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11

SERVICE BULLETIN
NIC 13.20 Rev.00
July 05, 2013

LM2500 and PGT25 Gas Turbine Families: Updated Shutdown


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

Serviceable Units
LM2500, LM2500+, LM2500 G4, PGT25, PGT25+, PGT25 G4 gas turbines in both SAC and DLE configurations

Compliance Category
O – Optional Identifies changes that may be beneficial to some, but not necessarily all, operators.
Accomplishment is at customer's discretion.

M - Maintenance Identifies maintenance guidelines or best practices for reliable equipment operation.

C - Compliance Required Identifies the need for action to correct a condition that, if left uncorrected, may result in
reduced equipment reliability or efficiency. Compliance may be required within a
specific operating time.

A - Alert Failure to comply with the Service Bulletin could result in equipment or facility damage.
Compliance is mandated within a specific operating time.

S – Safety Failure to comply with this Service Bulletin could result in personal injury. Compliance is
mandated within a specific operating time.
Timing Code
1 Prior to Unit Startup / Prior to Continued Operation
2 At First Opportunity / Next shutdown
3 Prior to Operation of Affected System
4 At First Exposure of Component
5 At Scheduled Component Part Repair or Replacement
6 Next Scheduled Outage
7 Optional

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The information published in this Service Bulletin is offered to you by GE in consideration of its ongoing sales and service relationship with
your organization. However, since the operation of your plant involves many factors not within our knowledge, and since operation of the
plant is in your control and ultimate responsibility for its continuing successful operation rests with you, GE specifically disclaims any
responsibility for liability based on claims for damage of any type, i.e. direct, consequential or special that may be alleged to have been
incurred as result of applying this information regardless of whether it is claimed that GE is strictly liable, in breach of contract, in breach of
warranty, negligent, or is in other respects responsible for any alleged injury or damage sustained by your organization as a result of applying
this information. The information contained in this Service Bulletin is confidential and proprietary. This Bulletin and the information contained
in it are protected by copyright and/or other intellectual property rights. This Bulletin and information are provided for authorized use
only, and may not be used by or disclosed to others without the prior express written consent of Nuovo Pignone S.r.l...
11
SERVICE BULLETIN
NIC 13.20 Rev.00
July 05, 2013

Background
As stated in Interim Change Notes (ICN), it is critical that the hot restart procedure follows a specific
sequence to avoid major engine damage. The basic objective is to cool the high pressure turbine rotor
(HPTR) and high pressure compressor rotor (HPCR) so blade tips maintain clearance with the more rapidly
cooling cases.
Some PGT25 / LM2500 gas generators experienced shaft locking events on a restart attempt following a trip
from high power. The photos below show examples of engine damage caused by an anomalous case
cooling, found excessive with respect to the rotor cooling.

Damages to blades Damages to cases

SOFTWARE MODIFICATION – SHUTDOWN AND HOT RESTART PROCEDURES (MANDATORY)

In order to avoid engine damage, new sequences are now required to allow the engine to cool after a
shutdown or during a hot restart.

The new systems are described below:

A. New Shutdown Procedure

The following types of engine shutdown may occur during engine operation, Normal shutdown and
Emergency shutdown:

Normal Shutdown:

Under normal operating condition, from whatever power the engine is running, during a normal
shutdown the unit is cooled down at minimum load and at idle; new Normal Shutdown (NS)
sequence adds further cool down motoring for 15 min @ 2000-2400 rpm that must be initiated no
later than 6 (six) minutes after Gas Generator speed (NGG) < 300 rpm.

Emergency Shutdown:

In an emergency shutdown, the engine can be shut down from any operating power. This can be
accomplished manually or automatically by control system. In this case NO cool down at idle speed
is performed. Depending on the cause of the Emergency Shutdown, the cool down motoring process
may or may be not be followed by a motoring period, depending on the following conditions:
2 / 11
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11
SERVICE BULLETIN
NIC 13.20 Rev.00
July 05, 2013

 After an Emergency Shutdown NO MOTORING (ESN), no further action is allowed


 After an Emergency Shutdown WITH MOTORING (ES):
o If T48 < 1150°F, Motoring cool down for 15 minutes @ 2000-2400 rpm is requested.
o If T48 > 1150 °F, Motoring cool down for 15 min @ 1000-1200 rpm is requested.

In both cases, motoring must be initiated no longer than 6 (six) minutes after engine rpm NGG < 300.

B. New Restart Procedures

CAUTION: IT IS UNDERSTOOD THAT THE CAUSE OF THE TRIP MUST BE DETERMINED AND RESOLVED
PRIOR TO RESTARTING THE ENGINE.

Restart may be initiated at any time if the prior shutdown sequence was normal.

Definitions:

4 HOURS LOCKOUT: Control logic that forces an engine stop for 4 hours after an emergency
shutdown at high power.

SOFT START: Hardware system that permits performing the restart procedure during lockout period.
The procedure is as follow:
o Verify HP rotor is free by manually applying less than 45 ft-lb (61 N*m) of torque on the AGB
starter shaft.
o If rotation is verified by the speed signal, then dry-motor the rotor at HP rotor speed of 1000-
1200 rpm for 20 minutes.
o After completion of 20 minutes of 1000-1200 rpm dry motoring, immediately proceed with a
normal purge and start cycle.

LOW SPEED VIBRATION CHECK:


Motoring @ 1000 to 1200 rpm (supported with monitor CRF vibration monitoring). If the CRF
vibrations are < 2 mils DA (3.19 mm/s or 50.8 microns) after motoring as described above, startup is
allowed. If the CRF vibrations exceed 2 mils DA, starting is not allowed and the low speed vibration
check must be repeated after 10 min @ 0 rpm between motoring cycles. To perform this check the
current vibrations monitoring system must be updated: the current system is not able to monitor
vibrations when the GG is running at low RPM.
After any type of emergency shutdown, it is only possible to immediately restart the engine by
following the applicable start sequences and procedures:

B.1 Restart after Normal Shutdown


After a NS (which includes 15 minutes of motoring @ 2000-2400 rpm), a normal start can be
executed at any time. If the cool down motoring fails or is not started within 6 minutes after NGG <
300 rpm, the 4 HOURS LOCKOUT logic applies in the next 4 hours and restart can be accomplished
only by following the SOFT START procedure.

3 / 11
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11
SERVICE BULLETIN
NIC 13.20 Rev.00
July 05, 2013

B.2 Restart after Emergency Shutdown with Motoring (ES)


Restart after low power (T48<1150°F)

A normal start can be executed at any time if a 15 minute motoring @ 2000-2400 rpm has been
completed. If Motoring fails or it is not started into 6 minutes, 4 HRS LOCKOUT logic applies in the
next 4 hours and restart can only be accomplished by following the SOFT START procedure.

Restart after high power (T48>1150°F)

If a 15/20 min LOW SPEED VIBRATION CHECK has been performed and T48 is less than 400 °F
(204°C), a restart can be accomplished only by following the SOFT START procedure due to the 4
HOURS LOCKOUT logic applied. If T48>400 °F, a further 15/20 min low speed vibration check can be
repeated observing 10 minutes @ 0 rpm between motoring cycles.

If Motoring fails or it is not started into 6 minutes from NGG < 300 rpm, 4 HOURS LOCKOUT logic
applies for the next 4 hours and restart can be accomplished only by following the SOFT START
procedure.

CAUTION: BY-PASSING THIS LOGIC AND CRANKING THE HP ROTOR MAY RESULT IN SEVERE HP
COMPRESSOR RUBS AND MAY DAMAGE THE COMPRESSOR BLADES AND VANES.

B.3 Restart after Emergency Shutdown with NO Motoring (ESN)


In this case, the logic control system forces 4 HOURS LOCKOUT and restart of the engine can be
accomplished only by following the SOFT START procedure.

Refer to the table below for a list of ESN conditions.


ESN trigger EHS related
1. HP rotor over speed trip. N
2. HP rotor back-up over speed trip. N
3. Loss of both HP rotor magnetic speed pick-ups N
4. Power turbine rotor overspeed trip. N
5. Power turbine rotor back-up overspeed trip. N
6. Loss of both PT rotor magnetic speed pick-ups N
7. Axial compressor stall detected. N
8. Very high gas generator vibration (1). N
9. Very high power turbine vibration (1). N
10. Loss of synthetic lube oil header pressure sensor N
11. Very low synthetic lube oil header pressure. N
12. Loss of power turbine lube oil header pressure sensor (2). N
13. Starter clutch over speed shutdown (Hilliard clutches only). N
14. Starter clutch re-engaged shutdown (Hilliard clutches only). N
15. Panel emergency shutdown no motoring push button. Customer specific
16. Customer emergency shutdown no motoring (if any). Customer specific
17.a. Very high gas level detected (inside turbine enclosure or) in the air
Y
inlet filter.
17.b. Very high gas level detected inside turbine enclosure (or in the air
N
inlet filter).
18. Gas turbine enclosure fire detected. Y
19. Gas turbine enclosure fire extinguisher manual discharge. Y
20. Loss of gas turbine enclosure ventilation. Not certified devices power
N
supply cut-out (3)
21. Process gas depressurized emergency shutdown. N

4 / 11
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and information are provided for authorized use only, and may not be used by or disclosed to others without the prior express written consent
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11
SERVICE BULLETIN
NIC 13.20 Rev.00
July 05, 2013

22. Very high axial displacement load gearbox and driven equipment. N
23. Very high radial vibration load gearbox and driven equipment (at NPT
N
speed less than 300 rpm if not latched in deviation from API670)
List of ESN condition

If mandatory modifications stated above are not applied (motoring sequences not updated), the engine
must be considered to be in 4 HOURS LOCKOUT status after every type of shutdown (NS, ES, ESN), as
per latest O&M requirements.

HARDWARE AND SOFTWARE IMPROVEMENT (OPTIONAL)

To mitigate the impact on the availability of units due to the modification of the previous sequences, GE Oil &
Gas has developed alternative ways to speed up the restart process by acting on the hydraulic starting
system (AUTOMATIC LOCKED ROTOR CHECK) or by introducing new electrical device (SLOW MOTORING).

The proposed hardware modification can be considered as optional.


These systems can be implemented separately and they are mutually independent:

1. Automatic Locked Rotor Check (SOFT START):

This device is a hardware modification to automatically apply the SOFT START procedure. It allows
verifying if the HP rotor is free, by applying less than 45 ft-lb (61 N⋅m) of torque to the AGB starter
shaft. This system is only applicable to hydraulic starting system and NOT to pneumatic starting
systems.

A solenoid damp valve, combined with a very slow flow ramp-up from hydraulic pump achieves a
slowly increasing differential pressure across the hydraulic starter, resulting in a slow increase in
torque at the hydraulic starter output shaft.

Dedicated pressure transmitters are used to verify the actual differential pressure needed to operate
the starter. By comparing it to the maximum allowed value, it is possible to verify the maximum
torque requirement.

The solution needs to be verified site by site since the presence of different pump stroke limitations,
isolation valves and/or small cooling systems can impact the items to be substituted or energized.

There are two possible options:

 Closed loop starting system


This is the typical version installed in the enclosure of older package design, where the cooler and
the tank are dedicated only to the starting system. A variable flow HP pump takes the oil directly
from the starter return line, and delivers it back to the starter inlet. The usual closed loop starting
system included manometers in place of pressure transmitters, and a solenoid valve was not used.

In this configuration, to implement the solution, the bypass Solenoid Damp Valve and pressure
transmitters (instead of manometers) are to be added to existing packages and a change in logic is
needed to introduce the Locked Rotor Check (Soft Start) logic.

5 / 11
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and information are provided for authorized use only, and may not be used by or disclosed to others without the prior express written consent
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11
SERVICE BULLETIN
NIC 13.20 Rev.00
July 05, 2013

 Open loop starting system

The typical version installed in the Package Redesign enclosures is also present in some older
packages. The pump takes oil directly from the shared oil circuit used on the Gas Turbine / load
equipment. A small pilot pump is present in place of the make-up pump. Oil is sent back to the main
circuit and common cooler/tank.

In this configuration, a by-pass valve and pressure transmitter are already present in all package
redesign version enclosures (open loop). Only a change in logic is needed to introduce Locked Rotor
Check (Soft Start) logic.

2. Slow Motoring
Slow Motoring (or Pony Motor) is a hardware/software modification to avoid the 4 HOURS LOCKOUT
sequence and shutdown motoring. The rotor is kept turning at slow speed (100 rpm) by a worm
gearbox driven by an AC motor and connected to the Accessory Gear Box through a specially
designed clutch.

6 / 11
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11
SERVICE BULLETIN
NIC 13.20 Rev.00
July 05, 2013

After any shutdown (ES, ESN, failed NS), slow rotation must be initiated as soon as the driven
equipment comes to rest but no longer than 6 minutes after Gas Generator Speed (NGG) < 300 rpm,
otherwise engine must be considered in 4 HOURS LOCKOUT configuration.

Slow rotation at about 100 rpm can be continuously done for 4 hours. During this period SOFT START
can be performed at any time skipping free HP rotation check. After 4 hours of slow rotation a
normal start can be accomplished.

The device can be powered by either plant AC, a plant battery pack (DC) or a dedicated battery pack
(DC). An inverter is required to provide AC power to the electric motor if DC is used.

Main Features:

 Low power (~550W) aluminum casing AC motor


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

Required utilities:

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


 Linear Actuator: 80W 24VDC
 Position Probes: 200 mA 24VDC

The system can be supplied with a DC UCP and inverter (optional), to back-up in case of loss of AC in
the plant.

A list of the Emergency Shutdown No Motoring events can be found in Table 2. For all these events,
motoring is not allowed, and 4 HOURS LOCKOUT is mandatory if a mitigation procedure (soft start or
pony motor) is not applied.

It is understood that the cause of the trip must be determined and resolved prior to restarting the
engine.

7 / 11
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11
SERVICE BULLETIN
NIC 13.20 Rev.00
July 05, 2013

Consult the table below for the applicability of the mitigation process.

ESN trigger EHS related Pony Motor ON


1. HP rotor over speed trip. N NO
2. HP rotor back-up over speed trip. N NO
NO
3. Loss of both HP rotor magnetic speed pick-ups N As soon as the speed pickups are not
available
4. Power turbine rotor over speed trip. N YES
5. Power turbine rotor back-up over speed trip. N YES
6. Loss of both PT rotor magnetic speed pick-ups N YES
7. Axial compressor stall detected. N YES
8. Very high gas generator vibration (1). N YES
9. Very high power turbine vibration (1). N YES
10. Loss of synthetic lube oil header pressure sensor N YES
11. Very low synthetic lube oil header pressure. N YES
12. Loss of power turbine lube oil header pressure
N YES
sensor (2).
13. Starter clutch over speed shutdown (Hilliard clutches YES
N If clutch is really failed, pony will not
only). have enough torque to run anyway
14. Starter clutch re-engaged shutdown (Hilliard YES
N If clutch is really failed, pony will not
clutches only). have enough torque to run anyway
15. Panel emergency shutdown no motoring push Customer Depending on customer
button. specific
Customer
16. Customer emergency shutdown no motoring (if any). Depending on customer
specific
17.a. Very high gas level detected (inside turbine
Y NO
enclosure or) in the air inlet filter.
17.b. Very high gas level detected inside turbine
N NO
enclosure (or in the air inlet filter).
18. Gas turbine enclosure fire detected. Y NO
19. Gas turbine enclosure fire extinguisher manual
Y NO
discharge.
20. Loss of gas turbine enclosure ventilation. Not
N YES
certified devices power supply cut-out (3)
21. Process gas depressurized emergency shutdown. N YES
22. Very high axial displacement load gearbox and
N YES
driven equipment.
23. Very high radial vibration load gearbox and driven
equipment (at NPT speed less than 300 rpm if not N YES
latched in deviation from API670)
List of Emergency Shutdown NO motoring (ESN) conditions

Recommendations

GE Oil & Gas recommends updating Shutdown and Hot Restart procedures in accordance with the
requirements provided by GE Aviation through the Interim Change Notes (ICN) and updated Operation &
Maintenance manuals (O&M).

8 / 11
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11
SERVICE BULLETIN
NIC 13.20 Rev.00
July 05, 2013

The new sequence requirements are mandatory for all existing families of LM2500/PGT25 Gas Generator
units, both new and in service. They need to be included in units currently in service, retrofitting or
upgrading.

A summary of requirements is listed in the following table:

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

This NIC supersedes both NIC 05.38 Rev. 01 and NIC 05.27 Rev. 01 that henceforth will be marked as
obsolete.

GE Oil & Gas is neither responsible nor liable for property damage arising from the failure to follow all the
procedures and guidelines listed in this document and its attachments.

Planning Information

Compliance
Compliance Category: (C)
Timing Code: (2)

Manpower skills

 SOFTWARE MODIFICATION:
One qualified technician for one day shift (with the updated software available). The Software
update must be evaluated and performed by GE Oil & Gas Headquarters based on the specific
customer configuration.

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11
SERVICE BULLETIN
NIC 13.20 Rev.00
July 05, 2013

 SOFT START hardware modification:


Each modification must be evaluated by GE Oil & Gas Headquarter based on customer hardware
configuration.
 SLOW MOTOR hardware/software modification:
Each modification must be evaluated GE Oil & Gas Headquarter based on hardware customer
configuration
Parts

 SOFT START:
Part number list must be evaluated by GE Oil & Gas Headquarter based on customer hardware
configuration and requests

 SLOW MOTOR:
Part number list must be evaluated by GE Oil & Gas Headquarter based on customer hardware
configuration and requests

Special Tooling
N/A

Reference Documents

O&M manuals references – ICNs

Ref. GG Model
LM2500-IND-GEK103089-044 LM2500 DLE
LM2500-IND-GEK97310-144 LM2500 SAC
LM2500-IND-GEK105048-051 LM2500+ DLE
LM2500-IND-GEK105054-048 LM2500+ SAC
LM2500-IND-GEK112767-036 LM2500+G4 DLE
LM2500-IND-GEK112859-032 LM2500+G4 SAC

Scope of work
The mandatory software update in accordance with the requirements provided by GE Aviation must
be evaluated and performed by GE Oil & Gas Headquarters based on the specific customer
configuration.
The optional updates (Soft Restart and Slow Motoring) must be evaluated and performed by GE Oil
& Gas Headquarters based on the specific customer configuration.

Note: In order to keep the GE Oil & Gas global installed fleet database updated, it is kindly requested that the
COMPLIANCE RECORD and USER SATISFACTION SURVEY be completed and sent to the addresses specified in the forms.

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11
SERVICE BULLETIN
NIC 13.20 Rev.00
July 05, 2013

Contacts
For units under warranty or covered under a Contractual Service Agreement (CSA) please refer to your GE
Oil & Gas Project Manager.

For technical questions or application and commercial requests please contact:

GE Oil & Gas


Customer Service Center
Via Felice Matteucci, 2
50127 Florence, Italy
e-Mail: customer.service.center@ge.com
Web: http://www.geoilandgas.com/businesses/ge_oilandgas/en/prod_serv/serv/cust_serv.htm
Phone: +39 055 427 2500
Fax: +39 055 423 2800
Please specify the Unit Serial Number and Service Bulletin associated with the request and whether
the request is technical or commercial.

To directly access and download GE Oil & Gas Service Bulletins published on your fleet or to subscribe to
our Service Bulletin e-mail notification service, please visit the Technical Updates Portal:

http://www.geoilandgas.com/businesses/ge_oilandgas/en/about/technical_bulletins.htm

This online tool is available only to registered GE customers. Please refer to NIC 07.37.SL for any additional
information.

The recommendations contained in this Service Bulletin are for information only. Unless otherwise indicated
in a Contractual Service Agreement (CSA) in force between the parties, all costs associated with
implementation of the recommendations are the Customer’s responsibility.

Warranty issues will be handled as per the terms of the contract.

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Technical Updates Communication
GE Oil & Gas
COMPLIANCE RECORD

SERVICE BULLETIN COMPLIANCE RECORD


Unit Contact Information Customer Contact Information
Serial Number: Customer Name:
Contact Name:
Operating Hours: Position:
No. of Starts: e-mail:

Service Bulletin Applied:


NIC Code: Issue date: Category:
Title:

Service Bulletin Completion Date:


100% of Service Bulletin Completed: YES NO

If No, please state what was completed and what was not:

Comments:



Please complete and Fax this form to: GE OIL & GAS Technical Update Communication
TES/TECH/TEUP Department – Mr. Franco Sciacchitano -
Fax: +39 055 423.2800
e-mail: oilandgas.technicalupdates@ge.com

NOTE: The Unit Compliance Record can also be transmitted automatically by email from the “My Compliance Info”
section of the Technical Updates Web Portal at:
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Technical Updates Communication
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USER SATISFACTION SURVEY

GE requests that you complete this User Satisfaction Survey to help us better serve you with
accurate and timely information on your equipment

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NOTE: To directly access and download GE Oil & Gas Service Bulletins published on your equipment and to
subscribe to automatic e-mail notification, please visit the Technical Updates Web Portal at:
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This online tool is available only to registered GE customers. Please refer to NIC 07.37.SL for any additional information.

Please rate the following based on a scale of 1 to 5, where 1 is Excellent and 5 is Poor.

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Please complete and Fax this form to: GE OIL & GAS Technical Update Communication
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