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SERVICE BULLETIN
NIC 13.20 Rev.00
July 05, 2013
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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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.
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 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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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
In both cases, motoring must be initiated no longer than 6 (six) minutes after engine rpm NGG < 300.
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.
3 / 11
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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
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.
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.
4 / 11
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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
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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.
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).
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.
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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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
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11
SERVICE BULLETIN
NIC 13.20 Rev.00
July 05, 2013
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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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
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:
Required utilities:
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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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
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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.
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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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
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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.
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.
9 / 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
of Nuovo Pignone S.r.l..
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SERVICE BULLETIN
NIC 13.20 Rev.00
July 05, 2013
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
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.
10 / 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
of Nuovo Pignone S.r.l..
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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.
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.
11 / 11
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Technical Updates Communication
GE Oil & Gas
COMPLIANCE RECORD
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:
http://www.geoilandgas.com/businesses/ge_oilandgas/en/about/technical_bulletins.htm
Technical Updates Communication
GE Oil & Gas
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
1. How many days after the Service Bulletin issue date did you receive this document?
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:
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.
Please rate the following based on a scale of 1 to 5, where 1 is Excellent and 5 is Poor.
Comments or Suggestions:
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