610 guide pins (see figure 10) through the larger boltholes in the coupling
wrench using alternating boltholes. Secure guide pins to compressor rear frame flange using nuts.
Ensure guide pins are seated against CRF flange prior to removing nozzle assembly.
m. Install four jackscrews from 1C6804 tool set (figure 9), from forward side to threaded
holes in compressor rear frame rear flange. Thread the jackscrews into holes until they just touch
stage 2 nozzle support.
n. Install 2C6187 lift fixture to rear of coupling nut wrench using a hoist. Secure using four
lockpins (12, figure 8). Remove slack from hoist cable.
o. Carefully raise hoist attached to lift fixture until a gap of approximately 0.25 inch
(6.4 mm) exists between spring loaded parts. See figure 1. This will exert an upward force on
turbine rotor and prevent excessive pressure on coupling nut threads.

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Figure 10. 2C6610 Stage 2 High Pressure Turbine Nozzle Guide Pin

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WARNING
PERSONNEL SHALL STAND CLEAR OF SIDE OF GAS GEN-
ERATOR WHEN USING TORQUE MULTIPLIER. TORQUE IN
EXCESS OF 30,000 LB FT (40,680 N·M) MAY BE REQUIRED
TO BREAK COUPLING NUT LOOSE. IF PARTS SHOULD
FAIL, THEY WILL DO SO WITH EXPLOSIVE FORCE AND
COULD CAUSE SERIOUS INJURY.
CAUTION
THE FOLLOWING TASK IS CRITICAL AND MUST BE PER-
FORMED WITH EXTREME CARE TO PREVENT DAMAGE
TO SHAFT THREADS, ROTOR BLADES, VANES AND
SEALS. AS COUPLING NUT IS LOOSENED AND ROTOR
MOVES TO THE REAR (UP), THE HOIST MUST BE RAISED
SUFFICIENTLY TO APPROXIMATELY 0.25 INCH (6.4 MM)
GAP IN LIFT FIXTURE TO PREVENT EXCESSIVE PRES-
SURE ON COUPLING NUT THREADS.
NOTE
HPT rotor coupling nut threads are standard (right hand) threads.
p. Break torque on coupling nut (counterclockwise direction) by applying force through

torque multiplier. Slowly and carefully loosen coupling nut approximately two turns, while using
jackscrews in compressor rear frame to move stage 2 nozzle upward with rotor to prevent exces-
sive pressure on shaft threads.
CAUTION
PARTS. THESE MATERIALS PLUS HEAT CAN CAUSE
PARTS MATERIAL DAMAGE.
q. If same rotor/stage 2 nozzle EMU is to be reinstalled, matchmark one rotor blade to

stage 2 nozzle flange to compressor rear frame flange.
r. Remove torque multiplier.

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NOTE
Keep hoist raised, as necessary, during entire loosening operation to
maintain 0.25 inch (6.4 mm) gap in lift fixture.
s. Continue to loosen coupling nut using 2C6341 spline wrench (14, figure 8), positioned
over torque tube (6) aft spline teeth, until threads are completely disengaged and turbine rotor for-
ward shaft is free of the compressor shaft.
CAUTION
USE CARE TO PREVENT DAMAGING AIR FILTER; FILTER
LIP MAY HANG UP ON BORESCOPE PORT. IF THIS
OCCURS, MOVE NOZZLE FORWARD AND ATTEMPT TO
MOVE IT SIDEWAYS OR SLIGHTLY TILT IT TO PROVIDE
CLEARANCE.
t. When turbine rotor is free of compressor rotor and stage 2 nozzle is free of compressor
rear frame, carefully lift assembly clear of gas generator.
u. If same HPT rotor/stage 2 nozzle EMU is to be reinstalled, mark compressor rotor shaft at
12 o’clock position using Dykem.
v. Transfer the rotor/nozzle assembly to 1C8059 turbine rotor vertical stand

(figures 1 and 11).
w. Remove 1C6950 coupling nut wrench and 2C6187 lift fixture from rear of turbine rotor as
follows:
CAUTION
EXERCISE CARE WHEN HANDLING TURBINE ROTOR
AFTER COUPLING WRENCH/LIFT FIXTURE ASSEMBLY IS
REMOVED. THE STAGE 2 NOZZLE ASSEMBLY WILL BE
LOOSE ON ROTOR AND SUBJECT TO DAMAGE.
(1) Remove lockpins (12, figure 8) and remove lift fixture 2C6187.
(2) Remove torque multiplier (and adapter) if used.
(3) Remove locknut (7), using wrench (9). Locknut has right hand threads.
(4) Remove torque tube (6) using a hoist.
(5) Remove pilot nut (5) using wrench (9). Pilot nut has left hand threads.

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(6) Retract jackscrews (10).
(7) Install lift nut (13) to coupling wrench (1) and remove lift fixture (3) and coupling
nut wrench (1) from rotor, using a hoist attached to lift eye.
x. Remove jackscrews from compressor rear frame. Remove guide pins.
y. If required, remove pressure lock seal (13, figure 3) from aft end of compressor rotor rear
shaft.
5. REMOVAL OF STAGE 2 HPT NOZZLE ASSEMBLY FROM HPT SINGLE SHANK

ROTOR.
a. Remove the stage 2 high pressure turbine nozzle assembly from the high pressure turbine
rotor (if required) as follows:
CAUTION
MACHINED AS A MATCHED SET. MAKE CERTAIN ASSEM-
BLIES ARE TAGGED AND IDENTIFIED AS A SET WHEN-
EVER EITHER MUST BE REMOVED. ALL PARTS MUST BE
MATCHMARKED AS THEY ARE REMOVED TO ENSURE
ASSEMBLY IN SAME RELATIVE POSITION. SHROUDS AND
INTERSTAGE SEALS CANNOT BE REPLACED AT LEVEL 2
AND MUST BE ASSEMBLED TO SAME RELATIVE POSI-
TION TO MAINTAIN PROPER CLEARANCES BETWEEN
ROTATING AND STATIONARY PARTS.
(2) If stage 2 rotor blades are to be removed, proceed as follows:
(b) Number stage 2 blades starting at 1-1 mark on rotor disk dovetail tangs. Num-
ber blades working in clockwise direction (aft looking forward). Fifth blade should be between
5-5 mark on disk.
blade No. 1.
(d) Loosen all bolts securing blade retainer but do not remove bolts.

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(h) Remove blades by pulling them out of rear disk. Place blades in container and
install cover on container.
(3) Using 1C5964 lift sling, remove stage 2 nozzle assembly from high pressure turbine
rotor and use two persons to carefully turn nozzle assembly over and set aft side down on flat
surface.
6. INSTALLATION OF STAGE 2 HPT NOZZLE ASSEMBLY ON HPT SINGLE

SHANK ROTOR.
a. Install the stage 2 high pressure turbine nozzle assembly on the high pressure turbine rotor
(if required) as follows:
(1) Place high pressure turbine rotor in 1C8059 vertical stand.
(2) Place stage 2 nozzle assembly forward end (air screen end) down over rotor.
(3) Install stage 2 high pressure turbine rotor blades according to position numbers made
during disassembly (or during preparation for shipment) as follows:
(a) Install blade marked No. 1 into dovetail slot between 1-1 marks stamped on rear
of dovetail tangs.
CAUTION
LOSS OF DAMPER SEAL AND GAS GENERATOR DAMAGE.
ward) of blade No. 1.
(c) Continue installing blades and damper seals, according to position marks, work-
ing in a clockwise (aft looking forward) manner. Blade No. 5 shall be between 5-5 marks on
dovetail tangs.
(d) Install all blades and damper seals.

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CAUTION
MAJOR GAS GENERATOR DAMAGE CAN RESULT FROM
lodged by hand pressure, reinstall or replace damper seals or blades as required.
CAUTION
BE REINSTALLED IN SAME POSITION FROM WHICH THEY
(f) Install stage 2 blade retainer and seal according to matchmark made during
removal just prior to rotor installation. Do not allow bolts to become dislodged during installa-
tion. Bolts must maintain a running torque of 3.5 lb in. (0.39 N·m). Tighten bolts to 110-120 lb in.
(14.3-15.6 N·m) of torque, loosen one-half turn and tighten to 110-120 lb in. (14.3-15.6 N·m) of
torque.
remove retainer. Check to make sure that seal has remained in place. Install retainer and check
clearance again. If clearance limit cannot be met, replace retainer.
7. INSTALLATION OF HPT SINGLE SHANK ROTOR AND STAGE 2 NOZZLE

ASSEMBLY.
NOTE
The HPT rotor/stage 2 nozzle EMU is assumed to be in 1C8059
vertical stand (figure 11).
a. Install lift nut (13, figure 8) into 1C6950 coupling nut wrench (1). Using a hoist, lift
wrench onto aft end of turbine rotor as follows:
(1) Make certain T-handle jackscrews (10) in outer flange of coupling nut wrench are
installed and retracted and adjust locking tabs (2) out and away from coupling nut wrench.

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Figure 11. 1C8059 High Pressure Turbine Single Shank Rotor Vertical Stand
NOTE
z No. 5 bearing inner race must be in place before coupling nut
wrench can be installed. If bearing is not in place, refer to
WP 221 00, bearings and seals.
z The 1C6058 spanner wrench has 24 lugs which engage the scal-
lops on the rear shaft for anti-torque purposes. Make sure that
these lugs are fully engaged with the shaft and not seated at an
angle.
(2) Install lift nut wrench assembly on rotor rear stub-shaft.
CAUTION
(3) Adjust locking tabs (2, figure 8) to engage stage 2 nozzle support flange. Tighten
tabs.
(4) Adjust jackscrews (10) in coupling wrench outer ring and finger-tighten against
shroud support.

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(5) Remove hoist and lift nut (13).
CAUTION
THREADS.
FIXTURE.
NOTE
and repair as necessary. When installing locknut, tighten finger-
tight only.
wrench (9).
(7) Carefully install torque tube (6) into rear of rotor and engage coupling nut (12,
figure 3) at front of rotor.
(8) Lock torque tube in place using locknut (7, figure 8) right hand threads. Locknut
must be flush or below surface of coupling wrench. Tighten nut securely using wrench (9).
WARNING
NOTE
If Sweeney model 8111 torque multiplier is used, an adapter,
PN 194495, provided by Sweeney Co., is required.
(9) Install torque multiplier 0-15,000 lb ft (0-20,340 N·m) on aft end of coupling nut
wrench (1). Refer to WP 001 00, table 1.

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GEK 97310
VOLUME II
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(10) Attach hoist to 2C6187 lift fixture (3) and install lift fixture to coupling nut wrench
(1). Secure with four lockpins (12).
WARNING
CLEANING SOLVENTS ARE HIGHLY FLAMMABLE, VOLA-
TILE AND TOXIC. THEY SHOULD BE USED WITH ADE-
QUATE VENTILATION. AVOID PROLONGED BREATHING
OF VAPORS AND REPEATED OR PROLONGED CONTACT
WITH THE SKIN.
CAUTION
RIZED LUBRICANT ON BOLT/NUT THREADS CAN
CAUSE SULFIDATION ATTACK AND PREMATURE
FAILURES.
z USE ONLY SPECIFIED LUBRICANTS ON SILVER
PLATED THREADS. LUBRICANTS CONTAINING COP-
PER MUST NOT BE USED. HEAT WITHIN A GAS GEN-
ERATOR MAY CAUSE CHEMICAL REACTION
BETWEEN COPPER, IN THE LUBRICANT, AND SILVER.
THE REACTION CAN CAUSE THREADS TO SEIZE TO A
POINT THAT DESTRUCTIVE FORCE IS REQUIRED TO
SEPARATE PARTS.
b. Clean the threads and mate face of the compressor rotor rear shaft with solvent (P-D-680).
Check threads for burrs. Remove any burrs, using a fine stone and fiber wheel. Thoroughly clean
threads and dry. Coat the aft 2-3 threads with antiseize compound, A50TF201. Do not over coat.
CAUTION
PRESSURE LOCK SEAL (13, FIGURE 3) MUST BE
INSTALLED IN AFT ID OF COMPRESSOR ROTOR SHAFT TO
PREVENT AIR LEAKAGE.
c. Visually inspect the pressure lock seal (13) at aft end of compressor rotor rear shaft, for
damage. Replace seal if necessary.
d. Raise HPT rotor/stage 2 nozzle assembly from vertical stand and position the assembly
above the gas generator.

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GEK 97310
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e. Clean the threads and forward face of the HPT rotor coupling nut, and the mate face and
coupling nut seating surface of the HPT rotor forward shaft with solvent (P-D-680). Check
threads for burrs. Remove any burrs, using a fine stone and fiber wheel. Thoroughly coat the for-
ward face of the coupling nut and all coupling nut threads with antiseize compound, A50TF201.
Overall thread coverage required. Remove excess thread compound.
f. Inspect in and around No. 4 bearing sump area for foreign material and verify that the
No. 4 bearing split nut lock ring is engaging both the nut and compressor rotor shaft splines.
g. If same EMU is being installed, ensure that previously made matchmarks (at disassembly)
are aligned.
NOTE
The Z mark on high pressure turbine rotor front shaft shall be
aligned to O or LO mark on compressor rotor rear shaft.
h. If a different EMU is being installed, the Z mark on high pressure turbine rotor front shaft
shall be aligned to O or LO mark on compressor rear shaft as follows:
(1) Locate Z mark on HPTR and O or LO mark on compressor rotor. Turn both rotors so
marks are aligned and at 12 o’clock position.
CAUTION
PARTS. THESE MATERIALS PLUS HEAT CAN CAUSE
PARTS MATERIAL DAMAGE.
(2) Mark Z on aft face of HPTR stage 2 disk in line with Z mark on rotor front shaft
using Dykem.

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VOLUME II
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CAUTION
EXERCISE EXTREME CARE DURING INSTALLATION OF
TURBINE ROTOR TO PREVENT DAMAGE TO SEALS AND
COUPLING NUT THREADS. ENSURE BORESCOPE HOLE IN
STAGE 2 NOZZLE ASSEMBLY IS ALIGNED WITH BORES-
COPE HOLE NEAR REAR OF COMPRESSOR REAR FRAME.
NOTE
z Make certain that a stage 1 borescope hole in air filter of stage 2
nozzle assembly is approximately 4.50 inches (114.3 mm) from
stage 2 borescope hole.
z To aid in aligning HPT EMU, install 2C6610 guide pins (see
figure 10) in compressor rear frame. See figure 10. Location of
guide pins to coincide with larger bolthole location in coupling
nut wrench outer ring.
i. Visually align turbine rotor front shaft with rear shaft of compressor rotor. Carefully
lower turbine rotor over compressor rear shaft until splines start to engage and the coupling nut
threads are almost touching the compressor rotor rear shaft threads. Adjust the stage two nozzle
assembly as necessary to align borescope holes. Pushing down on the aft end of the turbine rotor
spring-loaded lift fixture 2C6187 will allow downward movement. Engage coupling nut threads
by applying force (clockwise) through torque multiplier.
j. Continue moving turbine rotor downward and turning torque multiplier until coupling nut
is tight.
CAUTION
RUNNING TORQUE OF COUPLING NUT SHALL NOT
EXCEED 200 LB FT (271.2 N·M) DURING TIGHTENING
OPERATION. IF TORQUE SHOULD INCREASE SIGNIFI-
CANTLY PRIOR TO SEATING, REMOVE ROTOR AND
INSPECT FOR CAUSE OF TORQUE INCREASE.
(1) Tighten coupling nut to 7,500 lb ft (10,170 N·m) of torque and loosen to
500-1,500 lb ft (675-2,034 N·m) of torque.
k. Retighten coupling nut to 2,000 lb ft (2,712 N·m) of torque by applying force through
torque multiplier. Record the wrench angle at 2,000 lb ft (2,712 N·m). Lower the hoist as the
coupling nut is tightened but always maintain an upward spring force from lift fixture 2C6187.
Maintain a gap of approximately 0.25 inch (6.4 mm) between the spring loaded parts of the lift
fixture (see figure 1) as coupling nut is tightened. When gap is correct, the coupling nut will turn
easily.

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NOTE
If torque multiplier has no protractor, matchmark the angular rela-
tionship of the wrench torque tube to the wrench housing using
marking ink.
l. Increase the torque until the wrench angle is 28-30 degrees greater than that recorded at
2,000 lb ft (2,712 N·m) or until the torque reaches a maximum of 10,000 lb ft (13,560 N·m),
whichever occurs first.
m. If the wrench angle is 28-30 degrees greater than that recorded at 2,000 lb ft (2,712 N·m)
and the torque is less than 10,000 lb ft (13,560.0 N·m), the coupling nut installation is acceptable.
n. If the above requirements are not met, remove, clean, recoat and reinstall HPT coupling
nut. Do not exceed the maximum allowable torque of 12,000 lb ft (16,272.0 N·m) or a total of six
complete torquing cycles of the HPT coupling nut. If these limits are exceeded, replate the HPT
coupling nut silver coating or replace coupling nut.
NOTE
New or replaced coupling nuts will achieve the angle of
28-30 degrees at a lower torque value, usually less than 8,000 lb ft
(10,848 N·m). Reuse of the coupling nut increases the torque
requirement over the maximum allowable 10,000 lb ft
(13,560.0 N·m) limit. Torquing, then loosening the coupling nut
constitutes one use or torquing cycle.
o. Remove 2C6187 lift fixture (3, figure 8) and torque multiplier. Remove locknut (7) and
pull torque tube (6) out the rear. Remove pilot nut (5). Pilot nut has left hand threads. Remove
coupling nut wrench and lift fixture (1 and 3) as a unit. Remove 2C6610 guide pins.
p. Measure concentricity of No. 5 bearing inner race on turbine rotor rear stub-shaft using
1C5937 concentricity fixture. Install support slightly aft of rotor and adjust indicator against
6 o’clock position of bearing race. Measure at approximately 12 equal points allowing rotor to
stabilize before each reading. Maximum runout is 0.010 inch (0.25 mm) FIR. If not within limits,
remove rotor and reinstall in a different circumferential position to obtain required concentricity.
Remove concentricity gage and support.
q. Install the HPT pressure tube damper sleeve (figure 7) into the aft end of the high pressure
turbine rotor. Compress the damper sleeve to insert and seat against ID of the pressure tube.
r. Install flexible oil seals (4, figure 3) in two larger grooves near aft end of oil tube (11).
Lubricate O-ring (5) with gas turbine lube oil and install in smaller groove near aft end of oil tube.
s. Apply a light coating of Prussian blue to forward end of oil tube.

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GEK 97310
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t. Visually inspect using strong light to make certain that pressure lock seal (13) is properly
installed in aft end of compressor rotor rear shaft.
CAUTION
ANTISEIZE COMPOUND, A50TF201 LUBRICANT. USE OF
UNAUTHORIZED LUBRICANT ON BOLT/NUT THREADS
CAN CAUSE SULFIDATION ATTACK AND PREMATURE
FAILURES.
u. Coat threads of oil tube (11) with antiseize compound, A50TF201, and install into aft end
of high pressure turbine rotor. Tighten as far as possible by hand.
v. Install 2C6084 antitorque assembly to aft end of high pressure turbine rotor. Make certain
lugs on antitorque assembly engage slots on turbine rotor. Secure assembly to compressor rear
frame with the six clamps provided. Tighten securely.
CAUTION
ENSURE THAT 2C6058 WRENCH ENGAGES OIL TUBE
TANGS FULLY AND THE THREE PULLER PINS ARE IN THE
RADIALLY OUTWARD POSITION.
w. Install 2C6058 oil tube wrench (figure 6).
NOTE
Make certain that torque multiplier is fully seated against wrench
support.
x. Install torque multiplier 0-10,000 lb ft (0-13,560.0 N·m). Engage antitorque lugs on

torque multiplier in bosses on 1C6950. Refer to WP 001 00, Table 1.
y. Tighten oil tube to 600-800 lb ft (814-1,085 N·m) of torque.
z. Measure and record drop dimension (X, detail C, figure 3) from aft end of oil tube to aft
end of rotor rear shaft. Mark point of measurement of shaft only.
aa. Remove oil tube. Inspect oil tube and seating surface inside compressor rotor rear shaft
for continuous Prussian blue pattern to ensure oil tube has seated.
ab. Remove marking compound from oil tube.

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GEK 97310
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ac. Reinstall the oil tube and tighten to 1,000 lb ft (1,356 N·m) of torque. Break torque and
tighten to 1,000 lb ft (1,356 N·m) of torque. Visually check to ensure that one slot in rotor shaft
aligns to a slot in oil tube to allow installation of keyed retaining ring (10). If necessary, increase
torque on oil tube to align slots. Do not exceed 1,200 lb ft (1,627 N·m).
ad. Remove torque multiplier and 2C6058 wrench. Trial fit keyed retaining ring. Increase
torque slightly if necessary to align retaining ring, but do not exceed 1,200 lb ft (1627 N·m).
ae. Measure drop dimension (X, detail C, figure 3) from aft end of oil tube to aft end of rotor
rear shaft at same point marked earlier. Measurement shall be equal to or less than measurement
made in step z.
CAUTION
KEYED RETAINING RING MUST BE INSTALLED WITH
OUTER KEY TO REAR, TO ALLOW PROPER THREAD
ENGAGEMENT BETWEEN SPANNER NUT AND SHAFT.
af. Install keyed retaining ring (outer keys to rear) to lock oil tube to rotor rear shaft. See
detail A, figure 3.
CAUTION
z NO. 5 BEARING SPANNER NUT HAS LEFT HAND
THREADS.
ANTISEIZE COMPOUND, A50TF201, LUBRICANT. USE
OF UNAUTHORIZED LUBRICANT ON BOLT/NUT
THREADS CAN CAUSE SULFIDATION ATTACK AND
PREMATURE FAILURES.
ag. Lubricate threads of No. 5 bearing spanner nut (7, figure 3) with antiseize compound,
A50TF201, and install on rear of high pressure turbine rotor. Tighten to 450 lb ft (610.2 N·m) of
torque using 2C6058P25 torque tube and torque multiplier 0-10,000 lb ft (0-13,560.0 N·m). Refer
to WP 001 00, table 1.
ah. Check with 0.001 inch (0.25 mm) feeler gage to make sure that bearing race is seated.
ai. Remove torque multiplier and torque tube.

30
GEK 97310
VOLUME II
SWP 202 01
CAUTION
USE ONLY APPROVED MARKING MATERIAL TO PREVENT
PART DAMAGE.
aj. Inspect for alignment at a pin hole in spanner nut to a pin hole in rotor rear shaft. If not
already aligned, select holes nearest alignment by counterclockwise rotation of spanner nut. Put a
thin line mark on No. 5 bearing inner race to represent edge of hole in rear shaft. Put a thin line
mark on spanner nut, clockwise from mark on race. The distance between marks is equal to mis-
alignment at pin holes.
NOTE
As an alternate method in aligning pin holes, use 2C6084P25 and
2C6084P26 tubes by aligning one of the lines scribed on the 2CP25
torque tube with a scribed line on the 2C6084P26 (inner) tube. Do
not exceed specified torque while attempting to align the lock pin
holes.
ak. Install wrench and torque multiplier. Increase torque to spanner nut (left hand threads) to
align marks on nut and race. Do not exceed 500 lb ft (678.0 N·m) of torque.
al. Remove torque multiplier; spanner nut torque tube and 2C6084 antitorque assembly.
am.Measure and record clearance C60 (see WP 400 00, Assembly Clearances and Drawings)
using a feeler gage.
CAUTION
LOCKING PIN MUST BE PROPERLY INSTALLED AND
SECURED BY RETAINING RING TO PREVENT SPANNER
NUT FROM COMING LOOSE DURING GAS GENERATOR
OPERATION.
an. Secure spanner nut with locking pin (9, figure 3). Install locking pin with grooved end
facing aft. See detail A, figure 3. Secure locking pin with retaining ring (8). Make certain retain-
ing ring is fully seated in retaining ring groove.
ao. Install stage 1 and 2 nozzle borescope plugs and washers in compressor rear frame. Plugs
are located at approximately 3 o’clock position near rear of frame (aft looking forward).
ap. Install four setscrews in forward face of compressor rear frame rear flange at 2, 4, 8, and
10 o’clock positions. See figure 2.

31
GEK 97310
VOLUME II
SWP 202 01
aq. Perform installation portions of the following work packages:
WP 208 00, SWP 208 01 Replacement of Turbine Mid Frame

WP 220 00 Removal/Installation of Power Turbine Assembly
WP 221 00 Inspection and Replacement of Miscellaneous Sump
Components
WP 400 00 Assembly Clearances and Drawings
8. INSPECTION OF HPT SINGLE SHANK ROTOR AND STAGE 2 NOZZLE

ASSEMBLE.
a. Stage 2 High Pressure Turbine Nozzle Assembly. See figures 12, 13, and 14 for compo-
nent description. Refer to table 1 for inspection limits.

32
GEK 97310
VOLUME II
SWP 202 01
Figure 12. Assembly of Stage 2 High Pressure Turbine Nozzle Assembly

Single Shank Rotor Configuration

33
GEK 97310
VOLUME II
SWP 202 01
Figure 13. Stage 2 HPT Nozzle Support, Single Shank Rotor Configuration
Figure 14. Stage 2 Aft Shroud Support

34
GEK 97310
VOLUME II
SWP 202 01
Table 1. STAGE 2 HIGH PRESSURE TURBINE NOZZLE ASSEMBLY. See figure 12.
On-Site
On-Site Max Repairable On-Site
Inspect Max Serviceable Limits Limits Corrective Action
NOTE
If stage 2 HPT nozzle must be replaced, the complete HPT rotor
assembly and stage 2 HPT Nozzle assembly must be replaced
with a matched set.
SCREEN ASSEMBLY
1. Screen for:
a. Obstruction on Not serviceable Any amount Clean
screen
b. Cracks, tears, Not serviceable
etc.
2. Front Air Seal for:
a. Cracks 12 per segment, 0.25 in
(6.4 mm) long
b. Distortion Up to 0.03 in (0.8 mm) Any amount Reform seal strips
out-of-line provided with hand tools
edges contact seal land
after assembly
3. Borescope Hole Washer for:
a. Wear 0.005 in (0.13 mm) deep
b. Distortion Not serviceable
a. Cracks at Two cracks, 0.25 in Not repairable Replace screen
cooling holes (6.4 mm) long at each assembly***
brace and at four braces,
cracks to maximum
length of 1.13 in
(28.7 mm) long provided
crack does not connect
three cooling holes

35
GEK 97310
VOLUME II
SWP 202 01
- Continued
On-Site
NOZZLE COOLING FEED AIR TUBES
1. All Areas for:
a. Cracks Not serviceable Not repairable Replace tube***
b. Wear Not serviceable Not repairable Replace tube***
NOZZLE SUPPORT. See figure 13.
1. All Body Surface Area for:
a. Cracks Not serviceable Not repairable Replace***
b. Nicks and Any number, any length Not repairable Replace***
scratches 0.016 in (0.41 mm) deep.
Remove high metal from
mating surfaces
c. Bulges and Three bulges or dents, Any amount that Bench high metal
dents 0.50 in (12.7 mm) diame- will not affect on mating flanges
ter, 0.19 in (4.8 mm) assembly mating surfaces or
deep. No high metal replace part
allowed on mating
surfaces
d. Plugged cool- Not serviceable Any number Clear holes
ing air holes
2. Stage 2 Nozzle Flange for:
a. Circumferen- Not serviceable Not repairable
tial cracks
b. Radial cracks Two radial cracks from
boltholes inward, pro-
vided they are separated
by a minimum of five
boltholes
c. Nicks and Any number, any length
scratches 0.016 in (0.41 mm) deep
metal from mating
surface

36
GEK 97310
VOLUME II
SWP 202 01
- Continued
On-Site
d. Missing or 10 percent may be
chipped ther- missing
mal sprayed
coating
3. Rear Mounting Flange for:
a. Cracks extend- Two radial cracks pro-
ing from bolt- vided they are separated
holes to edge by a minimum of five
of flange boltholes
b. Nicks, scores, Any number, 0.020 in
and scratches (0.50 mm) deep, after
removal of high metal.
Must not extend more
than 75 percent across
surface
4. Air Seal for:
a. Wear on wear 0.020 in (0.51 mm) deep, Any amount Reform air seal to
strip provided OD is not less 36.446 in
than 18.223 in (925.73 mm)
(462.86 mm) radius diameter at wear
strip or replace
nozzle per note at
beginning of this
table***
b. Loose tack Not serviceable Any amount Tack weld
weld at sup-
port to seal
junction
c. Circumferen- Not serviceable Not repairable Replace nozzle
tial cracks assembly per note
at beginning of
this table***

37
GEK 97310
VOLUME II
SWP 202 01
- Continued
On-Site
d. Axial cracks One per saw cut, 0.25 in Not repairable Replace nozzle
saw cuts (6.4 mm) long assembly per note
at beginning of
this table***
e. Deformed Not serviceable Any amount pro- Straighten or hand
wear strip vided weld is sound blend to smooth
contour
f. Deformed, Any amount not worn Not repairable Replace nozzle
missing or through. No loose or assembly per note
worn seal missing clips. Deforma- at beginning of
strips or clips tion allowed if slot is this table***
sealed
g. Burns or Not serviceable Not repairable Replace nozzle
erosion assembly per note
at beginning of
this table***
5. Shroud Stop for:
a. Cracks Not serviceable Not repairable Replace nozzle
assembly per note
at beginning of
this table***
b. Wear Any amount 0.010 in Not repairable Replace nozzle
(0.25 mm) deep assembly per note
at beginning of
this table***
6. Ferrule for:
a. Nicks and Any number 0.040 in Not repairable Replace nozzle
scratches (1.02 mm) deep after assembly per note
removal of high metal at beginning of
this table***
b. Tack weld One tack weld loose per Any amount Weld using
loose ferrule AMS 5786 filler
material

38
GEK 97310
VOLUME II
SWP 202 01
- Continued
On-Site
7. Surface AV for:
a. Missing hard 5 percent may be missing Not repairable Replace nozzle
coat assembly per note
at beginning of
this table***
STAGE 2 FORWARD SHROUD SUPPORT. See figure 13.
1. All Areas for:
a. Circumferen- Not serviceable Not repairable Replace
tial cracks segment***
b. Radial cracks Two cracks from bolt- Not repairable Replace
hole to OD of support. segment***
One crack at slot, 0.38 in
(9.7 mm) long
c. Wear on Any amount, 0.010 in Not repairable Replace sup-
mounting (0.26 mm) deep up to port***
support 1.00 in (25.4 mm) from
ends, 0.030 in (0.78 mm)
deep
d. Distortion Not serviceable Any amount, pro- Mechanically
vided there are no straighten. Inspect
resulting cracks for cracks
from rework
STAGE 2 AFT SHROUD SUPPORT. See figure 14.
1. Flat Plate Area for:
a. Cracks from Ten cracks 0.25 in Not repairable Replace***
boltholes (6.4 mm) long provided
crack does not connect
with slot
b. Cracks from One per slot 0.25 in Not repairable Replace***
slot hole (6.4 mm) long two per
slot 0.150 in (3.81 mm)
long

39
GEK 97310
VOLUME II
SWP 202 01
- Continued
On-Site
c. Cracks in plate Ten cracks 0.25 in Not repairable Replace***
(6.4 mm) long
d. Wear Any amount, 0.005 in Not repairable Replace***
(0.13 mm) deep
2. Aft Mounting Supports for:
a. Cracks Three axial cracks,
0.25 in (6.4 mm) long
separated by at least
2.00 in (50.8 mm). No
circumferential cracks
allowed
b. Wear on Any amount, 0.010 in
shroud track (0.26 mm) deep after
mating surface removal of high metal
c. Corrosion or 0.020 in (0.52 mm) deep
burning in area not greater than
0.25 in (6.4 mm) by
0.25 in (6.4 mm),
11 areas maximum
NOTE *
If any one or all of the HPT interstage air seals must be replaced,
the complete HPT stage 2 nozzle assembly and HPT rotor assem-
bly must be replaced with a matched set.
INTERSTAGE AIR SEAL
1. Honeycomb for:
a. Annular wear One per step, 0.25 in Not repairable See NOTE*
groove (6.4 mm) wide, not to
exceed 0.13 (3.3 mm)
deep

40
GEK 97310
VOLUME II
SWP 202 01
- Continued
On-Site
b. Corner cell A section of first cell rib Not repairable See NOTE*
ribs dented or may be dented 1.00 in
bent (25.4 mm) long, second
cell rib 0.75 in (19.1 mm)
long
c. Cell damage/ Any number of isolated Not repairable See NOTE*
erosion cell areas of 0.50 in
(12.7 mm) square
2. Housing for:
a. Axial cracks Two axial cracks, 1.00 in
(25.4 mm) long, not
within 2.00 in (50.8 mm)
of end
b. Circumferen- Not serviceable Not repairable See NOTE*
tial cracks
c. Damage or Any amount. No cracks Not repairable See NOTE*
distortion at allowed
cooling slots
STAGE 1 TURBINE SHROUDS
NOTE **
a. Cracks Accept axial cracks pro- Not repairable See NOTE**
vided they are spaced
6.00 in (152.4 mm) apart
and do not extend into
radial rib

41
GEK 97310
VOLUME II
SWP 202 01
- Continued
On-Site
b. Wear on mat- Any length, 0.005 in Not repairable See NOTE**
ing surface (0.13 mm) deep, 0.010 in
(0.26 mm) deep for total
length of 1.00 in
(25.4 mm)
c. Bent edge on Not serviceable 0.06 in (1.6 mm) Mechanically
support from original straighten. Inspect
contour for cracks
d. Dents 0.020 in (0.52 mm) deep, Dents up to 1.00 in Remove protru-
provided it can be (25.4 mm) long are sion by blending
assembled acceptable, if
removal of protru-
sion does not thin
flange to less than
50 percent of origi-
nal flange thickness
e. Nicks and Any number, 0.01 inch Any number, Blend to remove
scores (0.3 mm) deep after 0.020 in (0.52 mm)
removal of high metal deep
f. Distortion and/ Acceptable if proper Not repairable See NOTE**
accomplished
a. Circumferen- Not serviceable Not repairable See NOTE**
tial cracks
b. Axial cracks One crack per segment Not repairable See NOTE**
in backing 0.50 in (12.7 mm) long;
strips four cracks per segment
0.25 in (6.4 mm) long
c. Nicks, dents Any number, 0.03 in Not repairable See NOTE**

42
GEK 97310
VOLUME II
SWP 202 01
- Continued
On-Site
3. Abradable Surface for:
a. Wear track 0.25 in (6.4 mm) deep Not repairable See NOTE**
full length of segment
b. Positive metal 0.010 in (0.25 mm) metal Any amount pro- Blend
due to blade build up on two shroud vided not more than
rub segments per assembly 0.025 in (6.4 mm)
into abradable sur-
face after removal
of positive metal
c. Erosion or 0.050 in (1.27 mm) deep, Not repairable See NOTE**
damage accumulation up to 30
percent of surface
d. Loosened or 75 percent in row of hon- Not repairable See NOTE**
missing filler eycomb cells adjacent to
exposing both forward and aft rails
backing strip and 50 percent in the first
and second row of honey-
comb cells adjacent to
both side plates. Three
may be missing or loose
at other places
4. Gas Face for:
a. Radial cracks Three per segment, Not repairable See NOTE**
0.20 in (5.1 mm) long,
separated by 0.50 in
(12.7 mm)
b. Erosion and/or 0.020 in (0.51 mm) deep Not repairable See NOTE**
missing metal by 2.00 in (50.8 mm)
long
c. Circumferen- Two per segment, Not repairable See NOTE**
tial cracks 0.100 in (2.5 mm) long
provided they do not
intersect with radial
cracks

43
GEK 97310
VOLUME II
SWP 202 01
- Continued
On-Site
STAGE 2 TURBINE SHROUDS
NOTE
a. Cracks Accept axial cracks pro- Not repairable See NOTE**
vided they are spaced
6.00 in (152.4 mm) apart
and do not extend into
radial rib
b. Wear on mat- Any length, 0.005 in Not repairable See NOTE**
ing surface (0.13 mm) deep, 0.010 in
(0.26 mm) deep for total
length of 1.00 in
(25.4 mm)
c. Bent edge on Not serviceable 0.06 in (1.6 mm) Mechanically
support from original straighten. Inspect
contour for cracks
d. Dents 0.020 in (0.52 mm) deep, Dents up to 1.00 in Remove protru-
provided it can be (25.4 mm) long are sion by blending
assembled acceptable, if
removal of protru-
sion does not thin
flange to less than
50 percent of origi-
nal flange thickness
e. Nicks and Any number, 0.010 in Any number, Blend to remove
scores (0.26 mm) deep after 0.020 in (0.52 mm) damage
removal of high metal deep
f. Distortion and/ Acceptable if proper Not repairable See NOTE**
accomplished

44
GEK 97310
VOLUME II
SWP 202 01
- Continued
On-Site
a. Circumferen- Not serviceable Not repairable See NOTE**
tial cracks
b. Axial cracks One crack per segment Not repairable See NOTE**
in backing 0.50 in (12.7 mm) long;
strips four cracks per segment
0.25 in (6.4 mm) long
c. Nicks, dents Any number, 0.03 in Not repairable See NOTE**
3. Abradable Surface for:
a. Wear track 0.25 in (6.4 mm) Not repairable See NOTE**
segment
b. Positive metal 0.010 in (0.25 mm) metal Any amount pro- Blend
due to blade build up on two shroud vided not more than
rub segments per assembly 0.025 in (6.4 mm)
into abradable sur-
face after removal
of positive metal
c. Erosion or 0.050 in (1.27 mm) deep, Not repairable See NOTE**
damage accumulation up to 30
percent of surface
d. Loosened or 75 percent in row of hon- Not repairable See NOTE**
missing filler eycomb cells adjacent to
exposing both forward and aft rails
backing strip and 50 percent in the first
and second row of honey-
both side plates. Three
may be missing or loose
at other places

45
GEK 97310
VOLUME II
SWP 202 01
- Continued
On-Site
4. Gas Face for:
a. Radial cracks Three per segment, Not repairable See NOTE**
0.20 in (5.1 mm) long,
separated by 0.50 in
(12.7 mm)
b. Erosion and/or 0.020 in (0.51 mm) deep Not repairable See NOTE**
missing metal by 2.00 in (50.8 mm)
long
c. Circumferen- Two per segment, Not repairable See NOTE**
tial cracks 0.100 in (2.5 mm) long
provided they do not
intersect radial cracks
5. Filled Honeycomb for:
a. Wear track 0.020 in (0.51 mm) deep, Not repairable See NOTE**
full length of segment, or
0.03 in (0.8 mm) deep,
4.00 in (101.6 mm) long
per segment
NOTE
The cumulative total of all axial and circumferential areas of
damage shall not exceed 1.00 square in (64.5 cm2) per shroud
segment.
b. Axial damage Any number of scores not Not repairable See NOTE**
extending into backing
strip, provided that the
cumulative total areas for
damage does not exceed
1.00 sq. in. (64.5 cm2) per
segment or 2.00 sq. in.
(387 cm2) cumulative for
entire shroud assembly

46
GEK 97310
VOLUME II
SWP 202 01
- Continued
On-Site
c. Circumferen- Any amount provided no Not repairable See NOTE**
tial damage one area of damage
caused by for- exceeds 0.10 in (2.5 mm)
eign objects wide for entire length of
shroud segment or 0.20 in
(5.1 mm) wide per shroud
segment and does not
extend into backing strip
d. Missing filler A total of 65 cells may be Not repairable See NOTE**
exposing missing or 75 percent in
backing strip row of honeycomb cells
adjacent to both forward
and aft rails and
50 percent in the first and
second row of honey-
both side plates
e. Cracks in Any number, 0.50 in Not repairable See NOTE**
abradable (12.7 mm) long provided
material cumulative length does
not exceed 1.50 in
(38.1 mm)
NOZZLES
Refer to paragraph 8.e., High Pressure Turbine Nozzles and figure 21.
*** May be repairable, consult GE for disposition of replaced part.
b. High Pressure Turbine Single Shank Rotor. See figures 15 and 16. Refer to table 2 for
inspection limits.

47
GEK 97310
VOLUME II
SWP 202 01
Figure 15. High Pressure Turbine Single Shank Rotor

48
GEK 97310
VOLUME II
SWP 202 01
Figure 16. Blend Repair of Front Shaft Air Seals and Thermal Shield Seal Serrations
Table 2. STAGE 1 HIGH PRESSURE TURBINE NOZZLES. See figures 15 and 16.
On-Site On-Site
NOTE*
If HPT rotor must be replaced, the complete stage 2 HPT nozzle
matched set.
FRONT SHAFT ROTATING AIR SEALS (1)
1. All Areas (except serrations) for:
a. Cracks Not serviceable Not repairable Replace turbine
rotor per NOTE*
located at the
beginning of this
table**

49
GEK 97310
VOLUME II
SWP 202 01
- Continued
On-Site On-Site
b. Nicks, dents Any number 0.015 in Not repairable Replace turbine

and scratches (0.39 mm) deep after rotor per NOTE*
removal of high metal located at the
beginning of this
table**
2. Seal Serrations for:
a. Wear on OD Within minimum OD Not repairable Replace turbine
limits of figure 15 rotor per NOTE*
located at the
beginning of this
table**
b. Turned metal Not serviceable Any amount provided Remove turned
minimum OD is metal
within wear limit of
figure 15
NOTE
Maximum individual or cumulative length of blends on any one
tooth shall not exceed 5 in. (125 mm); total cumulative length of
all blends on the six serrations per seal shall not exceed 16 in.
(406 mm), or forward tooth on forward seal may be removed
100 percent provided cumulative length of all blends on remain-
ing seal teeth does not exceed 8 in. (203 mm). Measurements to
be made at outside diameter of serrations (including blend
radius). Do not leave serration sections less than 1 in. (25 mm)
long between blends.
c. Cracked or Not serviceable Any number may be Blend. Inspect for
cracked out blended out if they cracks
serrations can be completely
removed between lim-
its of preceding
NOTE and figure 16

50
GEK 97310
VOLUME II
SWP 202 01
- Continued
On-Site On-Site
d. Nicks and Any number, 0.02 in Any number may be Blend. Inspect for
dents (0.51 mm) deep after blended out if they cracks
removal of high metal can be completely
its of preceding
NOTE and figure 16
e. Scratches Any number, 0.030 in Any number may be Blend. Inspect for
(0.8 mm) deep after blended out if they cracks
removal of high metal can be completely
its of preceding
NOTE and figure 16
f. Bending Not serviceable Any length may be Straighten with
straightened a maxi- hand tools. Shall
mum of 0.13 in not be overbent and
(3.2 mm) axially rebent. Inspect for
cracks
FORWARD SHAFT (2)
NOTE
Limits for areas aft of 13 in (330 mm) from shaft front face.
1. All Areas for:
rotor per NOTE*
located at the
beginning of this
table**
2. Splines for:
a. High metal Not serviceable Any amount Remove high metal

51
GEK 97310
VOLUME II
SWP 202 01
- Continued
On-Site On-Site
b. Nicks and Any number 0.03 in Not repairable Replace turbine

dents (0.8 mm) wide by rotor per NOTE*
0.25 in (6.4 mm) long located at the
after removal of high beginning of this
metal. None allowed table**
area of nicks and
dents on each tooth
not to exceed 15 per-
cent of that tooth area
c. Scratches Any number 0.020 in Not repairable Replace turbine
(0.52 mm) deep, rotor per NOTE*
0.06 in (1.5 mm) located at the
wide, 0.63 in beginning of this
(16.0 mm) long after table**
removal of high
metal. None allowed
area of scratches on
each tooth not to
that tooth area
3. Pilot for:
a. Nicks and Any number 0.06 in Not repairable Replace turbine
dents (1.5 mm) deep after rotor per NOTE*
removal of high metal located at the
beginning of this
table**
b. Pick up and Not serviceable Any amount Remove high metal
high metal
c. Scratches Any number, any Any number pro- Blend to remove
length 0.010 in vided not more than damage
(0.26 mm) deep, any 13 percent of surface
length is affected

52
GEK 97310
VOLUME II
SWP 202 01
- Continued
On-Site On-Site
4. External Surfaces for:

a. Nicks Any number, 0.010 in Any number, 0.016 in Blend to remove
(0.26 mm) deep after (0.41 mm) damage and inspect
removal of high metal for cracks
b. Dents Any number, 0.016 in Not repairable Replace turbine
(0.41 mm) deep rotor per NOTE*
located at the
beginning of this
table**
length 0.005 in (0.26 mm) deep damage
5. Cooling Air Holes for:
a. Nicks and Not serviceable Any number that can Blend to remove
scratches be removed by blend- damage
ing to a maximum of
0.031 in (0.79 mm)
deep. Holes can be
increased in diameter
by 0.125 in (3.18 mm)
and edge radius
increased to 0.125 in
(3.18 mm) maximum
(true radius not
required) to remove
damage

53
GEK 97310
VOLUME II
SWP 202 01
- Continued
On-Site On-Site
STAGES 1 AND 2 BLADE RETAINERS (5), (19)

1. All Areas for:
a. Cracks Not serviceable Not repairable Replace blade
retainer, however,
engine vibration
levels may not be
exceeded during
engine opera-
tion***
b. Nicks and Any number, 0.010 in Any number, 0.016 in Blend to remove
dents (0.26 mm) deep (0.41 mm) deep damage
length, 0.010 in (0.41 mm) deep damage
(0.26 mm) deep
STAGES 1 AND 2 DISKS (30), (21)
1. All Areas for:
rotor per NOTE*
located at the
beginning of this
table**
2. Dovetail Serrations for:
a. Nicks and Three dovetail serra- Corner radii of dove- Blend to remove
dents tions, 0.010 in tail and posts can be damage
(0.26 mm) deep after locally increased to
removal of high metal 0.078 in (1.98 mm)

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GE Industrial AeroDerivative

Subject: Revision, dated 30 June 2003 to LM2500 Industrial Gas

Questions and/ or comments on the technical content of this publication

Corrections or additions to the distribution requirements of this manual should be

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COPYRIGHT 1989-2003 General Electric Company, USA

GE Industrial Aeroderivative Gas Turbines

LIST OF EFFECTIVE PAGES

Dates of issue for original and changed pages are:

Original . . . . . . . . . . . 0 . . . . . . . . . .30 June 2003

Total number of pages in this manual is 1586 consisting of the following:

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1-1 GENERAL INFORMATION meters. These will eventually replace

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

1-1.4 Arrangement and Use of This c. The chapters contained in Volume I

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

c. WARNING indicates a procedure, 1-1.10 Changes to Illustrations. Illustra-

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

Figure 1-1. Change Symbols

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

1-2 SAFETY WILL CAUSE SERIOUS DETERIO-

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

FIRE HAZARDS: FROM PARTS, ENSURE THAT

COMPRESSED AIR HAZARDS:

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

ELECTRICAL HAZARDS: PROCEDURAL HAZARDS:

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

TOOLING HAZARDS: CAUTION

WARNING ALL HARDWARE ITEMS HAVE

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

d. Rotating parts of the starter operate at a OBSERVER SHALL BE STA-

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NOTE (5) Replaceable 1st and 2nd stage

d. The LM2500 engine is constructed

e. Features of the engine include the

(1) Controls and accessories exter-

(2) Individually replaceable compres-

(3) Individually replaceable high

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Figure 1-2. LM2500 Gas Turbine-Right Side (Sheet 1 of 4)

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Figure 1-2. LM2500 Gas Turbine-Left Side (Sheet 2 of 4)