Installation/Initial Startup and Engine Operation
DESCRIBED IN PARAGRAPH 7-2
g. Perform verification test per paragraph 7-3.7.
h. Make a normal start (paragraph 7-4.4, Starting and Operation) and set power at idle. When the engine is stabilized at idle, do the following:
• Check engine and supply systems for leaks
• Check for loose parts, tubing, cabling, etc.
• Check all parameters and verify that val-ues are within normal range per Table 7-5
• Observe and record all results
• Correct discrepancies prior to load applica-tion
i. Operation to maximum power.
1. Slowly increase control setting (refer to packager’s manual) to increase gas generator speed (NGG). After each 500 RPM increase, log all instrument readings, paying particular attention to variable stator vane (VSV) position and vibration. If variable stator sys-tem is not within limits, inspect it per WP 419 00. If vibrations are not within limits, consult local General Electric Company representative.
2. Operate GG up to rated power. The GG’s output will normally be limited by compressor discharge pressure (PS3) or on extremely cold days cor-rected core speed. Hold at this power setting until engine stabilizes.
NOTE
Normal operating parameter ranges and limits are shown in Tables 7-5 and 7-6.
Refer to Tables 7-7 and 7-8, and the appropriate Addendum in Volume 1 when operating with NOx Suppression.
3. Compare recorded readings to typi-cal values in Table 7-5 and trouble-shoot as required.
4. Log all instrument readings once they stabilize.
7-21 7-3.7 Verification Test
If no verification test is specified by the pack-ager, the verification test described below should be performed after the initial opera-tional checkout (paragraph 7-4.6) has been completed. Record any abnormal condition and perform any needed corrective action.
a. Verify all service systems (electrical, air, fuel, lube oil, fire control, water, indica-tors, and controls) are checked out and ready for operation.
b. Make a start (paragraph 7-4.4, Starting and Operation).
c. Hold at idle for 5 minutes minimum.
d. Perform PT overspeed shutdown test on each channel, with the PT unloaded, by slowly increasing power turbine speed (NPT) until automatic shutdown occurs.
Shutdown should occur at appropriate trip speed for model. If automatic shutdown does not occur, shutdown manually and check speed indication and automatic shutdown systems.
NOTE
Optimization of control schedules via com-bustor mapping should be accomplished prior to operation at full power.
e. Restart the engine and slowly advance to full power. If the accel follows a cold start, it should be at a rate not to exceed zero to maximum load in less than 5 minutes. A ramped (constant rate) load increase should be maintained during the accel.
f. Stabilize at full power for 3 minutes, then observe and record the data specified in Table 7-5, Typical Operating Levels.
g. Reduce power to idle.
h. Perform a normal shutdown, (paragraph 7-4.5.1, Normal Shutdown).
i. Inspect for leakage and loose parts and take any corrective action required.
j. Check lube and scavenge pump screens for evidence of contamination.
Table 7-5. Typical Operating Levels
Parameter IDLE Max Power
Max Operating Limit
(Note 1) T2, °F (°C)
(Inlet temperature) 40 to 70
(4.4 to 21.1) 40 to 70
(4.4 to 21.1) N/A P2, psia (kPa absolute)
(Inlet pressure) 14.5 - 14.8
(99.97 - 102.04) 14.5 - 14.8
(99.97 - 102.04) N/A NGG, rpm
(Gas generator speed) 5900 - 6100
(Note 2) 9150 - 9600 10,050 (Note 3)
PS3, psia (kPa absolute)
CDP 40 - 55
(275.8 - 379.2) 280 - 320
(1930.5 - 2206.3) 300-335 (Note 9) (2068.4 - 2309.7) T3, °F (°C)
(Compressor discharge tempera-ture)
285 to 365
(140.6 to 184.9) 835 to 890
(446.1 to 476.6) 935 (501.6) WF36, lb/hr (kg/hr) @ 19,000
BTU/lb (10,555 kcal/kg) (Gas fuel flow)
1200 - 1500
(544.3 - 680.4) 11400 - 14300
(5170.9 - 6485.4) N/A WF36, lb/hr (kg/hr) @ 18,400
BTU/lb (10,555 kcal/kg) 1200 - 1500
(544.3 - 680.4) N/A
PT5.4, psia (kPa absolute) (Power Turbine [PT] inlet pres-sure)
17 - 19
(117.2 - 131.0) 60 - 70
(413.7 - 482.6) N/A T5.4, °F (°C) (see Figure 7-6)
(PT inlet temperature) 1150 to 1350
(621.1 to 732.2) 1455 to 1520
(790.6 to 826.7) 1566 (Note 4) (852.2)
PT speed for 60 Hz (rpm) 0 - 3600
PT speed for 50 Hz (rpm) 0 - 3000
VSV position, degrees 30 to 34 4 to 8 N/A
Lube supply pressure, psig
(kPa gage) 8 - 15 (Note 5)
(55.2 - 103.4) 20 - 60 (Note 5)
137.9 - 413.7) 8 min (Note 6) (55.1 min) Lube supply temperature, °F (°C) 140 to 160
(59.9 to 71.1) 140 to 160
(59.9 to 71.1) 200 (Note 7) (93.3) Lube scavenge pressure, psig
(kPa gage) See appropriate
packager manual 5 - 100
(34.4 - 689.4) 110 (Note 7)
7-23 Table 7-5. Typical Operating Levels - (Cont.)
Parameter IDLE Max Power
Max Operating Limit
(Note 1) Lube scavenge temperature
(B-sump), °F (°C) (Note 8) Lube scavenge temperature
(C-sump), °F (°C) (Note 8) Gas manifold pressure, psig
(kPa gage) Natural gas fuel manifold pressure,
psig (kPa gage)
(With or without water/steam injection for NOx suppression)
20 - 390
(137.9 - 2689.0)
Natural gas fuel manifold tempera-ture, °F (°C) (Natural gas models only)
-65 to 150 (-53.8 to 65.5) Starter supply pressure (optional air/
gas starters only)
35 - 40 psig (241.3 - 275.7 kPa) Liquid fuel manifold pressure, psig
(kPa gage) (Liquid fuel only models only)
150 - 900 psig (1034.2 - 6205.2) Liquid fuel manifold pressure, psig
(kPa gage) (Liquid fuel and dual fuel, water injected models only)
0 - 395 (0 - 2723.4) Liquid fuel manifold temperature, °F
(°C) (Liquid fuel models)
20° (above wax point of fuel) to 150 ° (11 to 65.5)
Recoup pressure, psig (kPa gage) See Chapter 11 See Chapter 11 See Chapter 11 NOTE 1:
Unless otherwise noted, limits are shutdown limits. Reference Chapter 9, Engine Troubleshooting for complete electronic control alarm and shutdown limits.
NOTE 2:
For T2 temperatures between -30°F (-34.4°C) and 130°F (54.4°C).
Table 7-5. Typical Operating Levels - (Cont.)
Table 7-6. Limits and Operating Requirements
Parameter IDLE Max Power
Max Operating Limit
(Note 1) NOTE 3:
NGG limit at T2=59°F (14.9°C); otherwise limited to 9,563 - 10,100 rpm over T2 from 10° to 120°F (-12.2° to 48.8°C) range. Shutdown limit 10,200 rpm.
NOTE 4:
Shutdown limit 1,600°F (871.1°C).
NOTE 5:
Correct and establish normal lube pressure range per Chapter 5.
NOTE 6:
At NGG > 4,500 rpm.
NOTE 7:
Alarm only.
NOTE 8:
Increase in scavenge temperature over lube supply temperature. Alarm limit 300°F (148.9°C).
NOTE 9:
Shutdown limit is 375 psia (2,585.5 kPa absolute).
Event/Item Max Limits/Requirements
Max Time Allowed for Ignition t > 10 seconds after fuel/ignition application (gas) t > 20 seconds after fuel/ignition application (liquid) Max Time to Reach Starter Cutout NGG > 4,500 rpm at t _ 90 seconds
Max Time to Reach Idle NGG > 6,050 rpm at t _ 120 seconds HP Rotor Vibrations 4 mils or 1.75 in/sec at > 125 Hz and
1.5 in/sec < 125 Hz
Fuel Supply Temperature (Gas) < Tsv +20°F (11°C) min; > 300°F (148.8°C) PT Rotor Vibrations 7 mils or 1.25 in/sec at 45 Hz and
0.75 in/sec < 45 Hz
7-25 Table 7-7. Gas Turbine/Gas Generator Steam Limits (Steam Only Models)
Table 7-8. Gas Turbine/Gas Generator Water Injection Limits for NOx Suppression Parameter
Max Operating Limit Min Operating Limit
Rela-tive to Fuel flow During Transients
See
Appendix A6 Steam Metering Valve
Closing Time
< 100 ms Steam Shutoff Valve
Closing Time (GT only)
< 1.0 sec NOTE 1:
The LM2500+ SAC steam injected GT does not require any particular minimum steam flow through the fuel nozzle steam manifold, 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 pre-vent condensate from developing due to an inadequate superheat and/or insufficient flow through the external pipes and components.
NOTE 2:
This pressure is for sea level operation and must be corrected for altitude for each engine installation.
Parameter
Manifold shall be free of pressure pulsations in the 0 to 100 Hz range. The water must be controlled in a manner to prevent any sudden pressure spikes which could momentarily displace fuel.
Figure 7-6. Transient Temperature Limits (Typical)
7-27 7-4 ENGINE OPERATION
Operational procedures are also presented in this section. Prior to operation of the engine, the site operators should be thoroughly schooled in both normal and abnormal (emer-gency) operations and the control system action/reaction to these conditions. This sec-tion offers guidelines for tracking engine oper-ation times and maintenance actions, a thorough history of the GT’s performance will aid in further operations and maintenance decisions.
7-4.1 Component Life/Repair Intervals Safe operation of the LM2500
+
SAC is depen-dent on properly scheduled maintenance, repairs, and component replacement. In order to properly track these conditions, packager-supplied time and event counters provide data for the parameters. Tracking instructions are TBD.7-4.2 Prestart Checks
Consult the packager's manual for mandatory prestart procedures to ensure that packager-furnished systems are activated and opera-tional.
Prior to any motoring or start sequence, GE suggests the following checks as a minimum:
• All maintenance requirements or discrep-ancies are cleared and signed off
• Ensure that the inlet and enclosure have been inspected and cleaned in accordance with instructions in the packager's manual
• Fuel shutoff valves are closed
• Ignition system is off
• Lube tank level is full
• Lube supply valves are open
• Lube oil temperature is above 20°F (-6.7°C) for MIL-L-23699 or above -20°F (-28.9°C) for MIL-L-7808
• T5.4 less than 400°F (204.4°C)
• All switches and interlocks set for proper sequence to allow motoring
• Fuel metering valve at start position
• VSVs at scheduled position
• Gas vent valves set for gas startup
• Liquid drain valves closed at liquid startup
• Fire alarm/extinguisher system activated
• Required checks and inspections for GT electronic control have been performed in accordance with packager’s manual Although not necessarily required as part of normal starting procedures, motoring is fre-quently used following maintenance to check the engine prior to making a start. Motoring is performed with the fuel shutoff valves closed.
7-4.3 Motoring Procedures CAUTION
IF A QUESTIONABLE CONDITION EXISTS, DO NOT OPERATE THE ENGINE UNTIL A THOROUGH INVES-TIGATION HAS BEEN MADE. DO NOT REPEAT HOT STARTS, COMPRESSOR STALLS, OR OTHER RECOGNIZED PROBLEMS WITHOUT PRIOR THOR-OUGH INVESTIGATION. FAILURE TO DO SO CAN RESULT IN UNDUE
STRESS BEING IMPOSED ON ENGINE COMPONENTS, WITH IMMEDIATE OR SUBSEQUENT DESTRUCTIVE FAIL-URE OF THE ENGINE.
NOTE
Be certain that checklists have been established for packager-furnished equip-ment. Consult the packager's manual for mandatory prestart procedures and make certain that the packager-furnished lube supply subsystem is activated and opera-tional prior to any motoring or start sequence.
After all preliminary checks have been com-pleted and lines flushed, GG can be motored as follows:
a. Make ignition and fuel-gas supply systems inoperative as follows:
(1) Disconnect power supply to ignition unit(s).
(2) Close manual shutoff valve(s) to fuel skids.
b. Motor GG until gas generator speed (NGG) stabilizes and check for oil sure. If there is no indication of oil pres-sure, stop motoring. Loosen oil fittings at lube pump inlet to bleed air from system and ensure pump is primed. Starter should motor GG to minimum of 2,200 rpm at full supply pressure to starter.
c. Repeat motoring and bleeding procedure until an indication of oil pressure appears.
7-4.4 Starting and Operation 7-4.4.1 Normal Starting Sequence
WARNING
FOR MAXIMUM SAFETY,