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LM6000 PC GE Industrial AeroDerivative Gas Turbines

GEK 105059 Volume I

CHAPTER 13 Critical Parts Life Management - LM6000 PC Engine

13-1 Purpose and Scope
CAUTION Critical life-limited parts must be removed from service before reaching the declared life limit. Serious engine damage can occur if all provisions of this caution are not complied with. Critical life-limited parts have undergone extensive analysis which provides a basis for establishing the industrial life limits defined in table 13-1. GE will continue evaluating component life limits and will revise the limits when technically justified. The critical parts life limitations have been substantiated based on engineering analysis that assumes this product will be operated and maintained using the procedures and inspections provided in the instructions for continued operation supplied with this product by GE, or its licensees. For Life Limited Parts and parts that influence Life Limited Parts, any repair, modification or maintenance procedures not approved by GE, or its licensees, or any substitution of such parts not supplied by GE, or its licensees, may materially affect these limits.

This chapter identifies specific parts of the LM6000 PC engine that are cyclic life-limited as a result of normal operation. Instructions for tracking the operating hours and operating cycles for such parts that have been identified as being limited in terms of operating service, are also provided. Critical life-limited parts are those parts that, should they suddenly fail, could threaten the structural integrity of the engine or its package. Stress cycles on gas turbine parts result from transients of speed and temperature that occur during starts, accelerations, and decelerations. Therefore, life limits are expressed in terms of engine cycles and can be related to normal operational data. Cycles are defined in paragraph 13-2, Definitions. Life limits of critical parts are established through analysis and testing. Accumulated cycles are to be calculated, tracked, and compared to published life limits to determine when a part should be permanently retired from service. No component shall be allowed to remain in service beyond its published life limit. Paragraph 13-5 defines how cycles are to be calculated.

13-2 Definitions
The following terms are used in this chapter: a. Full Cycle: A full cycle is defined as a cycle from zero gas generator speed with acceleration to high power setting, followed by shutdown of the gas turbine. High power setting is considered to be any power setting above synchronous idle where the generator breaker is closed.

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LM6000 PC GE Industrial AeroDerivative Gas Turbines

b.

Partial Cycle: A partial cycle is defined as any decrease in power (mW) greater than X percent from a current steady state power (any power setting above idle) to any controlled lower power setting, followed by a subsequent increase in power (>10 percent). Steady state power is considered to be any power setting above synchronous idle where the generator breaker is closed. If X = 0-50, then Kp = 0 If X >50, and 75, then Kp = 0.1 If X >75, and 100, then Kp = 0.75

g.

Partial Cycle Factor: Coefficient used as a numeric expression of the amount of damage caused by a partial cycle (Kp). Trip Cycle Factor: Coefficient used as a numeric expression of the amount of damage caused by a trip cycle (Kt).

h.

13-3 Affected Parts

The critical life-limited parts for the LM6000 PC engine are listed in table 13-1.

13-4 Parameters to be Tracked

Engine operating hours and cycles must be recorded and tracked for each critical lifelimited part. Each part is uniquely identified by the combination of its part number and serial number. Parameters to be tracked are shown in the Critical Parts Tracking System Data Sheet shown in figure 13-1. A data sheet must be created and maintained for each critical part throughout its entire life. CAUTION It is the owners/users responsibility to establish a tracking system to ensure that adequate records are maintained for each critical life-limited part and that no such part exceeds its life limit. When any critical life-limited part is transferred from one location to another or used as a rotable spare, this event must be recorded on the Critical Parts Tracking System Data Sheet for that part. The data sheet, containing the life history record of a critical life-limited part, maintains documentation of the parts cyclic life history as the part transfers from one location to another.

c.

Trip Cycle: A trip cycle is defined as a cycle from zero gas generator speed with acceleration to high power setting (any power setting above synchronous idle), followed by rapid (uncontrolled) shutdown. An example would be a fuel metering valve being immediately closed. A decel-tominimum load or step-to-idle are not considered trip cycles for the purpose of Critical Parts Life Management. Declared Life: Declared life is the cyclic life limit of a critical lifelimited part. Accumulated Cycles: Accumulated cycles represent the calculated life consumed by a part, considering both full, partial, and trip cycles experienced by the part during operation. Full Cycle Factor: Coefficient used as a numeric expression of the amount of damage caused by a full cycle (Kf).

d.

e.

f.

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LM6000 PC GE Industrial AeroDerivative Gas Turbines

GEK 105059 Volume I

13-5 Calculating Accumulated Cycles and Recording Data

As defined in paragraph 13-2, a cycle may be designated as full, partial, or trip. In order to take credit for the increased capability of a partial cycle, the life consumed is calculated by considering full, partial, and trip cycles. The consumed life of the part is designated as the accumulated cycles of the part. Accumulated cycles are calculated using the equation:

a.

Accumulated Cycles = (Kf x Full Cycles) + (Kp x Partial Cycles) + (Kt x Trip Cycles) The coefficients Kf, Kp, and Kt are listed for each component in table 13-1.

b.

The owner/user is responsible for the maintenance of accurate records of all engine hours and cycles. The operator should monitor status of the parts to ensure that none listed in table 13-1 exceed the declared life limits published in this chapter.

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LM6000 PC GE Industrial AeroDerivative Gas Turbines Table 13-1 Declared Life Limits for LM6000 PC Engine

Module LPCR

Component

Part Number

Industrial Life Limit (Cycles)

Kf

Kp

Kt

Stg 0 Disk Stg 1 Disk Stg 2-4 Spool LPC Fwd Shaft LPC Fwd Shaft FMS Fwd Shaft Mid Shaft HPCR Stg 1 Disk Stg 2 Disk Stg 2 Disk Stg 3-9 Spool Stg 3-9 Spool Stg 10-14 Spool CDP Seal CDP Seal HPTR Stg 1 Disk Stg 1 Disk Stg 2 Disk Stg 2 Disk

L24546P05 L24547P03 1781M30G04 L24548P06 L44648G01, G02 9080M27P09 L47747P01, P02, P03 9380M26P06 9380M27P08 9380M27P10 1333M66G10 1333M66G09, G13, G14, and L44659P01 1703M49G01, G02, G03, G04 L47299P02 L47299P03, 1782M82P02, P03, and L43372P04 1531M84G10, G12 1531M84G11 9362M43P05 9362M43P10

20,000 20,000 20,000 20,000 TBD 8,500 TBD 11,200 17,200 TBD 11,900 TBD TBD 11,300 TBD

1 1 1 1 TBD 1 TBD 1 1 TBD 1 TBD TBD 1 TBD

See Note 1

1 1 1 1 TBD 1 TBD 1.97 1.96 TBD 1.76 TBD TBD 3.94 TBD

10,100 TBD 6,200 TBD

1 TBD 1 TBD

1.688 TBD 2.67 TBD

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LM6000 PC GE Industrial AeroDerivative Gas Turbines Table 13-1 Declared Life Limits for LM6000 PC Engine (Continued) Module LPTR Stg 1 Disk Stg 1 Disk Stg 2 Disk Stg 2 Disk Stg 3 Disk Stg 4 Disk Stg 5 Disk Shaft Balance Piston L47741P01 L47741P02 L47742P01 L47742P02 L47743P02 L47744P02, P03 L47745P02 L47746P01 L45001P07 and L47958P01, P02 20,000 TBD 16,400 TBD TBD TBD TBD TBD TBD 1 TBD 1 TBD TBD TBD TBD TBD TBD Component Part Number Industrial Life Limit (Cycles) Kf Kp

GEK 105059 Volume I

Kt

See Note 1
TBD TBD TBD TBD TBD TBD TBD TBD TBD

Note 1: For appropriate partial cycle factor (Kp), refer to Partial Cycle definition in paragraph 13-2.b.

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Figure 13-1 Critical Parts Tracking System Data Sheet Example

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LM6000 PC GE Industrial AeroDerivative Gas Turbines

GEK 105059 Volume I

APPENDIX A Fuel/Water Requirements

This appendix contains specifications for the following: A1 A2 A3 A4 A5 A6 Natural Gas Fuel Liquid Fuel Water Purity - NOx Suppression Water Purity - Compressor Cleaning Liquid Detergent - Compressor Cleaning Lubricating Oil

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A-1(A-2 Blank)

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