Maintenance Course

Solidaris LLC
1700 Rockville Pike, #535

Rockville, MD.
US
LM6000 Gas Turbine

Generator Set
Maintenance Course
Presented by: S&W Energy Solutions, Inc.
September, 2012
Rev. 0
LM6000 GENERATOR PACKAGE MAINTENANCE COURSE
Disclaimer:
This document is intended for training use only.
It is not intended to cover all possible variations
in equipment or to provide for specific problems
that may arise. Technical drawings and
descriptions herein are intended to illustrate
conceptual examples and do not necessarily
represent as-supplied system details. System
users are advised to refer to drawings of current
release when conducting troubleshooting,
maintenance procedures, or other activities
requiring system information.
Solidaris LLC advises that plant personnel read

this training manual and the Operation &
Maintenance Manual to become familiar with the
generator package, its auxiliary equipment and
its operation.
This manual is not a replacement for experience

and judgment. The final responsibility for
proper, safe operation and maintenance of the
generator package lies with the Owners and
Operators.
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Course Introduction
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TABLE OF CONTENTS
Sections 1 - 5 for REVIEW purposes only. Covered under LM6000 FAM/BOC Course
Section 6
06A - Maintenance Administration

06B - Maintenance Checks Periodicity
06C - Equipment Testing
06D - Engine Checks
06E - Generator Checks - Brush
Section 7 – Borescope
Section 8
08A - Level 1 and Level 2 Work Packages

08B – ICM Interim Letter
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Course Introduction
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THIS PAGE INTENTIONALLY LEFT BLANK
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Course Introduction
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SECTION 6A
MAINTENANCE ADMINISTRATION
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Maintenance Administration
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MAINTENANCE MANAGEMENT SYSTEMS

The primary objective of the Maintenance Systems is to manage maintenance and
maintenance support in a way that will ensure maximum equipment operational readiness.
There are basically two sub-systems that make up standard maintenance systems.
They are:
 Planned Maintenance System
 Maintenance Data System
Planned Maintenance System (PMS)

The planned maintenance system is an overall management tool that provides a simple and
efficient way in which basic maintenance on all equipment can be planned, scheduled,
controlled, and performed.
1. Define the minimum planned maintenance required to schedule and control

maintenance work packages.
2. Provide for the detection and prevention of impending casualties.
3. Forecast and plan manpower and material requirements.
4. Plan and schedule maintenance task.
5. Estimate and evaluate material readiness.
6. Detect areas requiring additional or improved personnel training and improved
maintenance techniques or attention.
7. Provide increased readiness of the plant.
Benefits Planned Maintenance System

As mentioned before, the Planned Maintenance System is a management tool. By using a
well-established program, the Maintenance Department and Plant Managers can readily
determine the status of the plant and overall reliability is intensified.
In addition:
1. Preventive maintenance reduces the need for major corrective maintenance, increases
economy, and saves the cost of repairs.
2. Better records since it provides additional useful data to the maintenance manager.
3. System assists in the prevention of unexpected changes in employee schedules. This
reduces frustrating breakdowns and irregular hours of work.
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MAINTENANCE INFORMATION SYSTEMS

Overview
A maintenance information system is a necessary part of a good maintenance program. Such a
system makes the maintenance program more effective and reduces its cost in the long run. A
suitable system allows the maintenance manager to gather data to support maintenance
decisions. It includes equipment failure data that may be fed back to designers or
manufacturers, used for process hazard evaluation, or sent to the purchasing department to
support changes to specifications or to support the selection or avoidance of particular
vendors or equipment types. The maintenance information system is also a valuable resource
for the planning department to use when preparing job packages for future maintenance work.
The maintenance information system provides:
1. An easily retrievable historical record for each major piece of equipment or group of
similar equipment. This record should include the original specification information,
manufacturer, a history of operation time and conditions, and a record of inspection
results and of all maintenance performed.
2. Equipment inspection and service schedules that specify the inspection and service
scope and standards. The schedule should indicate which safety precautions apply and
which permits are required during each activity. When fire protection equipment or
systems are involved, proper backup procedures should be required.
3. A persistent follow-up or tracking system to ensure that proper inspection and

maintenance service are being performed according to schedule.
4. An equipment repair and maintenance task priority assignment system that

automatically increases the priority of deferred jobs.
5. Specifications for special replacement parts and materials for individual pieces of
equipment so that proper parts and materials are used during maintenance procedures.
A list of qualified suppliers for these items should be maintained. Management of
change procedures should be followed before any substitutions are authorized.
6. An inventory of spare parts and an inventory control system. The control system
should include written procedures for proper storage of large, complex or sensitive
parts such as turbine rotors, electric motors or coils, or electronic modules.
7. Programs to analyze the effectiveness and cost of inspection and maintenance

procedures.
8. Written notification to management and other affected departments so they will be

promptly alerted when critical or safety-related components and systems are out of
service for maintenance or any other reason.
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In most organizations, the maintenance information system uses computers to assist in

program management. With the present state of the technology, there is no reason that even
small organizations cannot benefit from the relatively low-cost computer equipment and
maintenance management software available.
Maintenance Data System (MDS)

The Maintenance Data System is exactly what it implies. The system works to collect
maintenance data and to store it for future use. The data system may be either computer based
or hard copy paper. From the MDS come the current plant maintenance tasks and scheduled
future maintenance periods. The key forms (Data) listed below are the minimum required for
a functional system.
1. Maintenance Action Form (MAF) is used by maintenance personnel to report deferred

maintenance actions and completed maintenance actions (including those previously
deferred). This form also allows the entry of screening and planning information for
management and control of intermediate maintenance activity workloads.
a. Reporting of completed maintenance/repair tasks
b. Reporting of maintenance or repair tasks that are unable to be completed due to
operational restrictions, insufficient training, depot level requirements, or
shortage of required material.
c. Reports spare part usage.
d. Reports man-hours utilized
2. Deferred Maintenance Report (DMR) lists deferred maintenance and alterations which
have been identified through Maintenance Action Form (MAF) reporting. The purpose
of the DMR is to provide plant maintenance managers with a consolidated listing of
deferred corrective maintenance/repairs so they can manage and schedule its
accomplishment.
a. Provides managers with critical information to assist in scheduling future
maintenance periods.
b. Provides managers a listing to assist in funding and scheduling of outside
depot level assistance required to complete tasking.
c. Allows for critical maintenance/repair parts ordering and tracking.
d. Allows for scheduling maintenance department employees to meet
maintenance-tasking requirements.
3. Parts Report is a listing of parts utilized for repair and maintenance.

a. Provides a list for re-ordering expended items
b. Provides managers with a method to ensure high failure or commonly used
parts are on hand.
c. Assists managers in projecting maintenance budget.
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The screen prints on the following pages are from an off-the-shelf maintenance program that
is available in numerous formats and range from simplified too extensive tracking program.
These programs can be arranged to meet the requirements of the customers utilizing them.
Work Request Form, Operators to Maintenance Department
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Maintenance Work Order Produced By The Program
Maintenance Task Assignments
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Parts Tracking
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OPERATOR EVENT LOGS

Operating Records and Reports
Operations records contain a narrative of the plant status, and of all events required to
reconstruct a history of operations. In this context, logs are defined as a narrative sequence of
events or functions performed by the operations staff.
Operation logs are established to record the data necessary to provide a history of plant
operations. The scope, type, and amount of data required by management is entered into the
logs, including documentation of actions taken, activities completed, and data necessary to
reconstruct events. Logs are reviewed to insure they are adequately maintained and that
operations personnel are aware of the information in the logs.
Operating records are not intended to replace frequent inspections of operating machinery by
supervisory personnel and are not to be trusted implicitly to provide warning of impending
casualties.
Personnel who maintain operating records must be properly indoctrinated. They must be
trained to correctly obtain, interpret, and record data, and to report any abnormal conditions
noted.
The plant manager’s directives specify which operating records will be maintained and
prescribe the forms to be used. The Operations Manager may require additional operating
records when (all factors considered—including the burden of added paperwork) it is deems
necessary when no standard record forms are provided.
Completed records must be stowed where they will be properly preserved, and in such a
manner as to ensure that any one of the records can be easily located. The Plant Supervisor
should establish the time period that logs will be retained on-site.
General Log Construction

Information to be recorded
All information pertaining to the safe and efficient operation of the plant is recorded in the
operations logbooks. To aid in reconstructing events, as much information as possible is
logged during emergencies and abnormal or unexpected events.
Timeliness of Recordings
1. Information is entered promptly or as soon as reasonably possible to prevent
inaccuracies.
2. Log keeping does not take precedence over controlling and monitoring the plant.
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Minimum information required:

1. Machine modes (e.g. operations, shutdown, maintenance, system contents, etc.)
2. Changes in plant operating mode or condition
3. Record of critical data
4. Abnormal facility configurations
5. Status changes in safety-related or important equipment
6. Occurrences of reportable events
7. Initiation and completion of tests or studies
8. Security, Medical and Fire incidents
9. Shift relief’s and call-ins
10. Out-of-parameter readings from equipment logs should circled in red to draw attention
and annotated in event log.
11. Equipment that is out-of-commission. (Tagged out)
12. Outside telecommunication discussions (Dispatch)
Legibility
1. All log entries must be legible, understandable, and made in pen of a color that can be
photocopied.
Corrections
1. Incorrect entries are scored with a single line and initialed. References to incorrect
entries are made in the shift summary.
Log Review
1. The designated supervisor reviews the operations logbook.
2. The supervisor has the responsibility for filing and storing the logs for the expected
life of the facility. Back-logs are available for review by Operators or staff returning
after an absence.
3. On-coming shift supervisors to get overall picture of plant operation.
It should be noted that many of the equipment operating software programs would print out
equipment parameters when commanded to do so. This is a practical solution for complete
data dumps, but will not suffice as a stand-alone operator event log.
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INDIVIDUAL EQUIPMENT OPERATING LOG

Equipment Logs
Equipment logs may help to spot trouble in the equipment. They also aid in ensuring proper
periodic maintenance and inspection are performed on the equipment. Logs may provide a
means of self-protection when trouble occurs and the cause can be placed on an individual.
A typical operating log may contain entries such as the following:
1. Date and time of readings

2. Ambient temperature
3. Pressure and temperature readings
4. Flow readings
5. Differential pressure readings
6. Visual Inspection
7. Oil levels
8. Operating hours
9. Remarks column
These types of readings give a complete picture of the current and past operating conditions of
the equipment or plant and can assist the maintenance department in keeping the equipment or
plant at its maximum efficiency.
Typical Equipment Log
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Good judgment must always be used in analysis of service troubles and specific corrections
should be followed whenever possible. One of the methods for determining when and what
corrective measures are necessary on equipment or a plant which is not operating properly is
to compare the pressures and temperatures of various parts of the system with corresponding
readings taken in the past when the equipment or plant was operating properly under similar
heat load and circulating water temperature conditions.
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EQUIPMENT HISTORY LOGS

History logs contain entries of when, what, and who performed periodic maintenance and
inspections on major pieces of equipment. It also allows for annotation for implementation of
technical directives. Such logs help ensure that the equipment or plant is well maintained and
that the life expectancy of the equipment or plant is fully used.
Equipment history log entries may include the following:

1. Date/type of maintenance.
2. Date/type of inspection.
3. History of major component change out.
4. What was done to equipment?
5. Who did the work?
6. Technical directive incorporated.
It is important to compare operating log readings of the equipment before and after the
maintenance was completed to ensure maintenance was accomplished properly, and that it
had no ill effects on the equipment or plant.
Conduct Initial Performance

Test (Keep logs & records)
Conduct employee On the

Job Training (OJT)
Continually assess systems

operational parameters Analyze data, review equipment material
condition, submit recommendations to
vendors for improvements and request
tech assist as required
Maintain equipment/repair
IAW vendor documentation
Document discrepancies
corrected and deferred
maintenance
Request technical assistance

as required
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Package Maintenance Levels

Normally overall package maintenance is divided into three basic levels according to shop
capability. Normally, some combination of these defined maintenance levels will satisfy the
requirements of each customer.
On-Site (External) - Level I
On-site external maintenance encompasses the following two categories of maintenance tasks:
(1) Preventive (tasks that are scheduled on the basis of equipment run hours or calendar time),
and
(2) Corrective (tasks that are unscheduled and accomplished as a result of a problem). The
work scopes for these tasks cover all work on the exterior of installed equipment plus sched-
uled inspections, turbine compressor cleaning (water wash), turbine engine changeout, and
changeout of components of driven equipment.
Off-Site (Medium Shop Repair) - Level II
This maintenance level includes complete teardown and rebuilding of the turbine engine by
subassemblies. Replacement of major subassemblies is within the capability of this
maintenance level.
Off-Site (Extensive Shop Repair) - Level III
Level III off-site repair includes all levels of maintenance, plus complete repair of a turbine
engine or drive equipment parts. A test cell is required for a Level III facility.
Maintenance Schedule
Normal maintenance of each GTG set during the initial 3 years of operation will require only
a weekly visual inspection of turbine and turbine-driven equipment exteriors. None of these
inspections or tasks requires equipment removal or disassembly. The weekly inspection will
require approximately 1 hour by one man and can be performed with the unit operating. The
scheduled maintenance tasks are recommended at 6-month and 12-month intervals and can be
performed in one 8-hour shift, requiring approximately 16 man-hours for the set of tasks on
the turbine engine.
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MAINTENANCE WORK PACKAGE DEVELOPMENT

Develop a plant concurrent Maintenance Work Package that includes all major maintenance
actions such as Planned Maintenance System (PMS), gas turbine maintenance work packages,
electronic calibrations, repairs, alterations, and testing to be conducted by plant’s maintenance
department during the maintenance periods, as applicable.
Establish a strategy for calibration of gages, instruments, and tools based on maintenance
requirements.
Identify all industrial activity, providing production and testing support equipment needed to
accomplish work, or to re-certify systems following work. Identify this equipment to the
industrial activity prior to the start of the maintenance period. This support equipment
includes the following, as applicable:
1. System certification to proper authorities. (i.e. Fire marshal, insurance agents)
2. System hydrostatic test equipment.
3. Calibration equipment.
4. Special tools. (i.e. Borescope, turbine tools)
5. Welding certifications.
PMS development will take a considerable amount of time, attention to detail and devotion to
assemble a complete listing of maintenance work packages. All turbine support systems,
balance of plant equipment vendor documentation needs to be reviewed and appropriate work
packages added to the program.
There are various sources listing maintenance checks that require to be performed. They are
as listed:
1. Engine Maintenance/Repair Work Packages

a. LM6000PC GEK 105059
b. LM6000PD GEK 105061
c. LM2500+ Marine GEK 105163
d. LM2500+ SAC GEK 105054
e. LM2500+ DLE GEK 105048
f. LM2500 GEK 97310
2. Vendor Documentation
3. Experience
4. GE LM Series Maintenance Videotapes
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MAINTENANCE AND REPAIR RESPONSIBILITIES

As discussed previously, in order to fulfill maintenance and repair responsibilities along with
administrative and supervisory responsibilities planning must be done ahead of time.
Determine all the work that must be done and prepare a schedule to ensure that it is done. The
schedule must be flexible enough to allow unexpected maintenance and repair work to be
done whenever the need for such work arises.
Review the Maintenance Data System (MDS); it will make your planning and scheduling
considerably easier.
Materials and Repair Parts

The responsibility for maintaining adequate stocks of repair parts and repair materials belongs
at least as much to you as it does to the supply department. The duties of the supply
department are to procure, receive, stow, issue, and account for the support of the plant.
However, the supply department is not the prime user of repair parts and repair materials; the
initiative for maintaining adequate stocks of repair materials, parts, and equipment must come
from the personnel who are going to use such items. Namely the maintenance department
Identification of Repair Parts and Materials

1. Identification of parts and materials is not usually a great problem when you are
dealing with equipment you work on daily; but it may present problems when you are
conducting repair work on equipment not normally tended.
2. The materials and repair parts to be used are specified for many repair jobs but not for
all. Most equipment will have an Illustrated Parts Breakdown
The fact that materials and repair parts are not specified in the instructions accompanying a
job does not mean that you are free to use your own judgment in selecting parts and materials
to accomplish a job. Instead, it usually means that you must know where to look for
information on the type of material or repair parts needed, then locate and requisition them in
order to complete the assigned job.
When you must make the decision yourself, select materials on the basis of the service
conditions they must withstand. Operating pressure and operating temperature are primary
considerations in selecting materials and parts for most equipment repair work.
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There are several sources of information that will be useful to you in identifying the
equipment and/or the repair parts needed. They include:
1. Operation & Maintenance Manual

a. Package O&M
b. Engine GEK Manual
c. Engine Illustrated Parts Breakdown (IPB)
d. Manufacturer’s technical manuals
e. Plans, blueprints, and other drawings.
2. Nameplates on the equipment
3. Vendor Information
a. Web based internet sites
b. Vendor Customer Representatives
4. Gas Turbine Serial Number

a. This will identify what upgrades are installed.
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REFERENCE MATERIAL
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PACKAGE OPERATION
&
MAINTENANCE MANUAL
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Purpose of O&M Manual

This manual set provides operation and maintenance information for the GE Aero Energy
Products gas turbine-generator (GTG) set. The GTG set uses a General Electric (GE) LM
Series turbine engine set to drive an air-cooled, alternating-current (AC) electrical generator.
The set produces 11 kV, 3ø, 50-Hz power and contains the necessary control and auxiliary
systems required for manual or automatic operation.
Scope of Manual
This manual describes the GTG set. The manual supplies functional descriptions of
mechanical and electrical systems. This information, when used with the site-specific
engineering drawings and the vendor-supplied support documentation, will enable a reader to
understand the function, operation, and maintenance of the GTG set. Familiarity with
appropriate illustrations will be helpful in understanding the various systems and equipment.
The operation data sheets, found in the Factory Test Procedure located in the Appendix of
this manual, provide a convenient reference to alarm and shutdown set points. Information
contained in this manual is presented in a logical progression by order of complexity.
Following introductory material, the mechanical and structural aspects of the system are
covered. The mechanical subsystems are then described, followed by a description of the
electronic control system, generator electronic-excitation control, electro-mechanical
monitoring and safety, and power control subsystems.
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TABLE OF CONTENTS
Description Chapter-Section Volume
Title Page Front Matter I
Record of Ownership Front Matter I

Record of Revisions Front Matter
List of Effective Pages Front Matter
Table of Contents Front Matter
Notice of Liability Front Matter
Introduction Front Matter
Warning and Caution Summary Front Matter
Site-specific Warnings and Cautions Front Matter
Product Bulletins Front Matter
Metric and SI Conversions Front Matter
General Information and Operating Instructions 1 I

Introduction and Description of System 1-1
Specifications 1-2
Controls and Indicators 1-3
Operation 1-4
Operating Instructions:
LM6000 Water Wash System (Pump System) 1-5
Maintenance 2 I
General Information 2-1
Servicing 2-2
Troubleshooting 2-3
Engine Alignment, Repairs, and Adjustments 2-4
Parts 3 I
Spare Parts 3-1
Recommended Spare Parts 3-2
Drawings 4 I thru IV
Drawings 4-1
Drawing Lists 4-2
Vendor Publications 5 V thru XVI

Vendor Information 5-1
List of Vendor Publications 5-2
Lubricant Specifications Appendix A I

Fuel-Water Specifications Appendix B I
Abbreviations and Acronyms Appendix C I
Factory Test Procedures Appendix D I
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Manual Arrangement
This manual is divided into nine sections. Each section is specific in its purpose. Each
section is listed and described below. Take time to familiarize yourself with the layout of the
manual before continuing.
Front Matter This section contains information about the owner of the manual,
revision history, a list of effective pages, the general table of
contents, the introduction to the manual, how to use this manual, and
a warnings and cautions summary.
General Information This section is divided into four subsections, providing an

and Operating introduction and a detailed description of each system that
Instructions comprises the gas turbine-generator set, technical specifications for
major components, illustrations and descriptions of the operating
equipment and panel-mounted controls and indicators, and a general
operations summary.
Maintenance This section is divided into four subsections, providing general

information on maintenance; maintenance definitions and concepts;
maintenance schedules; servicing information; troubleshooting of
the prime mover, generator, and ancillary equipment; and repairs
and adjustments to the equipment.
Parts This section contains recommendations on spare parts, lists of

required and recommended spare parts, and points-of-contact to
order or find information on parts for the gas turbine-generator set.
Drawings This section contains a listing of mechanical and electrical drawings

sent with the manual. The list contains the GE Aero Energy
Products engineering document number, the revision level of the
drawing, and the title of the drawing.
Vendor Publications This section contains vendor publications that provide operation,
maintenance, and parts information for the equipment and related
components in the gas turbine-generator set. The publications
include vendor material ranging from catalog data sheets to
complete sets of operation and maintenance manuals and parts
manuals.
Lubricant The appendix contains the lubricant requirements necessary to

Specifications operate and maintain the GTG set.
Fuel – Water This section contains information and specifications of particular

Specifications importance to the operator, such as fuel and water requirements for
the engine.
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Abbreviations and This is a listing of abbreviations and acronyms commonly used in

Acronyms the power-generation field.
Factory Test This section contains the published Factory Test Report as issued by
Procedure GE Aero Energy Products. This report contains an equipment
identification record, general information on the factory operational
load test, test conditions, test instrumentation, data documenting the
safety alarm and shutdown test, and a list of recorded data.
GE AEP F&ID Drawings,

The O&M Volumes contains the drawings required to maintain and troubleshoot the system,
equipment, and related components in the turbine-generator system. Drawings prepared by
equipment manufacturers or vendors are provided in these manuals, and companion GE AEP
drawings may be provided in this chapter.
Drawing Types and Their Uses

Two types of drawings have been identified in the following pages. These drawings,
mechanical and electrical, are the documents that define the configuration of your unit.
Mechanical and electrical drawings provided have been carefully detailed to include all the
engineering and design data required to fully understand and operate your LM Series GTG
set. The mechanical drawings illustrate subsystem flows, both off-skid and on-skid. The
electrical drawings illustrate interconnection of the devices identified on the mechanical
drawings and should be used in conjunction with the mechanical drawings. A letter has
identified the revision level of each drawing produced by GE AEP. This letter will be found
in the title block.
NOTE Questions regarding applicable revision levels should be referred to GE Aero

Energy Products, Jacintoport Engineering, Document Control, or your project
contact.
Mechanical Drawings
The mechanical drawings included in this manual provide engineering-design and device set
point data on the turbine-generator set and its subsystems. Refer to the expanded explanation
of applicable drawing types that follows in this section. General Arrangement drawings, Flow
and Instrument Diagrams, and Instrument Diagrams are defined in the expanded listing that
follows.
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Mechanical Drawing Types

General These drawings provide isometric, plan-and-elevation, and physical configuration data
Arrangement about major pieces of equipment, including skid interconnection-interface information
Drawings and installation and footprint data. Data regarding the actual size and dimensions of
major equipment may be found on these drawings. Related drawings have been
identified on sheet 1 of each General Arrangement drawing.
Flow and These drawings define the flow characteristics, start permissives, and device set point
Instrument and control-logic data. Flow (in gpm or scfm), filtration requirements, pressure-
Diagrams limiting, and shutdown responses are identified on these drawings. Together with the
wiring and system wiring diagrams, these drawings define each system and its related
components. Related drawings have been identified, as they were on the other
drawings, on sheet 1 of each Flow and Instrument Diagram drawing.
Instrument These drawings identify protective devices which have been interlocked to the control
Diagrams system software and which respond to out-of-tolerance conditions by activating alarms
and initiating system wide shutdowns as applicable. Related drawings have been
identified, as they were on the other drawings, on sheet 1 of each Instrument Diagram
drawing.
Electrical Drawings
The electrical drawings included in this manual illustrate device interconnection and control-
loop specifications used in the turbine-generator set and its subsystems. Refer to the
expanded explanation of applicable drawing types that follows in this section. Interconnect
Wiring Diagrams, One- and Three-Line Diagrams, Wiring Diagrams, and System Wiring
Diagrams are defined in the expanded listing that follows.
Electrical Drawing Types

Interconnect These are a series of three drawings (typically the first drawings found in the section
Wiring covering electrical drawings). The first of these drawings provides an overview to the
Diagrams interconnection of major equipment to the main skid and the turbine-control system.
The two remaining drawings provide the detailed information required to interconnect
subsystem devices to the control system and other ancillary items. Related drawings
have been identified, as they were on the other drawings, on sheet 1 of each
Interconnect Wiring Diagram drawing.
One- and These two drawings define the operation of the GTG set as it has been configured for
Three-Line installation at your site. Your one-line drawing establishes the overall configuration of
Diagrams your unit and its interconnection to the utility or plant grid. Your three-line drawing
further defines the interaction of the systems identified on the one-line drawing and
establishes the manner in which devices—meters, switches, lamps, and the control
system— interact and receive and transmit data. Also shown on these drawings are the
system circuit breaker and the current and potential transformers. Related drawings
have been identified, as they were on the other drawings, on sheet 1 of the One- and
Three-Line Diagram drawings.
Wiring These drawings show simplified wiring for terminal block–to–terminal block
Diagrams installation and interconnection of control devices. These are the first level of wiring
diagrams and do not provide point-to-point wiring data. Point-to-point wiring data are
presented on the System Wiring Diagrams. Related drawings have been identified, as
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they were on the other drawings, on sheet 1 of each Wiring Diagram drawing.
System These drawings provide precise, detailed information regarding device interconnection
Wiring to the terminal blocks and, from the terminal blocks, to the control system and the
Diagrams ancillary equipment that assists the control system in maintaining steady-state
operation of the turbine generator. These drawings detail wiring connections by wire
color, termination number, wire number, terminal block number, and associated device
and applicable end termination in the control system. Related drawings have been
identified, as they were on the other drawings, on sheet 1 of each System Wiring
Diagram drawing.
Other Drawing Types
Logic Flow These drawings define the machine logic that controls system devices. Each step in
Diagrams the logic of the specific system (e.g., fire suppression and gas detection or turbine-
control system) is enumerated using standard logic-flow symbology.
Vendor Some vendors of specialized control system and mechanical components have job-
Drawings specific drawings associated with each piece purchased for your unit. Other data from
the applicable vendor may also be found in these sections.
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Mechanical Drawing
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General Arrangement Drawing
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Electrical Drawing
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ENGINE GEK MANUALS
 105059 Engine O&M

 105060 Illustrated Parts Breakdown
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GEK 105059 – ENGINE OPERATION AND MAINTENANCE MANUAL
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ENGINE MAINTENANCE
Engine GEK manuals have a series of work packages that are designed for maintenance,
repair and inspection of the package prime mover. There is no package support included in
this manual.
Chapter 12 of the GEK manual defines the requirements and frequency for performing
preventive maintenance checks, inspections, and servicing. Dry motoring procedures,
generally associated with maintenance, are also provided, as are definitions of terms used to
evaluate equipment condition and damage during inspections.
GEK Levels of Maintenance

Level 1 - Corrective maintenance allows replacement of external parts, adjustments, and other
work (preventive and corrective) up to and including removal and replacement of the
entire engine.
Level 2 - Corrective maintenance permits the replacement of major engine sections (modules)
and the replacement or repair of certain internal parts. Level 2 maintenance is
performed on-site on a non-installed engine or on an installed engine in the
enclosure, as permitted by the enclosure design. Maintenance is performed with the
engine horizontal.
Level 3 - Preservation, Handling, Storage, and Balance of the gas turbine.
Level 4 – Various inspections on the gas turbine
GEK General Checks and Inspections

This section provides general guidelines, conditions, and definitions for conducting engine
checks and inspections. Preventive maintenance and servicing inspections and checks are
performed to reduce unscheduled shutdown time. If the frequency of inspection/service
requires change, coordinate with the packager. Table 12-1 illustrates a sample of checks and
service intervals.
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Preventative Maintenance and Servicing Checks
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Additional Preventative Maintenance and Servicing Checks from Svc Letter 6000-05-03
Sprint nozzle clean, flow and Every 25,000 hours of WP 1916 00
inspection at authorized repair source SPRINT operation
High pressure compressor variable Every 12,500 hours WP 1412 00
compressor vane bushing replacement
Additional Recommended Checks from Service Letter 6000-05-03

Starter carbon seal cleaning Annually WP 2813
D/E Sump drain interface cleaning Annually N/A
(disconnect package drain to clean
engine and package drain as required)
Fuel nozzle (PA or PC). Clean, flow At hot section interval (PA & PC) WP1510,
and inspect at authorized repair source WP1511, WP1512,
WP1513, WP1514
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Level 1 Maintenance Examples

WP 0001 00 Numerical List of Support Equipment, Consumables, and Expendables
WP 1110 00 Axial Inlet Centerbody Assembly Replacement
WP 1111 00 Low Pressure Compressor Inlet Temperature/Pressure (T2/P2) Sensor

Replacement
WP 1112 00 Variable Inlet Guide Vane (VIGV) Actuator Replacement

WP 1112 01 Variable Inlet Guide Vane (VIGV) Actuator Replacement with Fixed Link
WP 3010 00 Gas Turbine in Enclosure Replacement
WP 3011 00 Preservation/Depreservation
WP 3012 00 Gas Turbine Maintenance Dolly Removal and Installation
WP 4010 00 Gas Turbine Inlet Inspection
WP 4011 00 External Engine Cleaning
WP 4012 00 Gas Turbine External Inspection (Visual)
WP 4013 00 Gas Turbine Exhaust System Inspection
WP 4014 00 Gas Turbine Water-Wash
Level 2 Maintenance Examples

WP 2110 00 Variable Inlet Guide Vane (VIGV) Assembly Replacement
SWP 2110 01 Inlet Frame Replacement
WP 2210 00 Low Pressure Compressor (LPC) Module Replacement
WP 2211 00 Low Pressure Compressor (LPC) Stage 0 Rotor Blades Replacement
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TROUBLESHOOTING
Troubleshooting is part of the technician's job. Troubleshooting is fault isolation using logical,
known troubleshooting techniques. The nature of troubleshooting is going to be first locating
the faulty unit and from there, locating the faulty assembly, and the faulty component.
The key to troubleshooting is following a logical sequence making measurements with test
equipment using a vendor technical manual that has known parameters in it and isolating the
fault.
There are numerous technical documentations available to assist with the troubleshooting of
the equipment. The following is examples of troubleshooting documentation for
1. LM Series Engines
2. Generator
3. Support Equipment
Troubleshooting For the LM Series Engines
General troubleshooting procedures for the GTG set are contained in Volume I, Chapter 10 of
the General Electric LM6000 Series On-Site Operation and Maintenance Manual, GEK
105059, located in Chapter 5 of this manual.
This chapter includes two major segments:

1. Troubleshooting Reference Table
2. Troubleshooting Procedures.
Troubleshooting Reference Table

The Troubleshooting Reference Table shows various problem events and system conditions,
alarms, control actions, and the setpoints that trigger these alarms or control actions. These are
grouped by major engine/facility systems. Each event also lists a numbered Troubleshooting
Procedure (TS-) or a SPAM (See Packager’s Appropriate Manual) reference. At the end of
the Troubleshooting Reference Table, items in the Miscellaneous category either (1) do not
trigger an alarm or control action or (2) are a combination of conditions, some of which may
or may not trigger an alarm or control action on their own, that must also be looked at in
combination with others.
Except where otherwise indicated, each event shown in this table is accompanied by an alarm,
regardless of whether it is accompanied by a control action. Limits are shown in the alarm
column for events resulting in an alarm only. Events that have both an alarm and an
accompanying control action will show the limits in the appropriate action column and an X
in the alarm column. In cases where one limit triggers an alarm only and a higher limit
triggers both an alarm and control action, the limits for each will be shown in the appropriate
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columns. In any case that has no particular limits and is simply an either/or condition, the
alarm and/or control action will be indicated by “X” in the appropriate columns.
Numbered Troubleshooting Procedures

The numbered Troubleshooting Procedures (TS-1 through TS-32) are referred to in the
Troubleshooting Reference column of the Troubleshooting Reference Table. These
procedures show symptoms for each engine or facility condition, possible causes for each, the
troubleshooting procedure to isolate the cause of the problem, and the recommended
corrective action. Events or conditions in the Troubleshooting Reference Table that have
only a SPAM reference are not discussed in the numbered troubleshooting procedures.
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Troubleshooting Reference Table
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Troubleshooting Reference Table Notes
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Numbered Troubleshooting Procedures
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Troubleshooting Reference
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Troubleshooting Reference
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GEK 105060 - ILLUSTRATED PARTS BREAKDOWN

Introduction
The Illustrated Parts Breakdown is an illustrated listing of the parts of the LM Series Gas
Turbine Models designed, developed, and manufactured by the GE AeroDerivative Gas
Turbines, Cincinnati, Ohio 45215.
The Illustrated Parts Breakdown is intended to be used for requisitioning, storing, issuing, and
identifying parts.
Major sections, assemblies, subassemblies, and attaching parts are presented in an orderly
sequence to provide both the detailed parts information and relationship of parts to
assemblies. The listing shows Part Numbers, Description, Quantity. Items in the listings are
keyed to those in the illustrations by common Index Numbers. Additional descriptive
identifying data, references to higher and lower assemblies, specialized part and marking
information, references to other publications, and GE Control Drawing Numbers are furnished
within the nomenclature of the specified item.
Explanation of Parts Breakdown

Figure and Index column: This column contains the Figure Number in which the part or
assembly is shown, and the Index Number common to the illustration and to the listing.
The Figure Number is separated from the Index Number by a hyphen. Both Figure Numbers
and Index Numbers are in numerical sequence. When an illustration is changed, additional
indexes are added between existing indexes by adding the preceding Index Number plus a
letter of the alphabet such as –22A, -22B, etc.
Part Numbers Column and Description

The Part Numbers column contains the part number assigned to each part in accordance with
the Contract drawing Specification.
The Part Numbers Column Contains:

1. COM’L ITEMS: Commercial Items use the word COM’L in the Part Numbers
column. Identifying information such as dimensions, size, material type, special
features and commercial catalog numbers is listed in the description column.
2. NO NUMBER: Articles without part numbers are listed as “No Number” parts in the
Part Numbers column. The Model Number (if any) and other descriptive data are
given in the Description.
3. GENERAL ELECTRIC PART NUMBERS: Parts designed by the General Electric

Company. Required explanations related to the General Electric Company parts are
noted in the Description.
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FIG 21
VSV ACTUATOR REPLACEMENT
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NAMEPLATES DATA
Nameplates on equipment supply information regarding the characteristics of the equipment.

Nameplate data seldom, if ever, include the exact materials required for repairs; however, the
information given on the characteristics of the equipment and on pressure and temperature
limitations may provide useful clues for the selection of materials.
Typical Name Data Plate
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PRODUCT BULLETINS
Product Bulletins are issued by GE Energy to inform customers of changes to and

improvements in the gas turbine product. All Product Bulletins issued by GE Energy and
cross-references to Product Bulletins are available from GE Energy. Bulletins will be mailed
to the customer and are also available on the LM6000 Operator and Maintenance Manual
(GEK 105059) CD-Rom.
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Excerpt of Service bulletin
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Interim – Interim Change Notice
Interim Change Notices are changes to the manual that have yet to be incorporated but are
still required actions.
Typical Interim Change Notice
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Letter – GE Letters (Product & Service)
GE issues letters to make their customers aware of certain concerns, product specific or
service specific, experienced by users that may be of interest to other users. Typically
customer issues of minor importance.
Typical Product Letter
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Papers - Position Papers (LM Series, LM6000, IEC NEC TCP 50/60 Hz)
A position paper is an essay that presents an opinion about an issue, typically that of the
author or another specified entity. Position papers are used by GE to make public the official
beliefs and recommendations of the group.
Typical White Paper
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New GEK Web Based Updated System
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VENDOR DOCUMENTATION
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Alternating-Current (Ac) Generator

Troubleshooting procedures for the generator are provided in the operation and maintenance
manual located in the O&M manual.
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Ancillary Equipment
Troubleshooting information for external systems of the GTG set is provided in vendor
literature contained in the O&M manual.
Information for repair for many of the subsystems and components of the GTG set are in the
original equipment manufacturers’ literature located in the O&M. The following adjustments
should be made as needed to maintain equipment in proper working order.
1. Instruments and Indicators—Instruments and indicators may need to be calibrated

more frequently than listed in the maintenance table, Ancillary Equipment Schedule,
in Section 2 of the O&M manual.
2. Transducers and Probes—Positioning and calibration of probes may need to occur

if indications appear to fluctuate or vary from normal. Refer to GE AEP flow and
instrument diagrams and the Factory Test Report for set points of mechanical and
electrical sensing instruments.
3. Pressure and Temperature Controllers—Adjustments may need to be made on pres-

sure and temperature controllers. Refer to GE AEP flow and instrument diagrams
contained in Chapter 4 for set points. Refer to O&M for vendor-supplied details of
the various controllers.
4. Equipment Alignment—Realignment of equipment may need to be performed to

compensate for normal wear. Excessive vibration or noise will generally indicate
when this should take place. Settling of the unit or foundation can adversely affect
machinery alignment. Refer to vendor documentation in Chapter O&M manual for
alignment tolerances of various equipment.
5. Air Filtration System—The air filtration system is designed to operate for extended
periods between maintenance intervals. The system is equipped with a differential
pressure switch that will trip an alarm when the air filtration system restriction
reaches the point that maintenance is required. Maintenance of the air filtration
system shall be carried out in accordance with the instructions provided by the air
filter manufacturer.
6. Control System—The areas in the control system that require regular maintenance to
ensure proper operation are the battery banks, with their attendant battery chargers;
switches; transducers; senders; thermocouples; and other sensing devices that are
employed to monitor the operation of the unit.
7. Battery Banks—The batteries require periodic testing and replenishment of electro-

lytes, and inspection and cleaning of battery terminal connections and battery cases.
The float-and-equalize voltage settings of battery chargers must also be checked and
adjusted. Maintenance procedures and recommendations for direct current power
systems are found in the battery and battery charger instruction manuals provided
with the equipment.
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SECTION 6B
MAINTENANCE CHECKS PERIODICITY
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Maintenance Check Periodicity
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INDEX OF MAINTENANCE CHECKS
Weekly Checks
Monthly Checks
Bimonthly Checks
Quarterly Checks
Semiannual Checks
Annual Checks
As Required Checks
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GEK GENERAL CHECKS AND INSPECTIONS

requires change, coordinate with the packager.
WEEKLY
GAS TURBINE ENGINE
Component Vendor & Maintenance Remarks
Part Number Frequency
GT Assy Inspect external engine

components for security of
installation
SYNTHETIC LUBE OIL

Reservoir Level GEPPLP, Weekly Check oil reservoir level and
724977A check system for leaks
HYDRAULIC START SYSTEM

Hydraulic Start NA Weekly Check oil level and check system
Reservoir for leaks
Hydraulic Start Weekly Inspect system piping, hoses and
System (Recommended) components for leakage and
(During Operation) indication of damage.
GENERATOR LUBE OIL

Jacking Oil Donaldson, Weekly  Inspect differential visual
Discharge Oil HPK0300B0802NX (Recommended) indicator during operation.
Filter (During Operation)  Visually inspect gage pressure
Reservoir Weekly Check oil level and check system
Level for leaks
Lubricating Oil Weekly Sample and visually inspect oil for
(Recommended) water entrainment/emulsification.
AC Lube Oil Weekly Check pump packing for leakage
Pump (Recommended)
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LIQUID FUEL SYSTEM & NOX WATER INJECTION

Low Pressure Kobe/Milwaukee, Weekly ☺Check oil level weekly when unit
Gear Box 0657603 is at rest, and add oil required.
VENTILATION AND COMBUSTION SYSTEM

Filter House Weekly Record the filter resistance.

(Recommended) Check that each filter is straight
and square to its frame.
FIRE PROTECTION SYSTEM

Optical Flame Det-Tronics, Weekly Visually verify proper operation
Detector X9800EQP (Recommended) via LED
(382A4669P0001)
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MONTHLY
SYNTHETIC LUBE OIL
Oil System GEPPLP, Various Monthly or 500 Check oil plumbing line to and on
Plumbing operating hours engine for security, chafing and
leaks. (Applicable sections of
GEK WP4012 00)
Turbine Lube GEPPLP, Monthly Visually inspect fin/fan cooler for
Oil Air/Oil (701209) indication of external fin
Separator blockage. Clean as necessary.
Lubricating NA Monthly or 700 ☺Analyze sample of oil IAW
Oil operating hours GEK WP4016 00.
GENERATOR LUBE OIL SYSTEM

Lubricating Monthly or 700 Sample and conduct lab
Oil operating hours spectroanalysis (In conjunction
(Recommended) with GT lube oil sample)

Filter House Monthly Inspect the filter media for signs
(Recommended) of damage.
Ensure that all conduits runs and
junction boxes are drained of
condensate and corrosion free.

Flexible Hose Kidde, Monthly Check for loose fittings, damaged
251821 threads, rust, dirt, and frayed wire
(377A2245P0002) braid.
(Dry Line) Wilson Fire, Monthly Check for deformation, cracks,
Discharge WFPS/108 dirt, or other damage. Replace
Pressure (382A6241P0001) switch if damaged.
Switch
Electronic Kidde, Monthly Check for physical damage,
Discharge 872450 deterioration, corrosion, and dirt.
Kiddie Heads (377A2233P0001)
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FIRE PROTECTION SYSTEM (Cont)

System Various Monthly Inspect hazard area components

Components
Cylinder Kidde, Monthly Check for leakage and physical
870269 damage.
(377A1188P0002)
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BI-MONTHLY
GENERATOR LUBE OIL

Generator Tuthill, 2 Months or 500 ☺Ensure motor is lubricated. When

Lube Oil AC 5C1G-CC hours lubricants are operated at elevated
Pump temperatures, the lubrication
frequency should be increased.
Over greasing can cause excessive
bearing temperatures, lubricant and
bearing failure.
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QUARTERLY
SYNTHETIC LUBE OIL
Turbine Lube GEPPLP, 3 Months or 2000 Stop the mist eliminator and drain
Oil Air/Oil (701209) Hours any accumulated oil. Replace the
Separator demister elements when a
differential pressure of 1.7 psid is
obtained or every year, whichever
occurs first.
Turbine Lube GEPPLP, 3 Months or 2000 Stop the mist eliminator and drain
Oil Air/Oil (701210) Hours any accumulated oil. Replace the
Pre-Separator demister elements when a
differential pressure of 1.7 psid is
obtained or every year, whichever
occurs first.
Air/Oil American 3 Months or 2000 Inspect heat exchanger for build
Seperator Technology, Hours up of dirt and debris.
Fin/Fan 780-1812
Cooler
Turbine Lube API Basco 3 months Vent coolers to remove air or
Oil Heat (Recommended) vapor accumulated in the system.
Exchanger (As apllicable)

Hydraulic GE Motors, 3 Months or 2000 Monitor oil temperature.
Starter Motor 5KE445SFC121 Hours Relubricate bearing (see placard
(377A1012P0001) with precise instructions at the
pressure-feed lubrication nipples).
Renew grease in the bearings.
Hydraulic Sauer-Sundstrand, 3 Months or 2000 Check hoses for damage or aging.
Pump SOV 90R130KC1NN80L Hours Replace if defective.
Actuated 4F1F03
GBA36421024
(382A9258P0001)
Oil Tank Fill Magnaloy, 3 Months or 2000 Replace or clean filler/ breather
Cap FB-A008X Hours filter routinely.
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Low Pressure Donaldson, 3 Months or 2000 Check visual indicators on both

Return Filter, HMK 25-04 Hours sides of filters. If indicator is
Case Drain activated, replace filter element.
Filters, Replace filter on a regular basis
Charge Pump and replace filter once a year
Filter regardless of visual indicator
indication.
Hydraulic Marvel, 3 Months or 2000 Check and clean when suction
Pump Suction 450M200 Hours PDT alarm activates. Remove and
Strainer clean during the tank and heater
inspection.
Hose GEPLPP, Various 3 Months or 2000 Check hoses for damage or aging.
Assemblies Hours Replace if defective.
GENERATOR LUBE OIL

Generator Vickers, 3 Months or 2000 Check for clogging. Remove access
Reservoir 3E8501-01 Hours cover and clean strainer.
Filler Strainer
Hose GEPPLP, Various 3 Months or 2000 Check hoses for damage or aging.
Generator API Basco 3 months Vent coolers to remove air or vapor
Lube Oil Heat (Recommended) accumulated in the system.
Exchanger (As Applicable)

Fuel Gas Mueller Steam, 3 Months or Remove access cover and clean
Strainer 377A7957P0001 2000 Hours strainer. Replace o-ring if
necessary and re-install strainer and
access cover.
Hose GEPLPP, Various 3 Months or Check hoses for damage or aging.
Assemblies 2000 Hours Replace if defective.
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LIQUID FUEL SYSTEM & NOX WATER INJECTION (CONT)

FCV-2005 Fisher, 3 Months or Verify proper operation. Check
Exhaust FSEZ- 2000 hours valve stem for leakage. If valve
Collector Drain 405/STEM15,FS65 stem is damaged or fails, replace
Flow Control 5-9/*3&8T valve.
Valve (382A6218P0001)
MOT-2186/ GE Motors, 3 Months or ☺Monitor oil temperature.

2194 5KE444SFC121 2000 Hours Relubricate bearing (see placard
Electric Motor (377A1010P0001) with precise instructions at the
- Water Inject pressure-feed lubrication nipples).
Pump Renew grease in the bearings.

Hose GEPPLP, Various 3 Months or Check hoses for damage or aging.
Assemblies 2000 Hours Replace if defective.
Turbine AWV INC., 3 Months or Check for cleanliness and freedom
Enclosure Fire 33389 2000 Hours from foreign matter that would
Protection (382A5531P0001) impede normal movement, and
Damper 50 1/2" seating of blades and seals on a
X 53" scheduled basis.
Turbine Fan: 3 Months or ☺Check for cleanliness and

Enclosure TCF Aerovent, 2000 Hours freedom from foreign matter.
Ventilation Fan C-31403 (66” dia) Verify belt status. Check tightness
- 66" Diameter GE Motor: of all screws and bolts and tighten
Centaxial Fan  Motor Dual Rating if necessary.
 125/104 hp, 60/50 hz,
Assembly and 460/380 vac
Motor  3 Phase, 1780/1475 rpm
 444T Frame, explosion
proof
Generator Fan: 3 Months or ☺Check for cleanliness and

Enclosure TCF Aerovent, 2000 Hours freedom from foreign matter.
Ventilation Fan C-31399-00 Verify belt status. Check tightness
(63 3/4" dia.) GE Motor: of all screws and bolts and tighten
Vaneaxial Fan  Motor Dual Rating if necessary.
 100/83 hp, 60/50 hz,
proof
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VENTILATION AND COMBUSTION SYSTEM (CONT)

Generator AWV INC., 3 Months or Check for cleanliness and freedom
Ventilation 2000 Hours from foreign matter that would
Back Draft impede normal movement, and
Damper seating of blades and seals on a
scheduled basis.
Air Filter - GEPPLP, 3 Months or Check to ensure that the operational

Combustion (Legged Air Filter) 2000 Hours and structural members are
and (733200) maintaining their function. Look at
Ventilation the internal surfaces of the clean air
sections and its ductwork while the
turbine is shutdown and no air
flows through the system. Check
for leakage. Dust streaks indicate a
leak at one of the seams. Locate the
leak and caulk as necessary to
reseal any openings. Check
pneumatic system thoroughly.
Generator AWV, 3 Months or Check for cleanliness and freedom
Exhaust 24475 2000 Hours from foreign matter that would
Damper impede normal movement, and
seating of blades and seals on a
scheduled basis.
VBV Drain GEPPLP, 3 Months or Check and clean when necessary.

Strainer - 40 (J05017) 2000 Hours
Mesh 1"-150#
Flat
Inlet Volute GEPPLP, 3 Months or Check and clean when necessary.
Drain Strainer (J05021) 2000 Hours
- 40 Mesh 1"-
150# Flat
WATER WASH SYSTEM

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SPRINT SYSTEM
Skid Mounted Mueller Steam, 3 Months or 2000 Check for pressure loss across
Y-Strainer - 761-SS(2") Hours strainer. If pressure loss or
2"-150#RF clogging is observed, remove
access cover and clean strainer.
Replace o-ring if necessary and
re-install strainer and access
cover.

Combustible Wilson Fire, 3 months ☺Calibrate sensor and DCU.
Gas Detector WFDCUEX-1
(382A6223P0001)
MEDENSHIA GENERATOR
Shaft Earthing 3 Months or 2000  Check that brush is free in
Brush Hours holder.
 Change when it becomes to
15mm length. Original length
is 30 mm.
Rotor Earth 3 Months or 2000 Refer to vendor documentation
Fault Detector Hours
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SEMI-ANNUAL
GAS TURBINE ASSEMBLY
GT Assy Borescope 6 Months or WP 4015 00

inspection 4000 Hours
GT Assy Variable Stator 6 Months or WP 1411 00
Vane Rig Check 4000 Hours
GT Assy VBV Door Rig 6 Months or WP 1312 00
Check 4000 Hours
GT Assy Vibration 6 Months or WP 4024 00
Monitoring 4000 Hours
System Check
GT Assy T4.8 6 Months or WP 1711 00
Thermocouple 4000 Hours
Inspection
GT Assy P4.8 Inlet probe 6 Months or WP 1712 00
inspection 4000 Hours
Combustion GEPPLP 6 Months or Conduct Inlet Inspection IAW IAD
Air Inlet 4000 Hours Service Letter No. 6000-02-05
Inspection
Borescope GEPPLP 6 Months or Conduct borescope IAW IAD
4000 Hours Service Letter No. 6000-02-05
SYNTHETIC LUBE OIL

Turbine Lube Pall, 6 Months or Schedule replacement of filter element
Oil Filters HZ8640A20KNTW 4000 Hours or every six months or sooner, and have
(Supply and PT-Y302 indication of ample supply of spare elements. If
Scavenge) (J00463) blockage external leakage is noted, replace O-
ring or bonded seal at leak. For bowl
seal leaks, replace O-ring seal. If
leakage persists, check sealing surfaces
for scratches or cracks; replace any
defective parts. Differential pressure
devices actuate when the element needs
changing or because of high fluid
viscosity in “cold start” conditions.
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SYNTHETIC LUBE OIL (Cont)

VGV Pump Aircraft Porous 6 Months or Schedule replacement of filter

Filter Element Media, 4000 Hours or element every six months or
40 Micron AC-B244F- indication of sooner, and have ample supply of
244OY1 blockage spare elements. If external leakage is
noted, replace O-ring or bonded seal
at leak. For bowl seal leaks,
replace O-ring seal. If leakage
persists, check sealing surfaces for
scratches or cracks; replace any
defective parts. Differential pressure
devices actuate when the element
needs changing or because of high
fluid viscosity in “cold start”
conditions. Conduct IAW GEK
WP4021 00.
Lube oil pump GE 6 months or Check engine attached lube oil
inlet screen indication of supply and sacavage pump inlet
inspection blockage screens (finger filter) for particulate
buildup IAW GEK WP4020 00
Magnetic Chip GE 6 months or high Check magnetic chip detector for
Detector alarm activates particulate buildup IAW GEK
WP4017 00
Turbine Lube Chromalox, 6 Months or Check heaters for coatings and
Oil Tank Heater 155-500710-849 4000 Hours corrosion. Clean if necessary. Check
and Thermostat (382A5610P0001) tank for sediment around the heater
and remove as necessary. Check
heater and tank for accumulated
sludge deposits and remove if
necessary. Inspect for loose or
corroded terminal connections/ends
and tighten and clean as necessary. If
corrosion is found, check box gasket
and replace as necessary. Check
conduit layout to correct conditions
that allow corrosion to enter terminal
housing.
Rev 1 Pg 6B-15
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Hydraulic Sauer-Sundstrand, 6 Months or Keep both interior and exterior of the

Starter Motor 5115005 4000 Hours motor free from dirt, water, oil, and
Assembly grease. Motors operating in dirty
places should be periodically
disassembled and thoroughly
cleaned. Check to see that the
bearings are in good condition and
operating properly. Check to see that
there is no mechanical obstruction to
prevent rotation in the motor or in
the driven load. Check to see that the
air gas is uniform. Check to see that
all bolts and nuts are tightened
securely. Check to see that there is a
proper connection to the drive
machine or that the load has been
made.
Reservoir Chromalox, 6 Months or Check for coating and corrosion and
Heater and 156-500541-585 4000 Hours clean if necessary.
Thermostat (382A5596P0001)
Pg 6B-16 Rev 1
06/26/2012
GENERATOR LUBE OIL

Generator Lube Inudfil, 6 Months or 4000 ☺Schedule replacement of filter

Oil Filter IDGL-2-320-2"- Hours element every six months or sooner,
CODE 61-06-V- and have ample supply of spare
CSV elements. Replace any defective
(382A5649P0001) parts. Differential pressure devices
actuate when the element needs
changing or because of high fluid
viscosity in "cold start" conditions.
Generator Chromalox, 6 Months or 4000 ☺Check heaters for coatings and
Lube Oil Tank 155-500710-850 Hours corrosion. Clean if necessary.
Heater - (382A5597P0001) Check tank for sediment around the
Thermostaticall heater and remove as necessary.
y Controlled Check heater and tank for
Heater accumulated sludge deposits and
remove if necessary. Inspect for
loose or corroded terminal
connections/ends and tighten and
clean as necessary. If corrosion is
found, check box gasket and
replace as necessary.
Generator Lube Supplied w/ 6 Months or 4000 A small amount of SHELL
Oil Pump Generator Hours ALVANIA EP grease should be
(Att. Pump) replenished through the oil plug
hole of the coupling case. Over
greasing can cause excessive
bearing failure.
AC Lube Oil 6 Months or 4000  Check Foundation bolts for
Pump and Hours tightness
Motor (Recommended)  Verify pump to motor
alignment
Rev 1 Pg 6B-17
06/26/2012

FCV-2001 Woodward 6 months, or upon Requirement from GEK
Fuel Metering 8915-1029 indication of problems 105059 Preventative Maint.,
Valve (382A5322P0001) Table 12-1
FSV-2004/ Woodward 6 months, or upon Requirement from GEK

2006 8918-082 indication of problems 105059 Preventative Maint.,
Fuel Shutoff (382A5524P0001) Table 12-1
Valve
SOV-2008 CO-AX, 6 months, or upon Requirement from GEK
Fuel Vent VFK502O664TTA indication of problems 105059 Preventative Maint.,
Solonoid Valve 256YVXG1P1A Table 12-1
(382A6357P0001) (24 VDC NO 2" 600#RF)
Ignition GE LM6000 6 months, or upon Requirement from GEK
System Component indication of problems 105059 Preventative Maint.,
Functional Table 12-1
Check
FCV-2019 Woodward, 6 Months or 4320 OP Index Cavitation-resistant
Water Injection 8915-1024 Hours (See vendor sleeve
Flow Control (382A4821P0001) documentation)
Valve
Low Pressure Kobe/Milwaukee, 6 Months or 3000 ☺Change lube oil every 6
Gear Box 0657603 Hours months or 3000 hours
thereafter.
Low Pressure Rotojet, 6 Months or 4000 ☺Change Bearing Oil
Water Injection ROA S-375 Hours, whichever
Pump (J04699) occurs first
Water Injection Falk Coupling, 6 Months Lubriacte Coupling
Drive Coupling G20-1020G (Use of General (Use of general purpose grease)
(Low Pressure) (365TS)(J00417) Purpose Grease)
Pg 6B-18 Rev 1
06/26/2012

Filter House 6 Months Check the clean plenum for
(Recommend degradation and moisture build-up.
ed) Check all joints for evidence of air
or dust leakage.
Turbine AWV INC., 6 months Sleeve bearing, S.S. pins w/ OIB

Enclosure Fire 33389 (Recommende bushings in linkage and kiddie trip
Protection (382A5531P0001) d) pin arm to be coated with “never-
Damper 50 1/2" seez” regular grade lubricant. Cycle
X 53" Damper
Turbine Fan: 6 months or ☺Lubricate fan and motor

Enclosure TCF Aerovent, 4500 Hours assembly
Ventilation Fan C-31403 (66” dia)
- 66" Diameter GE Motor:
Centaxial Fan  Motor Dual Rating
 125/104 hp, 60/50 hz,
proof
Generator Fan: 6 months or ☺Lubricate fan and motor

Enclosure TCF Aerovent, 4500 Hours assembly
Ventilation Fan C-31399-00
(63 3/4" dia.) GE Motor:
Vaneaxial Fan  Motor Dual Rating
 100/83 hp, 60/50 hz,
proof
Generator AWV INC., 6 months Sleeve bearing, S.S. pins w/ OIB

Ventilation (Recommende bushings in linkage to be coated
Back Draft d) with “never-seez” regular grade
Damper lubricant. Cycle damper assy.
Generator AWV, 6 months Sleeve bearing, S.S. pins w/ OIB
Exhaust 24475 (Recommende bushings in linkage and kiddie trip
Damper d) pin arm to be coated with “never-
seez” regular grade lubricant. Cycle
Damper
Rev 1 Pg 6B-19
06/26/2012
VENTILATION AND COMBUSTION SYSTEM (Cont)

Expansion Joint Various 6 Months Visual Inspection
VBV Duct
Expansion Joint Various 6 Months Visual Inspection

Inlet Volute
Combustion Air GEPPLP 6 Months or Conduct Inlet Inspection IAW IAD

Inlet Inspection 4000 Hours Service Letter No. 6000-02-05
WATER WASH SYSEM

Water Wash Chromalox, 6 Months or ☺Check heaters for coatings and
Tank Heater - 156-500509-025 4000 Hours corrosion. Clean if necessary.
2 1/2" NPT (382A5598P0001) Check tank for sediment around the
480V 9KW heater and remove as necessary.
Check heater and tank for
accumulated sludge deposits and
remove if necessary. Inspect for
loose or corroded terminal
connections/ends and tighten and
clean as necessary. If corrosion is
found, check box gasket and
replace as necessary. Check
conduit layout to correct conditions
that allow corrosion to enter
terminal housing.

Electronic Kidde, 6 months Test electronic control heads
Kiddie Heads 872450
Cylinder Kidde, 6 months Check CO2 cylinder weight

870269
(377A1188P0002)
Optical Flame Det-Tronics, 6 Months Calibrate sensor.

Detector X9800EQP
(382A4669P0001)
Pg 6B-20 Rev 1
06/26/2012

Fire/Gas Alarm Wilson Fire, 6 Months Inspect for loose fittings, damaged
Horn and FSASHH24SMRW/ threads, rust, dirt, and frayed wire
Strobe TCWL braid. Check for deformation,
(J00169) cracks, dirt, or other damage.
Replace component if damaged.
MEDENSHIA GENERATOR
Labyrinth 6 Months or Check that no oil leakage exist.
Seal 4000 Hours
Air Inlet Screen 6 Months or Check that screens are free from
4000 Hours obstruction and cleanliness.
Generator Lube Supplied w/ 6 Months or A small amount of SHELL

Oil Pump Generator 4000 Hours ALVANIA EP grease should be
(Att. Pump) replenished through the oil plug
hole of the coupling case. Over
greasing can cause excessive
bearing failure.
MANUAL VALVE PREVENTATIVE MAINTENANCE

Preventative maintenance operations essentially consist of periodic inspections to ensure that
the valve is working correctly.
 The valves must be opened and closed at least once every 6 months and, should such be
required on the basis of the fluid or the application of the valve and its importance,
opening and closing check plans will have to be established for shorter periods.
 The user will be responsible for establishing opening and closing plans that are adequate
for the work conditions and the fluids used!
 WARNING! Never leave the valves open or closed for a long period of time.
 A very high torque increase could be due to the inclusion of foreign bodies in the seats. It
is important not to force the valve! Proceed with an inspection of the seats in order to
avoid damaging the ball.
 We advise replacement of the seals and the seats whenever an in-depth revision of the
installation is made.
Rev 1 Pg 6B-21
06/26/2012
YEARLY
SYNTHETIC LUBE OIL
Lube Oil GEPPLP, Yearly Clean and inspect interior of lube

Reservoir 724977A oil reservoir. (Based on oil
analysis sample IAW GEK
WP4016 00)
Turbine Lube Tedeco, Annually (more Inspect filler cap for missing parts
Oil Tank Fill MF9639LKPSS often if repeated which would prevent cap from
Cap problems occur) sealing and allow water or
contaminates to enter tank.
Replace missing parts as
necessary. Inspect flange seal area
for leakage. If leaking replace O-
ring.
Turbine Lube Tedeco, Annually (more Replace missing parts as
Oil Tank 3E8501-101 often if repeated necessary. Inspect flange seal area
Basket (377A2452P0001) problems occur) for leakage. If leaking replace O-
Strainer ring.
Turbine Lube Protecto Seal, Annually (more Replace component if damaged or
Oil Tank FF6672 often if repeated fails.
Flame problems occur)
Arrestor
Turbine Lube GEPPLP, Annually Replace the demister elements
Oil Air/Oil (701209) when a differential pressure of 1.7
Separator psid is obtained or every year,
whichever occurs first.
Turbine Lube GEPPLP, 3 Months or 2000 Replace the demister elements
Oil Air/Oil (701210) Hours when a differential pressure of 1.7
Pre-Separator psid is obtained or every year,
whichever occurs first.
Turbine Lube API Basco Annually Check internal components for
Oil Heat (Recommended) fouling.
Exchanger
Pg 6B-22 Rev 1
06/26/2012
SYNTHETIC LUBE OIL

Turbine Lube Dollinger Annually Under normal conditions, the

Oil Tank AE-229-110 'Profilter Element requires changeout
Demister 2” every second change of the Final
Stage Elements.
Maintain optimum performance of the
Profilter Element and inspect the
element for dirt build-up. This would
be evidenced by heavy build up of oil,
dirt, etc. on the inlet side of the
element. Also inspect for damage in
the form of holes or tears. Changeout
of the Final Stage Elements is
required
when regularly scheduled system
maintenance is conducted.
The Vent Breather Element should
also be replaced every second change
of the Final Stage Elements.
Lube Oil GE Annually Inspect interior of lube oil reservoir.
Reservoir Clean and replace oil if necessary
(Based on results of spectroanalysis of
lube oil IAW GEK 105059, WP4016
00

Charge Pump Donaldson, Annually (more Replace filter on a regular basis and
Filter Element P16-5332 often if repeated replace filter once a year regardless
problems occur) of visual indicator indication.
Clutch Drain Streamflo Strainers, Annually (more Replace missing parts as necessary.
Return Strainer 377A7898P0001 often if repeated Inspect flange seal area for leakage.
problems occur) If leaking replace O-ring.
Case Drain Donaldson, Annually (more Replace filter on a regular basis and
Return Filter HMK 05-04 often if repeated replace filter once a year regardless
problems occur) of visual indicator indication.
Hydraulic Hayden, Annually (more Check fan blades, check V-bolt
Starter Oil 377A6812P0001 often if repeated drives, lubricate fan motor bearings,
Cooler problems occur) consult troubleshooting guide for
excess vibration or noise, tighten all
bolts and set screws.
Rev 1 Pg 6B-23
06/26/2012
GENERATOR LUBE OIL

Generator Dollinger, Annually (more Replace filter elements

Reservoir AE-129-660 often if repeated
Air/Oil problems occur)
Separator (Recommended)
Jacking Oil Donaldson, Annually (more Replace filter on a regular basis and
Discharge Oil HPK0300B0802NX often if repeated replace filter once a year regardless
Filter problems occur) of visual indicator indication.
Generator Amot, Annually (more Replace thermostatic element and
Lube Oil 2"BCSJ-140-02-D often if repeated seals whenever some variation in
Thermostatic (J00176) problems occur) the controlled temperature is
3-Way Control noticed.
Valve
Generator Voith/Eckerle, Annually (more Protect pump from freezing
Jacking Oil IPV-3/3/3/3- often if repeated temperatures. Ensure motor is
Pump 5/5/3.5/3.5/-102 problems occur) lubricated. When lubricants are
(RCN1970A) operated at elevated temperatures,
the lubrication frequency should be
increased. Over greasing can cause
excessive bearing temperatures,
lubricant and bearing failure.
Generator Tedeco, Annually (more Inspect filler cap for missing parts
Lube Oil Tank MF9639LKPSS often if repeated which would prevent cap from
Fill Cap problems occur) sealing and allow water or
contaminates to enter tank. Replace
missing parts as needed.
Generator Watts, Annually (more Check valve stem for leakage. If
Lube Oil 1/2"-S8000-LL often if repeated valve is damaged or fails, replace
Pressure problems occur) valve.
Sensing Valve
Generator Magnaloy, Annually (more Inspect coupling. If coupling is
Lube Oil 200 often if repeated defective or fails, replace coupling.
Auxiliary problems occur)
Pump
Coupling
Pg 6B-24 Rev 1
06/26/2012

Water Injection Indufil B.V., 12 Months ☺If alarm is activated, replace
Duplex Filter - IDGH-2-320-2" filter element. Replace filter once
CODE 61-25-V-SS a year regardless of visual
(382A5653P0001) indicator indication.
Low Pressure Rotojet, 12 Months ☺Disassemble, clean and inspect
Water Injection ROA S-375 pump. Replace parts as necessary.
Pump (J04699)

Filter House 12 months Prefilters to be replaced.
(Recommended)
WATER WASH SYSEM

Water Wash GEPPLP, Annually (more Open, Inspect and clean reservoir.
Tank 724981A often if repeated Check reservoir for leakage.
problems occur)
Open and inspect in
conjunction with
heater maintenance.
In-Line Filter Parker, Annually (more ☺Replace filter on a regular basis
12A-F16L-50-BN- often if repeated and replace filter once a year.
SS problems occur)
(377A6552P0001)
Pump/Motor Goulds, Annually (more Protect pump from freezing
Assembly - 1SVDK7-GE often if repeated temperatures. Ensure motor is
3600 RPM (382A5578P0001) problems occur) lubricated.
22GPM
Instrument Air Hankison, Annually (more ☺Replace filter on a regular basis
Filter HF9-24-8-G often if repeated and replace filter once a year
problems occur) regardless of visual indicator
indication.. Replace moisture
drain
Rev 1 Pg 6B-25
06/26/2012
WATER WASH SYSTEM (CONT)

Motor GE Motors, Annually ☺Lubricate Motor.
Supplied With (more often if Keep both interior and exterior of
Pump repeated problems the motor free from dirt, water,
occur) oil, and grease. Motors operating
in dirty places should be
periodically disassembled and
thoroughly cleaned. Check to see
that the bearings are in good
condition and operating properly.
Check to see that there is no
mechanical obstruction to prevent
rotation in the motor or in the
driven load. Check to see that all
bolts and nuts are tightened
securely. Check to see that there is
a proper connection to the drive
machine or that the load has been
made.
Pg 6B-26 Rev 1
06/26/2012
SPRINT SYSTEM
Electric Motor GE Motors, Annually ☺Lubricate Motor.
Supplied by Pump (more often if Keep both interior and exterior of
Manufacturer repeated problems the motor free from dirt, water,
occur) oil, and grease. Motors operating
in dirty places should be
periodically disassembled and
thoroughly cleaned. Check to see
that the bearings are in good
condition and operating properly.
Check to see that there is no
mechanical obstruction to
prevent rotation in the motor or
in the driven load. Check to see
that all bolts and nuts are
tightened securely. Check to see
that there is a proper connection
to the drive machine or that the
load has been made.
Pump Goulds, Annually (more Protect pump from freezing
3SVD-10STG-GE often if repeated temperatures. Ensure motor is
(382A5652P0001) problems occur) lubricated.
Filter Indufil, Annually (more Replace filter on a regular basis
TSGH-2-200-1 1/2" often if repeated and replace filter one a year
ANSI-150# problems occur) regardless of visual indicator
(382A1201P0001) indication.
FCV-2104 AWC, Annually (more Check valve stem for leakage. If
Flow Control 1CPT4466TSEA.12 often if repeated valve stem is damaged or fails,
Valve - 1" 5/10DFP17424D/20 problems occur) replace valve.
B754Z24DV53
(382A5526P0001)
Rev 1 Pg 6B-27
06/26/2012
MEDENSHIA GENERATOR
Bearing 12 Months or 8000 Check for shaft voltage or
Insulation Hours resistance.
Insturmentation 12 Months or 8000 Check that the function and
and Protective Hours settings are correct.
Devices
Attached Lube 12 Months or 8000 Change out the bearing
Oil Pump Hours
Bearing
Pg 6B-28 Rev 1
06/26/2012
AS REQUIRED
GT Assy Inlet & coupling As Required WP4010 00

inspection
GT Assy External Engine As Required WP4012 00

Inspection
GT Assy Compressor water As Required WP 4014 00

wash
GT Assy Vibration As Required WP 4020 00

Monitoring System
Check
GT Assy Exhaust coupling As Required WP 4013 00

check
GT Assy Stage 1 HPC blade 16,000 hrs of HP WP 2413 00

replacement SPRINT
operation or
25,000 hrs of
total SPRINT
operation,
whichever comes
first
GT Assy Stage 2,3 and 4 At same time as WP 2413 00

HPC blade cord stage 1 HPC
length check (sys blade
with E-SPRINT) replacement
GT Assy Stage 1 LPC blade Every 25,000 TBD

inspection hours of LP
SPRINT
operation
Note 1: “As required” is defined as anytime maintenance is performed in the area or when the
area is accessible.
Rev 1 Pg 6B-29
06/26/2012
MEDENSHIA GENERATOR
Component Vendor & Maintenanc Remarks
Part Number e Frequency
Painting 5 years or Check that it has no damage

40,000 hours
Labyrinth 5 years or Check the deterioration of pressurized
seals 40,000 hours pipes.
Stator  Remove contaminates by means of
Windings brushes, a vacuum cleaner, waste cloth
Rotor and detergents
Windings  Check the cracks, distortion and
Rotating deterioration of coil surface.
5 years or
Rectifiers,  Check the looseness of wedges, bolts,
40,000 hours
fuses for nuts, balance weights etc.
diodes and  Check the conductivity diodes and
CR absorbers fuses
AC Exciter
PMG
Bearing 5 years or  Check the radial and thrust surfaces.
Metal 40,000 hours  Check the corrosion due to shaft
current.
 Check the top clearance of bearing by
means of lead stripes.
 Check the side clearance of driven end
bearing with thickness gauge.
Air Gap 5 years or Check the air gap for generator, AC exciter,
40,000 hours PMG and rotor earth fault detector
Whole 10 Years or  Withdraw the rotor from the generator
Generator 80000 hours frame and perform cleaning of all
items.
 Remove contaminates by means of
brushes, a vacuum cleaner, waste cloth
and detergents
 Check all items from 5 year periodic
maintenance.
 Check for cracks of retaining rings.
 After reassembly, check the alignment
such as the radial differences and
parallelism of the coupling by means of
dial gauges and thickness gauges.
Pg 6B-30 Rev 1
06/26/2012

Low Pressure Rotojet, As required Replace Seals. Max allowable

Water Injection ROA S-375 leakage is 1 pint/hr
Pump (J04699)
Water Injection Falk Coupling, 3 years Lubricate Coupling.

Drive Coupling G20-1020G (Use of special (Use of Kalk long term grease
(Low Pressure) (365TS)(J00417) grease required) (NLGI #1/2 grade))

Filter House 24 months High efficiency filters to be
(Recommended) replaced. Check all surfaces for
corrosion.
Auxiliary Skid GEPPLP, No Vendor docs

Enclosure (382A7074P0001)
Damper/Motor
/Fan Assembly
Space Heater GEPPLP, No Vendor docs
Generator (FX412480360-5T)
Enclosure
(For
Winterization)
Auxiliary Skid GEPPLP, No Vendor docs
Enclosure (382A7074P0001)
Acoustical
Louver

Distribution Various 2 years Blow out distribution piping
Piping
Combustible Wilson Fire, 2 Years Replace clock batteries.
Gas Detector WFDCUEX-1
(382A6223P0001)
Rev 1 Pg 6B-31
06/26/2012

Cylinder Kidde, 5 Years Inspect and/or hydrostatically test

870269 CO2 cylinders and flexible
(377A1188P0002) discharge and actuation hoses
Optical Flame Det-Tronics, 7 Years Replace Clock Battery
Detector X9800EQP
(382A4669P0001)
WATER WASH SYSTEM

Water Wash NA 2 Years Check for blockage and clean
Nozzles
GENERATOR LUBE OIL

Generator Lube GE Motors, 7.5 HP 4 Years ☺Lubricate Motor
Oil AC Pump 5KS213RSP226
Motor (377A1000P0001)
Jacking Oil GE Motors, 1.5 Years ☺Lubricate Motor
Pump Electric 5KS254RSP221
Motor (377A1001P0001)
Pg 6B-32 Rev 1
06/26/2012
SECTION 6C
EQUIPMENT TESTING
Rev 1 Pg 6C-1
Equipment Testing
06/26/2012
Pg 6C-2 Rev 1
Equipment Testing
06/26/2012
CLEANLINESS
Cleaning
Cleaning as a maintenance man or maintenance manager is one of your most important aids in
the prevention and control of corrosion. To take full advantage of the benefits, an adequate
cleaning program must be in place and adhered too.
The term clean means to do the best job possible using the time, materials, and personnel
available. A daily wipe down of all machinery is better than no cleaning at all.
The importance of frequent cleaning cannot be overemphasized. Any cleaning procedures,

however, should be in the mildest form possible to produce the desired results. For example,
spraying water around multi-pin connectors can cause electrical shorts or grounds, with a
possible loss of control functions or equipment damage.
In general, gas turbine engines and enclosures should be cleaned as often as necessary to keep
surfaces free of salt, dirt, oil, and other corrosive deposits. A thorough inspection and cleaning
of gas turbine intakes and enclosures should always be done in conformance with Planned
Maintenance requirements.
Since gas turbines are more subject to internal corrosion than engines used in other types of
applications, internal cleaning is of particular importance. This is accomplished by means of
water washing. A mixture of cleaning solvent water-wash compound and distilled water is
injected into the engine air inlet while it is being motored and then rinsed with distilled water
in the same manner. It is then operated for about 5 minutes to remove all liquid. For more
detailed information on this procedure, consult the applicable maintenance work package.
Characteristics of Metals
As a member of the maintenance organization, you should have a thorough knowledge of the
characteristics of the various metals used throughout the engineering plant, as well as the
engines themselves.
To some extent, all metals are subject to corrosion. To keep corrosion to a minimum,
corrosion-resistant metals are used to the fullest extent possible consistent with weight,
strength, and cost considerations.
On exposed surfaces, the major preventive for providing relative freedom from corrosion is a
coating of protective surface film. This film can be in the form of electroplate, paint, or
chemical treatment, whichever is most practical.
Most of the metals used in the engineering plants require special preventive measures to guard
against corrosion. In the case of aluminum alloys, the metal is usually anodized or chemically
treated and painted. Steel and other metals such as brass or bronze (with the exception of
stainless steels) use cadmium or zinc plating, protective paint, or both.
Rev 1 Pg 6C-3
Equipment Testing
06/26/2012
In all cases, the protective finish must be maintained to keep active corrosion to an absolute
minimum.
PRESERVATION AND DEPRESERVATION OF GAS TURBINE

ENGINES
The main purpose of engine preservation is to prevent corrosion of the various types of
materials that make up the engine and its accessories. Preservation also ensures against
gumming, sticking, and corrosion of the internal passages.
Engine preservation and depreservation is vital because the corrosion of engine structures can
and does have a great effect on the operational and structural integrity of the unit. Therefore,
it is important that you know about methods of preservation, materials used, and
depreservation procedures.
Preservation for Extended Shutdown or Storage

If you know that an engine is to be secured for an extended period or stored, you must make
plans to preserve it prior to the extended shutdown.
When an LM Series engine is to be layed-up or inoperable for an extended period of time,

precautions must be taken to preserve the gas turbine in order to minimize exposure to
atmospheric corrosion. Details of preservation depend on the duration of non-operation and
whether the gas turbine is being stored in an engine enclosure or in a shipping container. GEK
manual 105059, table 6-1 provides a summary of these details. Refer to WP 3011 00 for
details of precautions and preservation procedures.
Depreservation
An engine that has been in storage (or inoperable) for an extended period of time must be
depreserved before it can be placed in service. Refer to WP 3011 00 for details of precautions
and preservation procedures.
Pg 6C-4 Rev 1
Equipment Testing
06/26/2012
Rev 1 Pg 6C-5
Equipment Testing
06/26/2012
SPECIAL TOOLS
Special tools are required to provide Level I and Level II maintenance activities. These tools
are listed in General Electric LM6000 Series On-Site Operation and Maintenance Manual,
GEK 105059, Volume II (WP 0001 00), and are recommended for customer-performed
maintenance. The basic tooling to remove the turbine from, and install it in, the engine
compartment, and an alignment fixture are provided by GE AEP in the basic scope of supply.
WP 0001 00 has the following information:

1. Table 1 lists recommended mechanics’ hand tools.
2. Table 2 lists special tools for Level I and Level II maintenance and for periodic
inspections/maintenance on support equipment.
3. Table 3 lists consumable materials.
4. Table 4 lists on-site expendables.
Note: Equipment listed in WP 0001 00, Tables 1, 2, 3, and 4 may not be provided in
the basic scope of supply. Some equipment listed is not essential, but is recommended
for ease of service. Additional items may be purchased from GE Aero Energy
Products.
Refer to Test and Calibration Equipment Required for Calibration of the Control System
Sensing Devices, in this section for a list of special tools and equipment required for calibra-
tion of the control system sensing devices.
Pg 6C-6 Rev 1
Equipment Testing
06/26/2012
Test and Calibration Equipment Required for Calibration of the Control System
Sensing Devices
Source/
Nomenclature Model/Part No. Manufacturer
Deadweight Tester 23-1, or equivalent Chandler, or equivalent

(for testing pressure switches)
Hot Oil Bath, electrically heated with Various Various

adjustable thermostatic temperature
control, oil agitator, and calibrated
thermometer (for testing temperature
switches)
Digital Multimeter (Qty 2) 8021B Fluke

177 Keithley
AC/DC Power Supply (Qty 2) 6234A Hewlett-Packard
Volt-Ohmmeter, 20 kOhm per volt 260 Simpson
Oscilloscope, Dual-Channel, 15 MHz 1222A Hewlett-Packard

2213A/2215A Tektronix
Jumpers, with Insulated Alligator Clips Various Various
Discriminating Optical Flame Detector 7100 Systron Donner

Field Test Unit (steam-injected units)
Ionization Detector Sensitivity Checker SCU-9 Pyrotronics Pyr-A-

Larm
Adapter Kit SAU-2 Pyrotronics Pyr-A-

Larm
Gas Detector Remote Calibration Meter 361-155 Delphian
Gas Detector Calibration Kit 360-642 Delphian
Gas Detector Calibration Adapter Fitting 360-643 Delphian
Megohm Meter, 500 V–5 kV 21-158 Biddle, or equivalent
Rev 1 Pg 6C-7
Equipment Testing
06/26/2012
WP 0001 00 Cover Page
Pg 6C-8 Rev 1
Equipment Testing
06/26/2012
WP 0001 00 Special Tools
Rev 1 Pg 6C-9
Equipment Testing
06/26/2012
WP 0001 00 Consumable Material
Pg 6C-10 Rev 1
Equipment Testing
06/26/2012
WP 0001-00 Consumable Material
Rev 1 Pg 6C-11
Equipment Testing
06/26/2012
EQUIPMENT TESTS
Maintenance departments have the responsibility for scheduling and performing various tests
on your equipment. The purpose of those tests is to determine how your equipment is
performing and if there are any equipment malfunctions. These tests are performed at various
times, such as
1. Before extended maintenance periods
2. Prior to seasonal shutdowns
3. Loss of efficiency
4. Required by Planned Maintenance (PM)
The equipment tests may be performed by plant personnel, outside repair agents, or by
inspection teams (such as insurance and fire certifications).
Pg 6C-12 Rev 1
Equipment Testing
06/26/2012
ENGINE TREND ANALYSIS

Preventive maintenance receives a great deal of attention from everyone in the field of turbine
engine operation, since letting an engine run as long as it will run and fixing it only after a
breakdown occurs is not only unwise, but extremely costly. On the other hand, it would be
just as unwise to constantly tear down an engine just to inspect it. You should know that vital
parts of an engine last longer and operate better if they are not tampered with unnecessarily.
Therefore, an attempt must be made to find a happy medium between these two forms of
maintenance.
One way to determine the condition of an engine is by monitoring its operation. This is done
by regularly obtaining certain engine operating data and by studying, analyzing, and
comparing it with previous data. The results of this information can be utilized by plant
personnel for interpretation of engine performance, and decide whether the engine needs to be
shut down for maintenance.
Trends analysis may be performed from the Turbine Control Panel HMI. The trend screen
allows for trending of separate values each. When setting up the trend screen, both live and
historical data can be trended on the HMI. The screen may be printed if a printer is available.
Turbine Trending Screen
Rev 1 Pg 6C-13
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Fuel Trending Screen
Lube Oil Trending Screen
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PERFORMANCE DATA RECORDING

For a more in-depth trending a Performance Data Recording should be conducted.
For diagnosing performance or emissions issues, best results are obtained when all the
parameters in the Performance Data Sheet are recorded and the data is recorded to the indicated
level of precision. Also for best accuracy in the analysis, the engine should be stabilized for at
least 5 minutes prior to data recording and several (3-5) readings should be taken at a given
power level.
The Performance Data Sheet shows typical parameters and precision levels which would
normally be required for a performance evaluation by GE.
Other considerations for best accuracy:
 Instrumentation should be recently calibrated
 VG systems should be rig checked and calibrated

 Crank soak washing should be performed prior to test
 Fuel sample should be collected and analyzed for lower heating value (LHV) and
specific gravity (SG) to assist in expedited analysis of performance data. Liquid fuel is
to be analyzed for contaminants and compliance with fuel specification
 High power data readings should be taken with VBV closed
 The same data should be used for periodic trending of engine performance.
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LM6000 GAS TURBINE PERFORMANCE DATA SHEET
ENGINE SERIAL N0. SITE
OTHER INFORMATION ABOUT SITE AND REASON FOR DATA

READING
REASON FOR CURRENT DATA READING [ ] ROUTINE [ ] OTHER

[ ] DIAGNOSTIC
SIMPLE OR COMBINED CYCLE [ ] SIMPLE CYCLE

[ ] COMBINED CYCLE (i.e. has boiler)
[ ] SIMPLE/COMBINED (has boiler and bypass capability)
DOES INLET SYSTEM HAVE A CHILLER? [ ] EVAPORATOR COOLER EVAPORATOR COOLER?

[ ] CHILLER
INLET LOSS (INCHES WATER), IF KNOWN ______________________________

EXIT LOSS (INCHES WATER), IF KNOWN ______________________________
INLET FILTER PRESSURE DROP, IF AVAILABLE ______________________________
LAST CRANK SOAK DATE ______________________________
HOW OFTEN DOES CUSTOMER CRANK [ ] MORE THAN ONCE A MONTH

SOAK ENGINE? [ ] ABOUT ONCE PER MONTH
[ ] ONCE EVERY FEW MONTHS
[ ] NEVER
DRIVEN EQUIPMENT AND MANUFACTURER [ ] GENERATOR 50

Hz (i.e. GENERATOR, GE) [ ] GENERATOR 60
Hz
[ ] COMPRESSOR
HOW IS ENGINE DISPATCHED? [ ] FULL POWER ALL THE TIME

[ ] FULL POWER DURING DAILY PEAK ONLY
[ ] MW AS REQUIRED
[ ] OTHER
LM6000 Performance Data Sheet (Sheet 1 of 4)
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ENGINE SERIAL N0. ______________ SITE ______
UNIT PRECISION RDG NO RDG NO RDG NO

TIME
DATE
COUNTERS
TOTAL HRS
T3 BASE HRS
T48/T3 BASE HRS
FIRED STARTS COUNTS
GENERAL
OUTPUT MW XX.XX
REGULATOR T3, T48, SPEED?
Ib/hr OR XXXXX. OR
FUEL FLOW (FOR GT)
GPM xx.x
SPRINT WATER GPM XX.X
Ib/hr OR XXXXX. OR
NOx WATER (FOR GT)
GPM XX.X
NOx STEAM (FOR GT) Ib/hr XXXXX
WATER:FUEL RATIO N/D X.XX
XN25 RPM XXXXX.
XN2 RPM XXXX.
BTU/LB OR XXXXX. OR
LHV
BTU/SCF XXX.X
SPECIFIC GRAVITY N/D .XXX
CYCLE TEMPERATURES
TO - DRY BULB °F XXX.X
TO - WET BULB °F XXX.X
T2SEL °F XXX.X
T25SEL °F XXX.X
T3A ºF XXXX.
T313 ºF XXXX.
T3SEL ºF XXXX.
T48SEL ºF XXXX.
T8 ºF XXX.
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TIME
DATE
CYCLE PRESSURES
PO PSIA XX.XX
P25SEL PSIA XX.X
PS3SEL PSIA XXX.
P48SEL PSIA XXX.X
PTB PSIA XXX.
PS3A PSIA XXX.
PS3B PSIA XXX.
VG SYSTEMS
VSVSEL % XX.
VBVSEL % XX.
VIGVSEL % XX.X
EMISSIONS
NOx PPM XX.X
NOx (15% 02) PPM XX.X
02 % XX.X
CO PPM XX
T48 INDIVIDUALS
T48A °F XXXX.
T48B °F XXXX.
T48C °F XXXX.
T48D °F XXXX.
T48E °F XXXX.
T48F °F XXXX.
T48G °F XXXX.
T48H °F XXXX.
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TIME
DATE
LUBE SYSTEM
GT LUBE SUPPLY
psia XXX.
PRESS
LUBE SCAV PRESS psia XXX.
LUBE FILTER dP psi XX.
HYDRAULIC FILTER dP psi XX.
LUBE SUPPLY
°F XXX.
TEMP
AGB SCAV TEMP °F XXX.
TGB/A SCAV °F XXX.
B SCAV TEMP °F XXX.
C SCAV TEMP °F XXX.
D SCAV TEMP °F XXX.
E SCAV TEMP °F XXX.
A/TGB CHIP DET Ω XXX.
B-SUMP CHIP DET Ω XXX.
C-SUMP CHIP DET Ω XXX.
GT VIBES
LP-CRF ips/mils X.X
HP-CRF ips/mils X.X
LP-TRF ips/mils X.X
HP-TRF ips/mils X.X
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VIBRATION ANALYSIS
The Most Basic Form of Vibration Analysis

The most basic form of vibration analysis is called an overall vibration measurement. This
reading provides a single number that describes the total amount of vibration energy being
emitted by a machine. The idea is that more vibration indicates a problem. A number of tables
and guides have been developed to explain what levels are acceptable for various machine
types. This technology is inexpensive but it can also be inaccurate and inconclusive. As an
example, a pump experiencing turbulence or flow noise will have a very high overall level,
although there are no mechanical faults. On the other side of the coin, the pump may have a
bearing problem that is serious but emits little vibration energy in comparison to the energy
emitted by the shaft and the flow noise. Thus the bearing problem may not be evident in the
overall reading. Finally, because the overall level provides only one number, it cannot
differentiate between faults. In other words, one will not know if there is imbalance,
misalignment, a bearing problem, a foundation problem etc. Overall readings were and are
used today simply because the devices needed to collect this information are inexpensive and
once were the only thing available. Unfortunately, many people today have incorrect concepts
of what vibration analysis is and how it works because this simplistic approach is the only
experience they have had with the technology.
Narrow Band Vibration Analysis

When computers became widely available, so did the capacity to collect narrow band
vibration data, or vibration spectra. A vibration spectrum separates measured vibration into
small frequency bands. Different machine components and different faults will produce
vibration and vibration patterns at specific frequencies. Thus, using a vibration spectrum, one
can relate individual peaks and patterns in the spectrum to individual machine components
and specific machine faults. In order to do this, one must have some information about the
machine, such as the number of fan blades, impeller vanes and gear teeth, as well as shaft
speeds and type of bearings (rolling contact or sleeve). Vibration data is most useful when
taken in all three axes (axial, vertical and horizontal) as different faults may appear in
different axis. This is the most common type of vibration measured today. Refer to the figure
below for a comparison between an overall vibration measurement discussed in the previous
section and narrow band vibration analysis.
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Predictive Maintenance Vs. Trouble Shooting

In short, using vibration analysis in the context of Predictive Maintenance is easy, accurate,
efficient and inexpensive. Using vibration analysis for troubleshooting is more difficult, often
less accurate depending on the consultant, and more expensive. Here is the difference: In
predictive maintenance, one routinely monitors the machine under repeatable test conditions
and looks for changes. If the machine is not failing, the vibration patterns won’t change. If it
is failing, the patterns will change, and it will be easy to determine what has changed and
what fault the machine has. How much and how quickly the pattern is changing tells one how
severe the problem is and indicates when action should be taken. Vibration analysis is
sensitive enough to find some faults a year or more before they progress enough to require
attention. It will take an experienced analyst no more than 5 to 10 minutes to compare a new
set of data to an older or reference set of data and point out what has changed and what the
problem is. Refer to Figure below for a trend plot that shows the change in machine condition
and specific faults over a 1-1/2 year period; this type of trend is the basis of predictive
maintenance.
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Troubleshooting is the process of taking measurements on a machine 1 time and trying to

determine if it has a fault or not. In order to troubleshoot a machine correctly, one must take
quite a lot of data including phase measurements and possibly structural measurements in
addition to spectral data. These can be quite time consuming and expensive. The results a
consultant provides will depend a lot on their experience and the types of tests they take. It
can take a whole day or more to accurately troubleshoot a machine. Additionally, even though
one may find some faults in a machine, without knowing the machine’s history it can be quite
difficult to decide what to do with the information. If you knew the machine has had the same
problem it has now for the past five years and has continued to operate fine, would you spend
money to fix it now?
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ULTRASOUND AND INFRARED THERMAL IMAGING
Thermal Imaging
The theory of thermal imaging is simple. All objects above absolute zero (0 Kelvin) emit
infrared radiation. While infrared energy is invisible to the human eye, infrared imagers
detect and convert these invisible wavelengths into visible light images that are displayed on
a screen. Images can be either monochrome or multicolored where the shades of gray or
color represent temperature patterns across the surface of the object. These thermal images
can be viewed in real time or stored on videotape, computer disk, or PC card. Thermal
images then can be recorded onto photographic film or paper; the images are called
thermographs or thermograms.
Thermal imaging is both non-contact and nondestructive. Since it is non-contact, it is useful

for inspecting energized electrical systems as well as mechanical systems and rotating
equipment. Since the infrared energy emitted from a surface is proportional to its
temperature, imaging radiometers are capable of providing surface temperatures as well as
images.
Ultrasonic Detector
An ultrasonic detector senses subtle changes in the ultrasonic signature of a component and
pinpoints potential sources of failure before they can cause damage. Longer wavelengths of
lower-pitched sounds are gross waves that can be difficult to locate. But higher frequency
sounds are short wave signals localized to the source of emission. For this reason, it is
possible to use ultrasonic sensors in relatively noisy environments.
Ultrasound and Infrared Working Together
Why do infrared and ultrasound work so well together? One answer is to look at our own
senses. The more senses we use, the better we are able to navigate through our world.
To expand on this concept, infrared inspection and ultrasonic inspection are expansions of
the senses of sight and hearing. Infrared "sees" what we cannot see; ultrasound "hears" what
we cannot hear.
By combining them we advance our ability to detect problems. In essence, infrared will
detect changes in emissions related to heat characteristics of equipment it "looks" at, while
ultrasound senses changes in sound patterns. Without getting into the basics of each
technology, let's examine some of the common areas of application for these two inspection
methods.
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Steam Systems
There are many opportunities to use both ultrasound and infrared in steam system
inspections. A simple way to determine when to use a specific instrument is to look at the
system from an objective perspective. Which components have more of a tendency to
produce a change that is heat related and which are more sound related?
As an example, the loss of or weakening of insulation is measured best by determining heat-

related changes. Pressure is calculated by checking temperature changes upstream and
downstream of a valve or steam trap. Sound-related processes are best tested by using
ultrasound. Valve leakage, steam trap inspection, and conditions such as cavitation in pumps
are examples of sound-related inspection.
Heat or infrared alone cannot be used to validate steam trap operation. There are many
subtle and not-so-subtle pressure changes that occur in and around the steam trap that can
effect changes in temperature which can in turn lead to a false diagnosis.
Since a trap produces a distinct sonic signature, listening to the sound of the trap as it cycles
can accurately determine the trap condition. Many steam trap manufacturers refer to this as a
"positive" test. Infrared is useful in determining blockage conditions and whether a trap is
on-line because the former will indicate a lower temperature than a working trap in the same
area and the latter will be observed as producing heat. Using both infrared and ultrasound
together will help make certain that the most common conditions of trap operations can be
thoroughly inspected.
Using the two technologies in valve condition inspection also can provide useful
information. In some cases, heat can be used to determine valve condition, while in other
situations, the fact that a valve leak can be isolated and heard will help improve the accuracy
of the diagnosis. By using an ultrasonic sensor's contact probe to touch a valve upstream and
downstream, valve leakage or valve blockage can be identified. A leaking valve will be
heard through the headphones as a gurgling or rushing sound while blockage will produce
no sound. Valve blow-by in steam systems will produce a higher temperature reading
downstream. Ultrasound will tend to find smaller leaks, especially when the fluid does not
have a higher temperature.
Pg 6C-24 Rev 1
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Loose connections
and damaged
conductors, electrical
problems that produce
increased resistance
resulting in higher
temperature of
affected elements, are
easily detected by
inspection with
infrared hermography.
(Photo courtesy FLIR
Systems, Inc.)
Heat Exchangers
The two technologies can be utilized quite effectively in the inspection of heat exchangers.
An infrared scan of a heat exchanger can indicate heat-related changes that can be diagnosed
as anything from flow blockage of the cooling element to tube leakage. Once the condition
is spotted with the scan, an ultrasonic detector can be incorporated to confirm a diagnosis
and, in some instances, locate a leaking tube.
The ultrasonic inspection is performed while the exchanger is either on partial load or off
line. By pressurizing, or by keeping a vacuum on the shell side, the headers of the exchanger
can be removed and the tube sheet scanned to identify the leaking tube. A leaking tube
produces a turbulent, rushing sound as air flows from the high-pressure to the low-pressure
side of the tube leak.
The sound will be isolated to the leaking tube and will be heard as the scanning module
passes over it. Combining infrared and ultrasound provides a fast, accurate way to keep on
top of heat exchanger problems.
Underground Leaks
Underground water leaks of any type are a very difficult proposition. Unless the leak is so
gross as to produce an obvious wet pool or bubbling around the site, many days can be spent
trying to locate the source. There are often situations in which inspectors have been called to
locate a leak after most other methods have failed. This experience indicates that not one
method works all the time. However, utilizing ultrasound and infrared together can produce
effective results.
In an actual event, a condensate return line in a major airport was reported to be leaking. The
area of investigation covered about 3 miles of piping located approximately 6 ft below the
asphalt surface. Standard methods using listening devices that detected only the audible
range were not successful. To find the leak quickly, a method incorporating ultrasound and
infrared was devised.
Rev 1 Pg 6C-25
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Recognizing that condensate was heated water, it was determined that a late-night scan
would be effective because the heated water would be easier to locate with the cooler ground
around it. A scan of the piping system as determined by piping diagrams was performed.
Every hot spot that could be suspected as a leak site was marked.
Metal wave-guides were then positioned in the ground over the marked hot spots. A contact
probe from the ultrasonic detector was placed directly on the wave-guide and an operator
listened for a flow. The IR/UL inspection began shortly after midnight and continued until 4
a.m. Identified leaks were repaired before the end of that same day.
Motors and Pumps

Here we have a combination of electrical, mechanical, and fluid flows that produce heat and
sound. While the condition of most bearings can be diagnosed through changes in sound as
determined by ultrasound, as well as by vibration analysis, there are also IR scans that detect
heat-related problems.
According to NASA research, the earliest indicator of incipient bearing failure is a change in
the amplitude of a monitored ultrasonic frequency. Ultrasonic inspection also can reveal lack
of lubrication and prevent over-lubrication.
Bad motor coils, windings, stators, or rotors can cause an increase in resistance and will
produce heat that is readily detected with an infrared scan. In addition, over-lubrication,
misaligned belts, and bearings in advanced failure states can be quickly spotted due to the
heat generated by friction and metal fatigue.
Pumps running dry, plugged feeds, and distorted vanes are all candidates for infrared
detection. Cavitation, which is caused by air bubbles being trapped in fluid and then bursting
under pressure, can destroy a pump or valve over time. Because these bursting bubbles
produce a distinct sound, ultrasound inspection can trend the cavitation from onset. As it
continues toward destructive levels, there is a combination of sound and heat.
Hydraulic Valves and Actuators

Heat is a good indicator of a leaking hydraulic valve. The forces of fluid moving through a
leak can produce heat as a by-product. This has been a useful effect in aircraft inspection.
However, not every leaking hydraulic valve will produce heat, and the proximity of valves
in certain configurations can lead to a potentially inaccurate diagnosis due to heat (and in
some instances sound) transference. This inspection process can be aided by incorporating
ultrasound with infrared. A valve, when leaking, will produce a louder sound downstream.
By comparing infrared results and ultrasonic readings taken upstream with those from
downstream, an operator can quickly make a positive diagnosis.
Electrical Equipment
This is the most common area of application. While infrared detects problems related to
resistance and heat, the ultrasound detector can be used to locate sonic-related problems.
Pg 6C-26 Rev 1
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Corona and tracking in its early stages do not produce readably detectable infrared emissions
but they do produce ultrasound.
In addition, with enclosed switchgear and transformers where surface heat cannot be relied
upon for diagnosis, scans can be aided by using ultrasound to listen. This can be
accomplished by scanning switchgear door seals and air vents while listening to the sonic
pattern. Corona produces a steady buzzing sound while tracking has a gradual build-up
followed by a sudden drop off of signal. Arcing is heard as sudden starts and stops.
Inspection time can be greatly sped up by utilizing IR and UL scanning. Since switchgear
can be inspected by scanning doors and air vents, there is no need to open each
compartment.
In all types of mechanical function, changes in heat and sound are the most reliable
indicators of potential problems. Fluid flow patterns, line blockage, and leaking valves and
steam traps are best-diagnosed through IR/UL inspection. Hydraulic systems produce sound
and heat that can be observed through an integrated approach, as does high voltage
equipment.
Using IR/UL inspection will allow users to accurately determine the condition of operating
equipment as well as identify the location of problems. These two technologies complement
each other and advance the goals of condition monitoring programs.
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SPECTROGRAPHIC ANALYSIS
Using Oil Analysis for Machine Condition Monitoring

Oil analysis can go far beyond simply revealing the condition of the lubricant. Advanced oil
analysis techniques are being used to monitor equipment condition. Through the use of these
advanced techniques, equipment reliability increases and unexpected failures and down time
can be minimized.
Many types of abnormal wear can exist inside a piece of machinery. However, there are only
a few primary sources of the wear. Problems related to the oil itself may contribute to wear
when the lubricant has degraded or become contaminated. Machine condition also can
contribute to the generation of wear if a component is misaligned or improperly balanced.
Improper use of the equipment, such as overload or accelerated heating conditions, also can
generate wear. Here are some examples of types of wear.
• Abrasive wear is the result of hard particles coming in contact with internal components.
Such particles include dirt and a variety of wear metals. Using a filtration process can reduce
abrasive wear that will, in turn, ensure that vents, breathers, and seals are working properly.
• Adhesive wear occurs when two metal surfaces come in contact, allowing particles to
break away from the components. Insufficient lubrication or lubricant contamination
normally causes this condition. Ensuring that the proper viscosity-grade lubricant is used can
reduce adhesive wear. Reducing contamination in the oil also helps eliminate adhesive wear.
• Cavitation occurs when entrained air or gas bubbles collapse. When the collapse occurs
against the surface of internal components, cracks and pits can be formed. Controlling
foaming characteristics of oil with an antifoam additive can help reduce cavitation.
• Corrosive wear is caused by a chemical reaction that actually removes material from a
component surface. Corrosion can be a direct result of acidic oxidation. A random electrical
current also can cause corrosion. Electrical current corrosion results in welding and pitting
of the wear surface. The presence of water or combustion products can promote corrosive
wear.
• Cutting wear can be caused when an abrasive particle has embedded itself in a soft surface.
Equipment imbalance or misalignment can contribute to cutting wear. Proper filtration and
equipment maintenance are imperative to reducing cutting wear.
•Fatigue wear results when cracks develop in the component surface, allowing the
generation and removal of particles. Leading causes of fatigue wear include insufficient
lubrication, lubricant contamination, and component fatigue.
• Sliding wear is caused by equipment stress. Subjecting equipment to excessive speeds or

loads can result in sliding wear. The excess heat in an overload situation weakens the
lubricant and can result in metal-to-metal contact. When a moving part comes in contact
Pg 6C-28 Rev 1
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with a stationary part, sliding wear becomes an issue. Providing proper lubrication, filtration,
and equipment maintenance can reduce much of the wear that occurs inside of equipment.
Potential problems can be identified with predictive maintenance techniques such as
vibration, infrared thermography, and oil analysis. By monitoring the equipment's condition
with oil analysis, a plant can identify various types of wear and take corrective action before
failure occurs. In many cases, oil analysis can identify problems with rotating equipment
even before vibration analysis detects it.
When an oil analysis condition monitoring program is implemented, it is important to select
tests that will identify abnormal wear particles in the oil. When components inside the
equipment wear, debris is generated. Identifying the wear debris can establish the source of
the problem. Here are some examples of laboratory tests that can help identify wear.
• Spectrometric analysis is the most commonly used technology for trending concentrations
of wear metals. The main focus of this technology is to trend the accumulation of small wear
metals and elemental constituents of additives, and identify possible contaminants. The
results are typically reported in parts per million. This technology monitors only the smaller
particles present in the oil. Any large wear-metal particles will not be detected or reported.
• Particle counting tracks all ranges of particles found in the sample. However, particle
counting does not differentiate the composition of materials present. Its main focus is to
identify the number of particles in the sample. The results are typically reported in certain
size ranges per milliliter or per 100 milliliters of sample.
•Direct-reading ferrography monitors and trends the relative concentration of ferrous wear
particles and determines a ratio of large to small ferrous particles to provide insight into the
wear rate of the lubricated component. This method can be used as a tracking and trending
tool, especially in systems that generate a high rate of particles.
•Analytical ferrography uses microscopic analysis to identify the composition of the material
present. This technology differentiates the type of material contained within the sample and
determines the wearing component from which it was generated. It is used to determine
characteristics of a machine by evaluating particle type, size, concentration, distribution, and
morphology. This information assists in determining the source and resolution of the
problem.
Each laboratory test has limitations. A well-balanced test package will correctly identify
potential problems in equipment. Many of the laboratory tests actually complement each
other.
The purpose of an oil analysis program should not be to merely check the lubricant's
condition. The real maintenance savings from utilizing oil analysis occur when equipment
problems are detected. Break-in wear, normal wear, and abnormal wear are the three phases
of wear that exist in equipment. Break-in wear occurs during the startup of a new
component. It typically generates significant wear-metal debris that will be removed during
the first couple of oil changes. Normal wear occurs after the break-in stage. During this stage
the component becomes more stabilized. The proportion of wear metals increases with
Rev 1 Pg 6C-29
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equipment usage and decreases when makeup oil is added or oil is changed. Abnormal wear
occurs as a result of some form of lubricant, machinery, or maintenance problem. During
this stage the wear metals increase significantly.
When oil analysis is used routinely, a baseline for each piece of equipment can be
established. As the oil analysis data deviate from the established baseline, abnormal wear
modes can be identified. Once abnormal wear modes have been identified, corrective action
can be planned.
Implementation of an oil analysis program with analyses consistent with the goals of the
program significantly reduces maintenance costs and improves plant reliability and safety.
Lubricant analysis for the purpose of machinery conditioning monitoring is at its best with a
significant amount of historical data. It is important to establish a baseline for each piece of
equipment. Certain analytical results may change with lubricant oxidation and degradation
from normal use; the major changes occur because of contamination from environmental
factors and machinery wear debris. The analytical costs of a properly implemented program
should be covered by the extension of the lubricant change interval. Increased reliability and
availability, and the prevention of unanticipated failures and downtime are added benefits.
Oil Analysis in Machine Condition Monitoring

The role of oil analysis has a varied and inconsistent history. In the petrochemical and power
generation industries, oil analysis has been conducted primarily to determine when and/or if
an oil change is required. In hydraulic applications, it has been used to control the
contamination that jams servo-valves and abrades components, leading to premature
component failure. In fleet applications, oil analysis has been applied to determine when
additives have depleted, soot is building up in the oil, fuel and/or coolant is contaminating
the oil, or abnormal component wear is occurring. Each application is valid and each
application provides information to support important, but varied, decisions. In sum, there
are three distinct categories, or dimensions, of oil analysis:
1. Fluid health analysis—Oil analysis reveals the general health of oil. The oil’s
physical, chemical, and additive properties can be measured and trended to guide
decisions about if and when an oil should be changed or regenerated with an additive
package. Oil analysis also identifies when the incorrect oil has been added to a system.
When oil is degrading abnormally, oil analysis often can determine if the degradation
is oxidative, hydrolytic, or from another root cause. In addition to simple oil change
decisions, oil analysis supports decisions to change oil base-stock or additive
formulation or control the environment in which the oil operates. Machines cannot run
healthfully without healthy lubrication, making these decisions imperative to the
reliability effort.
2. Contamination monitoring—Contamination is a leading cause of machine

degradation and failure. Abrasive particles and moisture combined lead to the
generation of the majority of wear in various industrial applications. Also, particles
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and moisture contamination strip the oil of its additives and exacerbate lubricant
degradation. Contamination monitoring enables the reliability organization to make
effective decisions to control this important cause of machine failure.
3. Wear debris detection and analysis—When a machine is ailing, it generates

particles. The detection and analysis of wear debris assists in scheduling maintenance
actions and in determining the root cause of a problem. An effective program of oil
analysis should include a focus on each of the three distinct dimensions of oil analysis.
Relying upon oil analysis information simply to guide oil change decisions leaves a
tremendous amount of information value on the table about the machine’s health and
the interface between the machine and its environment.
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Typical Oil Analysis Report
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PARTICLE ANALYSIS
Particle analysis is the second phase of oil analysis. This test evaluates the particulate from 5-
100 plus microns. A particle count is a totally separate test from the spectroanalysis. In many
cases there is no correlation’s between a particle count and the spectroanalysis. Particle
Analysis is one of the most misunderstood procedures in oil analysis.
It is the purpose of this section to give a clear understanding of what type of particle tests are
available, different formats of information and how to interpret the data.
Partic le Analysis
Two of the most common methods of particle counting are:

 Automated Mechanical Method
 Manual Optical Method
Automated Mechanical Method
The most common method is an automated mechanical method. This method employs a
particle-counting machine that uses some form of a laser beam or light source to count the
particulate.
Advantages
1. Easy to perform
2. Requires limited technician training time
3. Provides automatic graphing capabilities
4. Fast
Disadvantages
1. Cannot count samples with high water content
2. Some use high dilution factors that decrease accuracy
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3. No identification of particulate composition (What type of particle is it?)

4. Photograph of contamination is not possible
Manual Optical Method
This method follows Aerospace Recommended practice ARP 598. In this method 50-100 mls
of fluid is filtered through a .8 micron guided milipore patch. The particulate are then
counted and identified using a high power microscope.
Advantages
1. Can count samples with high water content
2. Uses little or no dilution factor to increase accuracy
3. Identifies the type of particulate
4. Photographs of contamination are possible
Disadvantages
1. Requires a highly trained staff
2. No automated graphing system
3. Time consuming
Data Reporting Formats
The three most common forms for data formats are:
 ISO- International Standard Organization

 NAS- National Aerospace Standards
 SAE- Society of Automated Engineers
Once a trend is developed using one type of test method, it is important not to cross methods,
using one method one time and the other the next.
It is important that the method of testing, optical or laser is known when comparing test
results. If there is a big discrepancy between the test results, call the laboratory and see if
they can help you find out why.
Pg 6C-34 Rev 1
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FILTER ANALYSIS
A filter analysis is used to gain even more insight into the system. The filter collects data
with every gallon of oil filtered. By evaluating the residue the filter collects we can:
 Determine system cleanliness

 Predict failure of components
 Determine source of contamination from inside or outside the system
The filter analysis is used in the following situations:

1. System is experiencing short filter life.
2. Vibration monitoring system is picking up abnormal vibrations.
3. high pressure differential across the filter
4. Large metal particulate present in the system.
5. Highly contaminated particle count.
6. Failure analysis investigation.
The filter analysis picks up where the particle count leaves off. When some components fail
they fail in large chunks. These particles are not circulating in the oil, but are picked up by
the filter or strainers. Take a roller bearing for example. When it fails the particulate that are
generated are too large to be picked up in a spectroanalysis and are usually from 25 to 100
microns in size. These are picked up in the filter and can be evaluated using filter analysis.
The Process
The residue is washed from the filter, dried and weighed. It is then evaluated for metal
content, organic matter, and foreign contamination. The percent of each contamination is
evaluated and reported.
MAJOR-40% or more
MINOR-20 to 30%
TRACE-10% or less
The residue is then photographed at 25X, 40X, and 100x magnification. This allows the
customer to see exactly what is in the filter.
The method of filter analysis was first used on aircraft applications. OAL found it so
effective that that started to perform the same procedures to industrial filters.
Rev 1 Pg 6C-35
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Particulate Magnification
Pg 6C-36 Rev 1
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REQUIRED LUBRICANTS
The turbine requires a synthetic oil supply, which has been approved by GE for use in the gas
turbine engine and which conforms to MIL-L-23699 lubricating oil specifications. Some
approved oils that meet this specification are listed in the Table below, Required Lubricants
and Consumables, under “Turbine Lube Oil.” Refer to the generator manual (located in the
O&M manual) for approved generator lubricating oils. Contact the GE regarding possible use
of other oils. The hydraulic system requires hydraulic fluid conforming to MIL-H-17672 and
ISO-VG46 specifications. Hydraulic fluids conforming to this specification are listed below.
Note: Oil companies reserve the right to revise their specifications periodically. It is
essential and a customer responsibility to verify the suitability of oils selected to meet
specifications.
Required Lubricants and Consumables
Specified Required
System Lubricant Address Quantity
Turbine Lube Mobil Jet Oil II Mobil Sales and Supply Corp. 220 gal (832.7 L)
Oil New York, NY
Exxon Turbo Oil 2380 Exxon Company, USA

Marketing and Technical Services 220 gal (832.7 L)
Houston, TX
Castrol 5000 Castrol Specialty Products Div. 220 gal (832.7 L)

Irvine, CA
Hydraulic Mobil DTE 25 Mobil Sales & Supply Corp. 40 gal (151.4 L)
Fluid Type 2075 TH New York, NY
Texaco Rando Texaco, USA 40 gal (151.4 L)

HDAZ-46 Houston, TX
Hydraulic Arco Duro AW-46 Lyondell PetroChemical Co. 40 gal (151.4 L)

Fluid (Cont) Houston, TX
Exxon Nuto H Exxon Company, USA 40 gal (151.4 L)

Marketing and Technical Services
Houston, TX
Rev 1 Pg 6C-37
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SAMPLING & ANALYSIS PERIODS

Lube oils and hydraulic fluid being supplied to the gas turbine package must meet the quality
standards set by the document in Appendix of the Operation & Manual (O&M) and the LM
Series GEK Maintenance Scheduled Maintenance and Troubleshooting Manual.
When to
Sampling Point How to test…
sample…
Gas Turbine Sump Weekly Check Oil Level
Monthly or
Gas Turbine Sump Lab Analysis
700 hrs
Generator Sump Weekly Check Level
6 months or
Generator Sump Lab Analysis
4000 hrs
Hydraulic Start System, Sump
Weekly Check Level
Tanks
In addition to the required oil analysis requirements, maintenance personnel may conduct on-
site qualitative testing.
Note There are no requirements for performing on-site Qualitative Testing by

the GE AEP Operation and Maintenance Manual. Should the maintenance
department choose to implement a qualitative lube oil sampling/testing
program, the following section is excerpts from Naval Ship’s Technical
Manual, No. S9086-H7-STM-010/CH-262R5.
Qualitative testing may includes the following set of sampling and testing procedures. It is
recommended to perform qualitative tests weekly on operating equipment.
The following equipment should be on-hand to accomplish testing:
1. Centrifuge, BS & W 1 EA
2. Centrifuge Tube, 100 ml 10 EA
3. Solvent, PD-680 Type II As Required
4. Test Tube Rack 1 EA
5. Goggles, Safety 2 EA
6. Bottle, Wash, 500 ml 2 EA
7. Apron, Laboratory 2 EA
8. Bottle, 8 oz. Sq. Glass 20 EA
9. Thermometer, Dial 2 EA
NOTE: BIOTEK HISOLV may be substituted for PD-680 Type II solvent.
Pg 6C-38 Rev 1
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No
Free Sample Sample

Obtain Sample No Yes Yes Wait 30min
Water? Hazy? 120degF?
No
Sample
Heat to 120degF
Hazy?
Yes
BRIGHT
Yes
Continue to Purify
and Identify
Pass LO through Unsat Visible
Find the No Contamination Log Results Yes
Purifier 3 Times Sample Sediment?
Contamination Source?
Source
Yes
Passed Sample
No Log Results CLEAR
3 Times? Satisfactory
Yes
Perform BS&W Unsat

Log Results
Testing Sample
Flow Chart for Systems With Online Purification Capabilities
Rev 1 Pg 6C-39
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Flow Chart For Systems Without Online Purification Capabilities
Lube Oil Clear & Bright Test Procedure

This test procedure is taken directly from the Naval Ship’s Technical Manual, No. S9086-H7-
STM-010/CH-262R5.
The degree of water and particulate contamination in lube oil samples may be quickly
assessed by the Clear and Bright test. Clear refers to the absence of visible particulate matter.
Bright refers to the absence of free water, moisture or other factors that affect the color and
clarity of the lube oil sample. For example, oil that is free of water contamination appears
bright, with no discernable haziness or cloudiness. As the amount of water contamination
increases, the sample gradually assumes a hazy or cloudy appearance due to the suspension of
tiny water droplets throughout the oil. When the level of water contamination reaches a point
where the oil cannot dissolve any additional droplets, the excess water falls to the bottom of
the sample and becomes visible as droplets or a layer of free water.
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When performing the Clear and Bright test, the following procedure shall be followed:
1. Obtain a clean, dry 8 oz. square glass bottle and draw a representative sample for
inspection. The sampling connection shall be flushed free of any stagnant oil by allowing
an amount of oil equivalent to the sample connection volume to drain into a clean
container before filing the sample bottle. All condensate in the sump shall be drained off
prior to obtaining the sample. Waste oil shall be placed in the settling tank for renovation
or properly disposed.
2. Assess the appearance of the sample by holding it in front of a strong light source. Inspect
the sample for the bright criterion by observing for any free water, haziness, or cloudiness
in the oil. If free water is present, it will be readily apparent as bubbles or a layer on the
bottom of the sample bottle.
If the oil appears hazy or cloudy, the temperature of the sample shall be checked with a
thermometer. If the sample is at operating temperature 1205F (534C) and the sample
appears hazy, dissolved air or water may be present; allow the sample to settle at room
temperature for 30 minutes. If dissolved air is present, the sample will clear from the bottom
to the top. If dissolved water is present, the sample will remain cloudy, or will begin to clear
from the top to the bottom. If the sample continues to appears hazy or cloudy after the 30
minute settle time, the oil fails the bright criterion. If the sample came from equipment
without online purification capability, conduct the transparency test.
If the lubricating oil does not pass the Clear & Bright tests, the transparency test, visible
sediment test, and BS&W (Bottom Sediment & Water) tests should be performed.
Transparency Test
STM-010/CH-262R5.
To perform the transparency test, hold a piece of paper with standard size print behind the
sample. If the printed words can be read through the sample, the oil passes the Transparency
Test and must be checked for the clear criteria. If the card cannot be read through the sample,
the oil fails the Transparency Test.
Visible Sediment Test

STM-010/CH-262R5.
This test allows a qualitative assessment of the level of particulate contamination present in a
sample, and provides a means of screening lube oil samples prior to conducting further
testing. To perform the test, the following procedure shall be used:
Rev 1 Pg 6C-41
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1. If visible sediment is noted, let the sample bottle stand for 10 minutes or until all of the
sediment has settled to be bottom. Gently lay the sample bottle on its side for 10 minutes
or until all visible sediment has accumulated along the intersection of the side (on which
the bottle is laying) and the normal bottom of the bottle.
2. If a solid, unbroken line of sediment is observed along this intersection, or if individual

particles greater than 1/8 inch along the largest axis are observed, more testing is required.
If a broken line of individual particles is observed, none of which is greater than 1/8 inch
along the largest axis, the sample passes the visible sediment test and is satisfactory for us
in equipment without online purification capability.
Bottom Sediment & Water Test

1. Obtain two clean, dry centrifuge tubes and fill each with 50 ml of well-shaken sample.
2. Set the tubes in the test tube rack and fill each tube to the 100 ml mark with solvent.
Tightly cork each tube and shake for 30 seconds to ensure adequate mixing of the oil
and solvent. The cork shall be covered with a thin plastic film (such as cellophane) so
that it can be reused.
3. Place the centrifuge tubes securely on opposite sides in the centrifuge and whirl at
1500 rpm for 30 minutes.
4. Remove the tubes and obtain the percent BS&W by adding the readings of the two
tubes.
5. At the end of the test, dispose of oily waste and clean the centrifuge tubes with
solvent.
Pg 6C-42 Rev 1
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Oil Loss Troubleshooting Chart
Rev 1 Pg 6C-43
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Oil Pressure, Temperature and Flow Chart
Pg 6C-44 Rev 1
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Rev 1 Pg 6C-45
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BEARING MAINTENANCE
Maintenance technicians at a plant recently witnessed first hand how high temperatures can
affect and potentially damage rolling bearings. Bearings in a fan used to evacuate superheated
air during a process began to overheat. Bearing temperatures, which normally hovered around
170°F (77°C), climbed to 195°F (91°C).
While the fan continued to run, plant technicians consulted with a bearing engineer to devise a
solution. But their efforts came too late: by the time the meeting ended, the grease inside the
bearing had dried up and smoke had begun to emanate from the bearing, causing shutdown.
Failure analysis quickly pinpointed a cause: process temperatures of 1000°F (538°C) or
more produced in the process resulted in an ambient temperature of 220°F (104°C). The
plant immediately took steps to shield fan bearings mechanically from the worst of this
heat. In addition, the "floating" bearing in the fan arrangement was offset in the
housing, providing it with more room to travel axially to accommodate shaft expansion.
Higher-than-normal operating temperatures, whether caused by ambient conditions or
generated within the bearing itself, have the potential to harm rolling bearings. Normal
operating temperatures differ, depending on the application. Maintenance technicians
should be aware of this and know the common causes of, and remedies for, bearing
overheating.
Electric Motors
The ball bearings used in most electric motors are pre-greased, shielded ball bearings. Normal
motor bearing operating temperatures range from 140°F (60°C) to 160°F (71°C).
Overheating in electric motor bearings is generally lubricant-related. For example,
when re-lubricating open bearings, users may inadvertently employ a low-temperature
grease which does not provide adequate viscosity at the normal operating temperature.
Or the user may over-grease the bearing, forcing bearing balls to push through excess
grease as they rotate, leading to a sharp temperature rise. Another cause of overheating
is mixing incompatible greases, which can reduce the consistency of the grease and
possibly the overall viscosity.
Fans
Commercial fans generally utilize ball and roller bearings mounted in cast iron or pressed
steel housings. Fans are exposed to a wide variety of ambient conditions, ranging from
below-zero temperatures for rooftop fans to extremely high temperatures for fans used in
industrial processes.
Normal bearing operating temperatures varies, depending on the environment and
application. The standard grease in most fan bearings remains effective to an
operating temperature of 180°F (82°C). If steady-state operating temperatures are
higher than 180°F (82°C), consider using a grease with a synthetic base oil. Viscosity
in synthetic oil does not vary as much with temperature as in a standard mineral oil,
and the rate of oxidation is much slower. For operating temperatures above 200°F
(93°C), a circulating oil system may be needed. These systems pump clean, cool oil
Pg 6C-46 Rev 1
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06/26/2012
through a bearing arrangement.

In hot-gas fans, special measures must be taken to protect bearings from high
temperatures. In virtually all cases, an aluminum disk or flinger placed on the shaft
between the bearing and the fan casing can act as a heat shield. Often, a blower wheel
or compressed air can be used to direct cooling air across the bearing housing or the
shaft.
Pumps
Depending on the application, normal bearing operating temperatures in pumps range from
100°F (38°C) to 180°F (82°C), with most running between 140°F (60°C) and 160°F (71°C).
Although grease is used in some vertical pumps, oil is the preferred lubricant in the majority of
pump applications. Standard bearing oils in pumps remain effective to approximately 180°F
(82°C). If normal operating temperatures are higher than 180°F (82°C), synthetic oil should be
used; if temperatures exceed 200°F (93°C), a circulating oil system will probably be required.
As in other bearing applications, higher-than-normal operating temperatures in pumps
can be caused by bearing over-lubrication. Overheating can also be caused by bearing
misalignment or ball skidding within the bearing. Specially designed bearings are
available to eliminate ball skidding. Ideally, bearing temperatures in pumps, especially
those in critical applications, should be regularly monitored.
Gear Drives
Bearings in gear drives normally operate at 160° (71°C)-180°F (82°C) and are lubricated with
static oil systems. As improved technology permits reductions in the size of gear drives, there
is a growing trend to transmit more power through a given size drive than ever before. This
practice can cause bearings in gear drives to run hotter and may necessitate the use of
alternative cooling methods.
Summary
In summary, proper bearing lubrication is the primary concern in all high-temperature
applications. That concern is heightened by the trend of running industrial equipment at
higher speeds than originally intended, further increasing bearing temperatures. The general
rule is to provide the minimum viscosity required at the expected operating temperature: 100
SUS (20cst) for roller bearings and 70 SUS (13cst) for ball bearings. In addition, the
increased thermal expansion of the shaft must be accounted for both axially (to ensure that
high thrust loads are not induced) and radially (to ensure that radial internal clearance is
adequate to avoid preload). The solution may also entail using a grease with a synthetic base
oil or converting to a different lubricant delivery system, such as circulating oil.
Rev 1 Pg 6C-47
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Single-Point Lubricators
In the petrochemical industry, bearing faults drive the majority of repair events for motors,
pumps and compressors. In a study performed at 12 petrochemical plants, the data showed
that approximately 60 percent of all motor repair events originated with bearing troubles.
This number differs significantly for pumps and compressors because of the impact on
equipment life due to the performance of mechanical seals. Historical data gathered at these
12 facilities showed that bearing problems represent approximately 70 percent of all repair
events for motors and 30 to 35 percent for pumps and compressors. This climbs to 80 percent
in equipment that is selected and supplied with lifetime lubrication.
When a bearing defect is allowed to progress to a catastrophic failure, the failure will be far
more costly. This is because damage tends to grow exponentially with time. As equipment
damage grows, so does the potential for extended downtime. Under these circumstances
where repeated bearing failures are present due to bearing distress caused by lubrication
deficiencies, it should be simple to justify the use of innovative techniques to reduce the
number of failures.
The single-point lubricator is one method of extending bearing life. This technology was
introduced into the petrochemical industry about 30 years ago with mixed results. In recent
years, manufacturers have introduced significant technological advances that have increased
the life of bearings and the reliability of single-point lubricators.
Lubrication by Automatic Single-Point Lubricators

Single-point automatic grease lubricators are refinements of the old compression grease cup
(Figure 1). Grease cups are small containers filled with grease that are fitted to the bearing.
Pg 6C-48 Rev 1
Equipment Testing
06/26/2012
The principle of operation is to force the grease into the bearing by turning down the cap or
piston covering the grease charge. The next development in this line of products is the spring-
loaded grease cup. The spring-loaded lubricator, a simple refinement of the compression cup,
is accomplished by replacing the screw-down cap or piston with a spring-activated, leather-
packed plunger. This plunger, when engaged by the spring pressure, slowly forces grease into
the bearing. Neither of the two types of grease cups is recommended for use under conditions
of wide temperature variation, where the consistency of the grease may be affected.
Single-point lubricators differ from the traditional grease cup by employing either a spring or
an expanding gas pressure to exert a force on the cap, piston or diaphragm in contact with the
grease volume. These continuous forced grease injection devices are screwed into the
threaded grease port. They range in size from 2 to 18 oz. (60 to 250 cc) of grease capacity and
can develop pressures as high as 65 psi (4 bar).
The original device, as shown in Figure 1, is spring-loaded. The flow of grease is adjusted by
the use of a metering control principle. A piston O-ring seal, which creates a changing level of
friction as it moves along the tapered wall of the reservoir dome, adjusts the flow. The
changing resistance is designed to counterbalance the changing force of the compression
spring as it gradually expands. Because the lubricators operate with a single universal spring
(other sizes are available) at the lowest reliable pressure (under two psi), no grease is moved
into the bearing until it is needed.
Variations in discharge flow rate are achieved by inserting different size orifices into the
discharge nipple of this field-refillable lubricator. In application, the design is highly affected
by the ambient temperature and the age of the grease in the canister. Tests performed by the
author on the spring-loaded lubricator showed that in some applications the bearings would be
overgreased, while in others, no grease would flow at all.
Rev 1 Pg 6C-49
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The device shown in Figure 2 is a significant improvement on the original concept of the
grease cup.
Further details in the operation of lubricators of the same design as Figure 2 show a cylinder
containing a pressure generator and a piston, which pushes the prepacked lubricant into the
bearing in response to the pressure generator.
The pressure generator is a rubber bladder containing an electrolytic solution and a sealed
plastic tube containing a galvanic strip of specially treated metal. After the injector is
installed, the activating screw is used to break the plastic tube. This exposes the galvanic strip
to the electrolytic solution, resulting in an electrochemical reaction within the bladder which
produces a gas. As the bladder pushes against the piston, the piston pushes the lubricant out of
the injector and into the bearing. When all of the lubricant has been expelled into the bearing,
the unit expires and is thrown away, and a similar unit is installed.
The rate of lubricant ejection is a function of the gas production, which in turn depends on
time and rate of reaction. Consequently, the rate of lubricant discharge can be predesigned
into this device to accommodate the user’s discharge rate specifications.
Should the lubricant discharge flow be restricted due to viscosity increase, hardening of the
grease or mechanical restriction in the supply line, the flow will be reduced or stopped. Under
these conditions, the gas pressure will increase to a maximum of 136 psi until normal flow is
restored.
If resistance to lubricant flow is reduced, the lubricant flow will temporarily increase. This
will continue until equilibrium between the amount of gas generated and the amount of
lubricant discharged is reached.
Similarly, as with the older devices, the discharge rates are affected by ambient temperature
variations because of the increase or decrease in the speed of the electrolytic action resulting
from temperature changes within the bladder. As the temperature rises, the discharge rate
increases and as the temperature drops, the rate decreases. A sudden large increase in
temperature also causes the lubricant to expand within the unit, which will cause a temporary
increase in discharge rate. Conversely, a sudden drop in temperature will cause the lubricant
within the unit to contract. This results in a temporary decrease in discharge rate, until the gas
production within the bladder compensates for the reduced volume within the unit, resulting
from the sudden temperature drop.
For lubrication of electric motor bearings ranging from 25 to 400 horsepower, injector
manufacturers recommend a unit, which at an ambient temperature of 77ºF (25ºC) would
discharge approximately 0.166 cc per day and would be in service for 24 months. Elevation of
the ambient temperature to 113ºF (45ºC) would increase the grease discharge rate by a factor
of 4 to 0.66 cc per day, resulting in six months of service life for the device.
Pg 6C-50 Rev 1
Equipment Testing
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Newer electromechanical devices are more sophisticated and capable of delivering lubricant
to multiple machine points. A typical cross-section of one such device is shown in Figure 3.
These devices consist of a reusable drive motor (battery or direct-wire powered), a
refillable/replaceable lubrication canister and a small pumping device. These units can be set
for different discharge periods and be turned on and off with a switch. They are also
temperature independent and have precise discharge periods. Additionally, some of these
units can be connected to a PLC to monitor operating conditions.
Newer units are available in capacities ranging from 60 to 500 cc (2 to 36 oz.). The choice of
selector switch fixes the rate of gas generated in the electrochemical cell. The dispenser is
adjusted to deliver lubricant at the specified rate against atmospheric pressures (14.7 psi
absolute). Added backpressure will reduce the discharge rate. Depending on the manufacturer,
selected units are capable of developing discharge pressure that exceeds 350 psi (23 bar).
Regardless of the type of device selected, questions remain on the appropriate method or
technique that should be employed to lubricate bearings. Various user organizations employ
different approaches of how to properly apply grease to different bearing configurations. A
study of 12 petrochemical facilities showed that lubrication practices for grease bearings of
general-purpose equipment varied, from one extreme of having no program for relubrication
to the other extreme of employing continuous lubrication via oil mist. Four plants stated they
had no lubrication program and ran equipment to failure. Correct grease application is
essential to assure that neither excessive nor insufficient grease conditions create
component failure. Match the manufacturer’s recommendations for grease volume

requirement with unit output when using single-point lubricators. Also consider these
conditions:
Rev 1 Pg 6C-51
Equipment Testing
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Area Classification
Make sure that the lubricator you are considering is designed to meet the electrical area
classification of the area of the plant where you plan to install it.
Overlubrication of Bearings
Too much grease in a bearing or its housing causes churning, resulting in a sharp increase in
temperature and often, premature lubricant and/or bearing failure. On start-up, grease-
lubricated bearings expel grease into vacant spaces around the housing. To prevent churning,
there must be sufficient empty space in the housing to accommodate this grease.
Relubrication volume is application-dependent, but a common rule for grease application is to
pack the bearing completely, but fill only one-third of the bearing housing.
Underlubrication of Bearings
Even with the correct grease in your single-point lubricators, underlubrication can occur. The
consequences are excessive heat and eventually metal-to-metal contact between bearing
components. Always take into account the changes in ambient temperature at your site. For
example, a common practice at a plant using electrochemical devices was to purchase 24-
month lubricators to be replaced yearly. This was done to compensate for high temperatures
during the summer.
Failure to Prevent Lubricant Contamination

Lubricant contamination is a leading cause of bearing failure. Dirt particles, other
contaminants and the application of incompatible grease are all factors that increase
equipment failures. The use of two incompatible lubricants will lead to deterioration in
lubricating capability.
Using the Wrong Seals

The use of the correct bearing design (seal and shields) supplemented with a bearing isolator
can be the difference between long-term reliable service and a “bad actor.” Review all your
applications with the bearing manufacturer to assure an optimum fit.
Failure to Relubricate Bearings

Even without exposure to contaminants, lubricant quality can deteriorate over time. Although
single-point lubricators will continue to operate, failure to keep track of lubricant condition
and age can lead to premature equipment failures. Contact the bearing manufacturer for
recommendations on optimum lubricant replacement intervals.
Failure to Provide Relubrication Training

Maintenance technicians commonly receive training on bearing selection and installation, but
not lubrication. Ensure that technicians are thoroughly trained in lubrication fundamentals as
well.
Pg 6C-52 Rev 1
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Recommendations
Lubrication should not be left to chance. Optimized grease lubrication requires knowledge of
bearing configuration, lubricant and operating conditions. Single-point lubricators should be
selected and applied judiciously to obtain the desired extended equipment life. These
lubricators have their place, but cannot be applied indiscriminately. They are quite useful in
keeping bearing housing grease cavities full, keeping in mind the importance of bearing
design and shield application. It is important to remember that this advantage can become a
disadvantage if an overgreasing situation is created. Single-point lubricators are attractive in
inaccessible locations. However, inaccessible should not mean forgotten. Climatic conditions
and age can lead to changes in grease quality, and eventually to separation problems, which
are frequently observed in many plants.
It is the responsibility of maintenance professionals to consider the cost of using single-point

lubricators for every lubrication point in the plant. One must be cautious of grease
compatibility issues when applying single-point lubricators with the refillable feature. The
wrong grease or the mixture of incompatible greases can create as much trouble as improper
lubrication does.
Depending on the application, single-point lubricators can extend the life of rotating
equipment and increase reliability while significantly reducing the cost of applying the
lubricant. In these days of reduced budgets and staffs, these devices can provide increased
long-term service for the general-purpose equipment of the plant.
Rev 1 Pg 6C-53
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GAUGE CALIBRATION
Purpose:
As an operator, you observe and detect malfunction in operating equipment and take
necessary action to prevent damage to the equipment. For accuracy, the best method of
observing and detect malfunctions in the operating equipment is through use of indicating
instruments, such as temperature and pressure gauges. These gauges range from direct acting,
such as ordinary thermometers, to electrically activated resistance detectors. The main
function of all indicating instruments is to give information on the operating equipment.
When you are operating equipment, these instruments give you the ability to compare normal
operating conditions. This comparison permits you to detect damage in equipment. It is
important that readings be taken at set intervals. By reviewing operating logs the operator or
shift supervisor can determine equipment condition and make corrective actions prior to a
component failure.
There are many types of measuring equipment found in power generation, auxiliary, and
control stations.
Calibration:
Calibration is a compression of a system or instrument of unverified measurement accuracy to
a measurement instrument of known or greater accuracy, to detect and correct any variation
from established or required performance specifications.
Power plants should have a method for calibration of portable (Torque wrenches,
micrometers) and permanently installed mechanical and electromechanical measuring
equipment/instrumentation found within your power plant.
Example of Instrumentation require calibration:

 Pressure Calibrators
 Temperature Calibrators
 Viscometers
 Flash point testers
 Standards
 Micrometers
 Torque Wrenches
 Hydrometers
 Test Equipment
Standard:
A standard is a device used to maintain continuity of value in the units of measurement by
periodic comparison with higher echelon or national standards.
Personnel Requirements
Personnel qualified to perform these task do the repair, adjustments, and calibration of
portable measuring instrumentation. If you have not established a calibration program,
instrumentation should be sent out for calibration. Each plant should have calibrated gauges
standing by as spares as gauges fail or used as replacement as gauges are sent for calibration.
Pg 6C-54 Rev 1
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Pressure Measurement
Pressure Measurement
Pressure is one of the broadest and most complex areas in the field of physical measurements.
Its large scopes results from numerous and diversified types of instruments, which are used
for pressure measurements, while its complexity stems from the many-sided nature of
pressure itself. Total pressure is composed of atmospheric and non-atmospheric components.
Atmospheric pressure: Produced by the weight of the atmospheric blanket, atmospheric

pressure has a pronounced influence on a great variety of phenomena. It directly influences
boiling points, density, and deformation. Correction for atmospheric pressure is required in
the physical measurement.
Non-atmospheric Pressure: The second type of pressure, which is artificially produced to

transfer or amplify force to produce work. This is the type of pressure used in a service
station to lift a car, in a machine shop to operate a hydraulic press, or in a turbine to power a
propeller or generator. We will deal mainly with liquid or gas pressure and it’s measurement.
Pressure might be described as force acting over an area. Mathematically the most common
equation for pressure is:
P=F (1) A
Where F = The force in units of lbs., newtons, dynes
A = The area in units of inch2, meter2, centimeter2

And P = The pressure in units of lbs/in2, newtons/m2, dynes/cm2
Sometimes difficulty arises regarding the distinction between force and pressure. This
generally can be avoided if the reader remembers that pressure describes force acting over a
particular area. If we restate equation (1) in terms of force we obtain.
F=PA (2)
The study of fluids at rest is called hydrostatics. Given a fluid in a state of equilibrium under
static conditions, the pressure of the fluid against a point on the surface in contact with the
fluid is numerically equal to the normal force exerted by the fluid against a point on the
surface. At any given point within a fluid in hydrostatic equilibrium, the pressure is equal to
the sum of the external pressure exerted at the top of the fluid and weight of the fluid in a
vertical column of cross-sectional until area existing over the point. Under static equilibrium
conditions of a fluid without flow, the pressures on every point of a horizontal plane of fluid
are equal, and the pressures in any direction about any point are equal. Straight, duplex,
differential, compound and vacuum gages are designed for measurement of either a pneumatic
or hydraulic pressure medium.
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Red arm Settings:

Some pressure gages and thermometers are provided with an adjustable pointer, which is
painted red, in addition to the indicating pointer. The red pointer (Red Hand) is supplied as an
aid to the operator.
Either the maximum or minimum setting, whichever is most applicable may be selected.
Where specified, if the maximum or minimum operating pressures are not available to
operators, the Red Hand should be set at maximum or minimum operating pressure (normal
conditions) to provide the operator with information
Conversion Factors:
To relate absolute pressure, gage pressure and vacuum, it is necessary to specify the
atmospheric pressure that exists at the time and the place of the measurement. Standard
atmospheric pressure or barometric pressures (bars) is taken as 14.696 psia, or 760 mm of
mercury column at sea level and 0 C (32F). The most commonly used approximations are
14.7 psig and 29.92 inches of mercury column. During the time and at the place of
measurements, the atmospheric pressure may vary considerably from the standard pressure.
Pressure gages indicate the pressure above atmospheric pressure and usually read in ponds per
square inch gage (psig). Low-pressure gages may read in inches of mercury (in Hg) or inches
of water (in H2O). When converting gage pressure in pounds per square inch (psi) to absolute
pressure in the same units of measurement, add 14.7 to the gage reading. As an example
would be a reading of 50-psig equals 64.7 psia.
To convert vacuum in inches of mercury to absolute pressure in inches of mercury, subtract

the vacuum gage reading from the barometric pressure reading. When converting from
absolute pressure in inches of mercury to absolute pressure in pounds per square inch,
multiply by the conversion factor 0.4912, as an example, for a vacuum of 14 inches of
mercury, with barometric pressure of 16.92 in. HG., MULTIPLYING 16.92 BY THE
COVERSION FACTOR 0.4912 EQUALS 8.3-PSIA PRESSURE. Commonly used
conversion factors are given.
Multiply By To Obtain
1 Atmosphere 29.9231 Inches of Mercury
1 Atmosphere 33.959 Feet of Water (fresh)
1 Atmosphere 14.69595 Lb/in2
1 Atmosphere 232.136 Oz/in2
1 Atmosphere 1.01325 Bars
Feet of Water 0.02984 Bars
Feet of Water 0.88109 Inches of Mercury
Feet of Water 0.43275 Lp/in2
Feet of Water 6.924 Oz/in2
Inches of Mercury 0.033864 Bars
Inches of Mercury 1.135 Feet of Water (fresh)
Note
1. Inches of Mercury (Hg) shall indicate inches of mercury referred to 0C (32F) one
inch of mercury is equal to 0.49115 lb/in2.
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2. Inches of Water (in. H2O) shall indicate inches of water referred to 20C (68F) one
inch of water is equal to 0.036063 lb/in2.
Pressure Snubbers:
A pressure snubber is a pressure-transmitting device that restricts the rate of the fluid flow to
a pressure-sensing instrument and, as a result, the rate of pressure change.
Pressure snubber should be used when a gage, transducer, or other pressure sensing
instrument is subject to constant and rapid pressure fluctuations or hydraulic shocks which
have the potential to damage the pressure sensing element and result in premature failure. In
the case of pressure gages, such pressure fluctuations may result in excessive wear to the
drive mechanism and rapid pointer oscillation, making reading difficult. A pressure snubber
greatly reduces the magnitude of the pressure oscillation and thus prolongs the life of the
pressure-sensing instrument.
Snubbers
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Safety:
As with any pressurized system safety is of primary concern. In addition to potential hazards
associated with working with a pressurized fluid, there are other cautions that must be
observed. These include contamination and reuse.
Contamination can occur when a fluid from a calibration system (or reuse from a different
application) comes in contact with the internal portions of a snubber, which is intended for
use in an incompatible fluid system, e.g oil in gas or water system. The consequences of
incompatibility can range from simple contamination resulting in improper snubber action to
explosive failure when oil is introduced into an oxygen system.
Reuse- It is strongly recommended that the Snubbers not be transferred from one application
to another. If a snubber transfer is necessary, then transfer from one application to another
should only be done after concerns about chemical and material, viscosity, and pressure
compatibility are addressed. In general, the same criteria used to select a snubber for a
particular application should be govern its reapplication.
There are several indicators of pressure snubber malfunction. These are minimal or no
snubbing action, excessive delay in response of the pressure sensing instrument, and lack of
response from the pressure sensing instrument. Lack of snubbing action may indicate
deterioration of either the porous metal element or the piston. Excessive delay or lack of
response is symptomatic of the accumulation of particulates either within the porous metal
element or around the piston assembly.
If improper operation traceable to the pressure snubber is indicated, then it should be removed
and inspected. If the snubber is of the porous metal design, then it should be replaced-it is not
practical to clean or repair it. If the snubber is of piston design, then it can be disassembled
and cleaned. If required, the piston can be replaced. Even if improper snubber operation is
not evident, Snubbers should be inspected annually for proper operation.
Pressure Gage Calibration:

Pressure gages are most often calibrated by adjusting their mechanisms so the pointer gives
accurate readings over the range of the gage. The accuracy is determined by testing the range
against a standard pressure at several points up to full scale, then rechecking as the pressure is
returned to zero. Some recommended practices are:
 Cycle the gage twice to full scale prior to testing.
 Test gage at 25% increments to full scale, and 25% increments downscale, including
normal operating pressure.
 The applied pressure should not exceed the test point when using upscale or down. If
it does, return to the previously checked point and continue from there.
 Test readings should be taken after the gage is lightly tapped near the center of the dial
in order to minimize fraction errors.
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C-Type Pressure Gages:

The C-type Bourdon tube named for its shape is constructed of a Bourdon tube connected by
mechanical linkages and gearing to a pointer. The movement of the pointer with respect to a
fixed dial indicates pressure changes with graduated markings representing magnitudes of
pressure.
Bourdon Tube Gage
Direct Drive Bourdon Tube
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As an example Military Gage accuracy are as follows:
2 inch dials +/- 3% of span

2 ½ inch dials =/- 2% of span
3 ½, 4 ½, 8 ½ inch dials +/- 1% of span
Pressure Transmitters:
Pressure transducers are sensors that convert a measured pressure into an electrical output
signal that is proportionate to the input pressure.
Some typical use of pressure transducers are used in industrial environments where a remote
reading of a pressure indicator is required, or when an electrical signal representing a pressure
is required for input into a control system, or data acquisition system, or a data recording
devices.
Capacitive Element- a diaphragm positioned between two fixed plates is deflected, causing
capacitance change in two circuits. If the dielectric of the capacitor is maintained constant or
compensated for, a highly stable very repeatable transducer is achieved. Small displacement
of the capacitor-diaphragm is a major inherent advantage.
Variable Reluctance/Inductive Sensors- a pair of coils excited by a carrier frequency is

influenced by changes in magnetic coupling of a pressure driven armature, which displaces or
rotates between two coils. The following two basic designs have developed around the
variable reluctance design.
BI-metallic Thermometers- Consist of two dissimilar metal strips fused together in a spiral or
helix configuration. The spiral-sensing element is enclosed in a protective metal tube with
one end of the element affixed to the close-end of the tube and a pointer stem and pointer
attached to the other end of the element. The helical element and likewise the indicating
pointer will rotate as the dissimilar metal strips thermally expand or contract at different rates.
The pointer and temperature scale dial are housed in a circular metal case, which is affixed
atop a sensing.
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BI-metallic Thermometers
Filled System Thermometers
Bi-Metallic Thermometers Calibration:

The calibration method for bimetallic thermometers is dependent on the stem size; most
thermometers are calibrated with a dry well temperature calibrator. The gage is calibrated at
1/3 increments of the total free scale. Based on manufactures tolerances most gauges are
calibrated at +/- 1 % of total free scale.
Resistance Temperature Detectors:

The RTD’s operate on the principle that electrical resistance changes in a predictable manner
with temperature changes. The elements of RTD’s are made of nickel, cooper, or platinum.
Nickle and cooper are used for temperatures of 600 F or lower. Platinum elements are used
for temperatures of 600 F or greater. Thermo wells protect sensors from physical damage by
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keeping them isolated from the medium being measured. This also lets you replace the
element with the system running. Which makes life a lot easier and less messy.
As temperature increases around an RTD, the corresponding resistance will also increase at a
proportional value. You can find the resistance values within the manufactures technical
manual. The most common method of heating an RTD is use of heated water bath and
calibrated thermometer. The most common fault you will find with an RTD will be either a
short circuit or an open circuit. You can quickly diagnose these faults by using digital display
readings or data log printouts. By observing the reading or the printout, you may find that the
indication is either zero or a very low valve. A malfunction of this type means a short circuit
exists in either the RTD or its associated wiring. A very high reading, such as 300F on a 0F
to 300F RTD could indicate an open circuit.
Transducers:
Transducers are devices that receive energy from one system and retransmitted it to another
system. The energy retransmitted is often in a different form then that received. A pressure
transducer receives energy in the form of pressure and retransmits energy in the form of
electrical current.
Transducer allows monitoring at remote locations on the gas turbine propulsion plants.
Mechanical gages provide pressure readings at the machinery locations or on gage panels in
the immediate area.
Pressure transducers are generally designed to sense absolute, gauge, or differential pressure.
The typical unit receives pressure through the pressure ports. It transmits an electrical signal,
proportional to the pressure input, through the electrical connector. Regardless of pressure
range of a specific unit, the electrical output is always the same. The electrical signal
conditioners before being displayed on an analog meter or a digital readout located on control
panel.
Pressure transducers should be calibrated on a bench before installation.
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GEK 105059
Maintenance Considerations
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SECTION 6D
LM6000 ENGINE CHECKS
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GEK GENERAL CHECKS AND INSPECTIONS

requires change, coordinate with the packager. The table below illustrates a sample of checks
and service intervals. Maintenance work packages (WP) are found in the GEK 105059.
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Additional Preventative Maintenance and Servicing Checks from Svc Letter 6000-05-03
Sprint nozzle clean, flow and Every 25,000 hours of WP 1916 00
inspection at authorized repair source SPRINT operation
High pressure compressor variable Every 12,500 hours WP 1412 00
compressor vane bushing replacement
Additional Recommended Checks from Service Letter 6000-05-03

Starter carbon seal cleaning Annually WP 2813
D/E Sump drain interface cleaning Annually N/A
(disconnect package drain to clean
engine and package drain as required)
Fuel nozzle (PA or PC). Clean, flow At hot section interval (PA & PC) WP1510,
and inspect at authorized repair source WP1511, WP1512,
WP1513, WP1514
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SECTION 6E
GENERATOR CHECKS
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SECTION 07
BORESCOPE
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GAS TURBINE BORESCOPE
This chapter will cover object damage and borescope inspection of the LM series engine. The
majority of this chapter deals with the LM series engine damage evaluation. The last part of
this chapter is on proper preservation and corrosion control methods for maintaining
turbines in peak operating status.
Object Damage
There are two basic types of object damage maintenance personnel will see. One of the most
damaging gas turbine casualties, and one of the easiest to prevent, is foreign object damage
(FOD). In this section we will discuss the hazards of FOD and some of the ways to prevent it.
The other type of object damage that can cause failure of a turbine is domestic object damage
(DOD).
Hazards
The effects of object damage and the hazards involved vary greatly with the size and
location of the object ingested. Small dents and abrasions may cause little or no damage.
However, if the engine ingests a large enough object, severe internal damage will result.
Large, soft items (such as paper) can clog the FOD screen, causing a loss of power and
elevated turbine inlet temperatures. The other type of damage that was mentioned is domestic
object damage (DOD). DOD occurs when an internal object from the engine breaks loose and
causes impact damage to the engine.
Prevention
To prevent FOD to engines while working in and around intake and plenum areas, you and
your personnel must observe the following safety precautions:
1. When performing maintenance inside the intake areas, always-follow all written
guidelines found in the plant SOP’s.
2. Remember to remove all loose objects from your person. You must also account for
all tools and equipment used in the intake.
3. After completing your work, inspect the intake for cleanliness, and re-inventory the
tools and equipment before securing the accesses.
4. Periodically inspect all intakes for cleanliness, the state of preservation, and
the condition of the FOD screens.
5. Correct any abnormal conditions.
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The frequency of inspection will depend on the operating conditions, Planned Maintenance
(PM) requirements, and Standard Operating Procedures (SOP’s). Remember, the PM’s only
provides minimum standards. PM’s can always be exceeded if you or your supervisors deem
it necessary.
To prevent DOD damage, maintenance personnel need to follow a strict regiment of cleaning
and inspections (internal and external). This attention to detail, as described in the next four
paragraphs, is absolutely necessary to avoid DOD damage.
1. Make sure the engine is properly cleaned inside and out. Always following the
standards in the work package PM’s and the manufacturer’s technical manual.
Cleanliness is an important factor in the fight against corrosion. Corrosion control
(discussed later in this chapter) also can reduce the chances of component failures that
can lead to DOD.
2. Perform frequent external and internal GTE inspections to reduce the possibilities of
DOD occurrences. GTE external inspections are very important. Locating loose,
missing, or broken external components (VSV retaining nuts) during these inspections
is a significant factor in preventing damage.
3. Using borescope inspections aids in determining the extent and prevention of DOD.
The most frequent damage is identified as potential component failures
(blade stress cracks).
4. Ensure all LM Series Engine GEK Interim Change Notices are implemented. This
document is sent out by GE AEP to update the GEK operation and maintenance
manuals. These changes are implemented for a variety of reasons, all to upgrade
dependability.
a. The maintenance department will need to ensure that pen updates are made to
the appropriate documentation or replaced as necessary.
b. The interim change notices will be sent out hard copy and/or on updated GEK
CD Rom.
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Sample Of Interim Change Notice
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Sample Of Interim Change Notice
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BORESCOPE INSPECTIONS
Borescope inspection requirements and procedures are found on the Maintenance Work
Package (WP 4015 00) found in the GEK manual. These instructions contain all the basic
information necessary to conduct an inspection. Included in the Work Package are the
serviceability limits and a list of conditions that require an inspection. Borescope inspections
are usually performed semiannually or when the engine has been operated beyond the
allowable limits listed on the Work Package.
General Inspection Procedures

It is a good practice to review the machinery history of an engine before you conduct an
inspection. Various component improvement programs will eventually effect all engines in
service. A rebuilt or modified engine may contain improved parts that differ from the
original. An example of this is the combustion chamber upgrade. If you review the machinery
history, you will discover the status of those parts that have been changed or modified.
Assuming that the engine history is normal and FOD is not suspected, you should be aware of
the following factors when conducting a borescope inspection:
1. Know your equipment.

2. Locate all inspection areas and ports.
3. Review previous borescope report
4. Establish internal reference points.
5. Scan the inspection area thoroughly in an orderly manner.
6. Note any inconsistencies.
7. Evaluate the inconsistencies.
8. Report your conclusions.
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GEOMETRIC ORIENTATION OF THE ENGINE

To communicate information about an engine inspection, you must establish a geometric
frame of reference for the engine assembly. A language for describing the physical damage is
also necessary. An example of this information is provided in geometric orientation of the
LM6000 below.
Engine Orientation – Aft Looking Forward
Geometric orientation of the borescope
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Circumferential R
a
d
i
a
Axial l
12
1
11 2
Clockwise
10 AFT 3
9 4
4 8 5
3
2 7 6
1
Fwd to Aft
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The figure to the left shows an example of radial and axial

cracking on a compressor blade.
The figure below shows an example of circumferential and

axial cracking in the combustion section.
A listing at the end of this chapter provides a list of

condition codes and definitions of terms that you need to
know when inspecting an LM series engine.
Radial & Axial Cracking On

Compressor Blade
Circumferential And Axial Cracking In The Combustion Section
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INDEXING AND ROTATING THE ENGINE
There are two ways to rotate the high-pressure rotor assembly of the engine during borescope.
Either by hand with a ½” drive wrench or a motorized electronic turning tool with adapter.
The borescope drive pad to rotate the high-pressure rotor is found on the backside of the
accessory gearbox (AGB). This drive pad may be utilized as an accessory drive. If so, the
accessory must be removed for access to the pad.
Accessory Gearbox Borescope Drive Pad
To rotate the low-pressure rotor assembly an individual, other than the one conducting the
borescope, will be required to utilize a strap wrench to turn the drive shaft between the turbine
and generator. Due to the location, it is recommended that two-way electronic communication
(radios) be established.
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Future Drive Turning Tool Kit
ELECTRONIC TURNING TOOL

A fully programmed electronic tool is available that automates the process of engine rotor
shaft positioning during borescope inspections for various types of turbines.
Benefits:
1. One-person operation.
2. Inspection time is reduced.
3. Inspection accuracy (& thoroughness) is increased.
4. Damaged blades can be flagged and quickly relocated for re-inspection.
System consists of three components:

1. Main power unit.
a. Provides power to the controller and drive unit.
2. Drive unit.
a. Attaches to the engine Accessory Gearbox drive pad to rotate the engine rotor
assembly.
3. Controller
a. Hand held controller used to jog/rotate the engine rotor assembly.
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CONTROLLER
LCD Status Display Consists of 4 Lines
ENGINE: displays the engine type selected
STAGE: displays the stage selected and at

the end of the line the # of blades in that
stage.
MODE: displays the mode being used.
STATUS: displays status messages on

operations and at the end of line display an
F if the current blade is flagged.
Mode Select Knob

Engine- Used to select the Engine that is
being Borescope inspected.
Stage- Used to select the stage of the engine

to be inspected.
Future Drive Controller Jog- Used to jog the engine back and forth
and used to set the zero point.
Blade Move- Used to move from blade to

blade.
Blade flag- Used to flag particular blades

for re-inspection during the inspection of a
particular stage.
Drive Unit
Interval- Used to perform an automated
blade move with a particular interval
between blade moves.
Go To Blade- Used to select and move to a

particular blade.
Speed- Used to select a speed between 1

and 99
Main Power Unit
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Engine Turning Pad Locations For HP Rotor Borescope Inspections
Detailed procedures are provided for indexing and reference point for distress reporting for
each stage in the GEK maintenance work package 4015 00.
During rotation of the engine, you should not concentrate on counting the blades. Instead,
concentrate on the specific condition of each airfoil.
Accessory drive gear ratios are listed below. All reference RPM’s in the figure below are
based on an HP compressor speed of 10,000 RPM’s. When rotating the wrench by hand,
calculate the drive pad ratio to establish how many full arcs of the ratchet wrench are required
to move the main rotor one full revolution. For example, when you are using the aft drive pad,
a 240-degree revolution of the input drive pad equals 360 degrees on the main rotor.
Accessory Gearbox Layout
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Indexing The HP Compressor Rotor To The Zero Reference
You may find the compressor rotor zero reference by use of the locking lugs on the
compressor blades. It is important to use a standardized reference to be able to map/record
findings.
1. Gain access through the borescope port through the 11th stage bleed air manifold.
2. Rotate rotor clockwise (forward looking aft) and use the borescope probe to view
stage 12-rotor blade platform. Locate the first blade to the left of the locking lugs. See
figure below.
3. Position this blade in line with leading edge of stage 12 stator vane (as viewed through
the borescope) Identify this blade as blade No.1.
4. The HPC rotor is now zero-referenced for all stages of compressor and HPT rotor
blades. Inspection of each applicable stage must start with HPC rotor position back to
Zero reference point at stage 12.
Hp Compressor Zero Reference
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BORESCOPE EQUIPMENT
A borescope is used to inspect internal parts on an engine without having to disassemble the
engine. This instrument helps a great deal during inspections and estimating the amount of
repair work needed and the time required for the repair
Borescopes are the ideal choice when straight-line access to the area of interest is available.
These rigid instruments use an optical lens system to transmit an image from the inspection
area back to the eye and a non-coherent fiber bundle to illuminate the object. Their ease of
use ensures a straightforward inspection solution with minimum set-up.
Most borescopes have the following basic components:

1. Eyepiece (zoom or wide angle)
2. Scan control ring
3. Probe
4. Scan mirror
5. Lamp
6. Focus control ring
7. Other electrical accessories
As with any optical instrument, you should handle the borescope with care to avoid damaging
its lenses and mirrors. The borescope is powered by alternating current. So, before you first
use it, be sure to read and follow the manufacturer’s operating instructions. There are
numerous types of borescope equipment, depending on manufacturer and cost considerations.
Illustrated below are two different types of borescope equipment.
Typical Borescope Video Probe XLPro Borescope
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Flex Borescope Flex Borescope
Borescope Light Source Fiber Optic Cable
Borescope Equipment: Viewing Probes: Probe # I (Yellow)
Used for all inspections requiring GREATER

MAGNIFICATION
Magnification Factor: 1:1 @ 7”
Field of Vision: 35
Focus Adjustment: ADJUSTABLE using the knob
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Borescope Equipment: Viewing Probes: Probe # II (Red)
Used for All INITIAL Inspections

Field of Vision: 62 to 64
Focus Adjustment: FIXED
Borescope Equipment: Viewing Probes: Probe # III (Green)
Used for Combustion Outer Liner and Blade Tip Inspections

Field of Vision: 62 to 64
Focus Adjustment: FIXED
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06/26/2012
Probe # I Probe # II Probe # III

YELLOW RED GREEN
o
90o Viewing 100 Viewing 70o Viewing
Angle Angle Angle
Bending
Focus
Section
Adjustment
Eye
Piece
Flexible Light
Insertion Angle Knob Source
Angle Knob
Sheath (Right-Left) Cable
(Up-Down)
Typical Flex Borescope Probe
Rev 1 Pg 7-19
Borescope
06/26/2012
Bending
Forward Section
Viewing
Adapter
Positioning
Slot
Side Light
Objective
Viewing Guide
Lens
Adapter Window
Flex Probe Tip with Changeable Viewing Adapters
Magnification
Angle Adapter
Attachment
Video
Camera
Borescope Attachments
Pg 7-20 Rev 1
Borescope
06/26/2012
VIDEO PROBE BORESCOPE EQUIPMENT
Video Probe XLPro Borescope
System Features Temperature Warning System and Interchangeable Probes
Rev 1 Pg 7-21
Borescope
06/26/2012
Borescope PC Connectivity Capabilities
XLPro Borescope Insertion Tube
Pg 7-22 Rev 1
Borescope
06/26/2012
Video Probe XLPro Borescope Insertion Tube Probes
Rev 1 Pg 7-23
Borescope
06/26/2012
LM6000 BORESCOPE PORTS
Low Pressure Compressor (Right Side)
S4-1 VIGV- Variable Inlet

Guide Vanes
S4-2 Low Pressure

Compressor
S4-3 Low Pressure

Compressor
S4-5 Low Pressure

Compressor
Low Pressure Compressor (Left Side)
S4-4 VIGV- Variable Inlet

Guide Vanes
Pg 7-24 Rev 1
Borescope
06/26/2012
High Pressure Compressor (Right Side)
S5-0 0 Stage Rotor Blades
S5-6 6th Stage Rotor Blades

(8th Stage Bleed
Manifold)
(8th Stage Bleed
Manifold)
S5-13 13th stage Rotor Blades
High Pressure Compressor (Left Side)
S5-1 1st stage Rotor Blades
S5-2 2nd Stage Rotor Blades
S5-3 3rd Stage Rotor Blades

(7th Stage Bleed
Manifold)

(11th Stage Bleed
Manifold)
Rev 1 Pg 7-25
Borescope
06/26/2012
High Pressure Turbine & Combustor (Right Side)
S6-1 Combustion Chamber

(UV Sensor)

(Upper Igniter)

(Lower Igniter)
S7-1 High Pressure Turbine
S7-2 High Pressure Turbine
High Pressure Turbine & Combustor (Left Side)

(UV Sensor)
Pg 7-26 Rev 1
Borescope
06/26/2012
Low Pressure Turbine
S8-1 (P-48 Probe) Low

Pressure Turbine
S8-2 Turbine Rear Frame
S8-3 Low Pressure Turbine
S8-4 Low Pressure Turbine
Rev 1 Pg 7-27
Borescope
06/26/2012
SERVICE LIMITS
This section discusses the types of damage that you might find when conducting a routine
inspection. This material will be limited to a discussion of the major engine areas. Service
limits are listed in WP 4014 00 and define the extent of damage that is acceptable for
continued operations, on-site maximum repairable limits and on-site corrective action.
Pg 7-28 Rev 1
Borescope
06/26/2012
Rev 1 Pg 7-29
Borescope
06/26/2012
Impact Damage Blade Dent
Gouge Impact Damage (Torn)
Blade Loss Impact Damage (DOD)
Pg 7-30 Rev 1
Borescope
06/26/2012
COMPRESSOR
Compressor Section
You should inspect the compressor section for nicks and dents, cracks, spacer rubs, casing
rubs, blade tip rubs, bent edges, missing pieces, and trailing edge erosion. Inspect the first-
stage compressor mid-span damper for leading edge dents and other types of defects.
Airfoil Surface Defects
Surface defects are the result of object damage or adjacent blade interference (tip clang).
Impacts in the center section of the airfoil are not common. Tip clang damage is the result of a
blade leading edge tip contacting the adjacent blade tip at approximately one-third of the
chord length forward of the trailing edge on the low-pressure (convex) side of the blade. This
is the result of compressor stall.. You should report any observed defect on the airfoil surfaces
in the inspection record. Your report should contain information relative to the stage, location
on the blade (estimate the percent of chord and span), and the condition of the surrounding
airfoil. You do not have to record the appearance of the defect (sharpness and contour).
Compressor stall is one of the worst things that can happen to an engine. Tip clang damage is
difficult to spot and gives the appearance of minor damage. The V-shaped notch on the top of
a blade caused by tip clang is only an indicator; it in itself is not the damage. The damage is at
the blade root and normally cannot be seen. If a blade has been overstressed, it must be
replaced.
Rev 1 Pg 7-31
Borescope
06/26/2012
Compressor Rotor Blade Tip Clang Damage.
Platform Shingling (Overlapping) Platform Fretting (Bowed)
Platform Distortion.
Compressor blade platform fretting or shingling can be observed on some after stage blades.
These distortions are the overlapping of one blade platform mating edge with the adjacent
platform edge. When shingling is found, the platforms will be distorted and bowed. When the
platforms are shingled, only the locking lug blades will exhibit this defect. Monitor this
condition to see if a platform crack develops. Also look for missing pieces around the locking
lugs. You must report and record any cracks in the platform. Be sure you have included the
following information:
1. The stage
2. The number of blades
Midspan Shroud Wear
Some stage 1 HP compressor blades show wear at the mating surfaces of the midspan damper
shrouds. Wearing of the tungsten-carbide wear coat causes the mating face contour to change
from a straight line to a stepped line. This occurs at the after edge of the clockwise blade
midspan (trailing edge) and the forward edge of the counterclockwise blade midspan shroud
(leading edge). In the step area, some metal maybe turned or protruding from the midspan
Pg 7-32 Rev 1
Borescope
06/26/2012
shroud mating line (mushrooming). This protrusion is indicative of wear-through. A missing

pad on one face would initiate an accelerated failure of the mating surfaces.
Rev 1 Pg 7-33
Borescope
06/26/2012
Compressor Blade Midspan Damper Carboloy Pad.
Blade Deposits
Compressor blades and stator vanes exhibit varying degrees of cleanliness. Variables such as
air-inlet configuration, ambient atmospheric conditions, and air contaminants (chemicals, salt,
dirt, water, and so forth) all tend to affect the surface condition of the compressor rotor and
stator blades.
Airfoil And Tip Cracks
Cracks in the compressor hardware are difficult to detect because they are tight and shallow in
depth. You can miss these subtle effects because of deteriorated borescope optics or if you
rotate the rotor too fast. You should record all crack information relative to the stage, area,
magnitude, direction, and adjacent blade condition.
Cracked Dovetail
A cracked dovetail of a blade may lead to blade loss. The location of the blade will determine
the extent of engine damage. Before the actual catastrophic failure of the blade, the separated
crack in the dovetail will be evident by a leaning blade platform. You can find this fault by
using the borescope to inspect each blade platform. The leaning blade platform will be higher
than the adjacent nonleaning blades. e A "leaner" is a blade that has a crack on the aft ide of
the dovetail and is leaning in the forward direction (fig. 2-12). If a leaner is detected, it must
be verified and the engine should be removed from service.
Airfoil and Tip Tears.- The most critical area of a torn blade is the area around the end of the
tear and its location on the airfoil. You should inspect this area for cracks that lead from the
tear and are susceptible to propagation. This condition could lead to the loss of the airfoil
section that would create downstream impact damage. You should record all information such
as stage, blade locations, area of the blade in which the defect was found, and the condition of
the rest of the airfoil and adjacent airfoils. Section A of figure 2-11 shows the nomenclature of
a blade.
Leading And Trailing Edge Damage

FOD and DOD can cause random impact damage throughout the compressor rotor stages. The
leading and trailing edge of an airfoil is the area of the compressor blade extending from the
edge into the airfoil. You must assess both sides (or faces) of the airfoil when determining the
extent of a given defect. If you observe a defect, estimate the percentage of damaged chord
length. Observe the defect and the condition of the airfoil area around the defect. If the
observed damage is assessed to be "object damage," the most difficult determination is the
differentiation between cracks, scratches, and marks made by the passing objects. Cracks are
usually tight in the airfoils, but the apex of the damage usually allows viewing into the airfoil
Pg 7-34 Rev 1
Borescope
06/26/2012
thickness. This provides a direct inspection of the area around the crack You may have to use
all the probes at varying light levels to determine the extent of the damage.
Tip Curl
Compressor rotor blade tip curl is a random and infrequent observation. Tip curl is usually the
result of blade rub on the compressor case. Tip curl also can be the result of objects being
thrown to the outer circumferential area of the flow path and then being impacted by the
rotating blade tip (either leading or trailing edge). These curled tips are usually smooth in the
bend area of the airfoil distortion. However, you should inspect the area at the change in
normal airfoil for tears or cracks. When you report tip curl, estimate he percent of the chord
length, the number of blades with curl, and the condition of the adjacent airfoil area. Record
any evidence of impact and inspect for the origin of the impact. Always look at the adjacent
blades for evidence of tip clang.
Missing Metal
Missing metal from compressor rotor blade airfoils is a result of the progression of cracked or
tom airfoils that release part of the airfoil into the flow path. Crack propagation in the root
fillet area can result in the separation of the entire blade. Severe FOD or DOD may result in
several random rotor and stator airfoils with missing metal. The inspection report hould
include the stage, the number of blades with missing metal, the amount, and the location on
the airfoil. Estimate the percent of chord, the span of the airfoil that is missing metal, and the
condition of the remaining airfoil.
Airfoil Powdering
Compressor rotor blades may have aluminum particles visible on the airfoils in varying
degrees (from stage to stage). This powder is indicative of a possible compressor stall or a
hard blade tip rub.
Rev 1 Pg 7-35
Borescope
06/26/2012
COMBUSTION SECTION
Inspect the combustor for eroded or burned areas, cracks, nicks, dents, hot streaks, flatness of
liners caused by hot spots, blocked air passages, and carbon buildup. If damage is found in the
combustion section, it usually consists of a burn-through in the dome area adjacent to a fuel
nozzle. The problem can usually be traced to a loss of film-cooling air caused by upstream
debris or to a faulty fuel nozzle.
Cracking is not normally a problem, but you should photograph and report any suspected or
confirmed cracks. Carbon deposits around the fuel nozzles occur on all engines and are not
considered serious. These deposits build up only on the venturi and swirl cup rather than on
the shroud or discharge orifice. They do not usually interfere with the fuel spray pattern.
If you find cracking, evaluate it to ensure that no pieces will detach and cause any secondary
damage to the HP turbine.
Combustion Section Damage

In the following paragraphs, we describe some of the damage that you might find during a
borescope inspection of the combustion section. Because the dark surfaces in the combustion
section absorb light, you will need a 1,000-watt light source for a proper inspection.
Discoloration
Normal aging of the combustor components will show a wide range of color changes. This is
not a cause for concern. As operating time is accrued on the combustor assembly, an axial
streaking pattern running aft of every other circumferential fuel nozzle will occur. On low-
time assemblies, the coloration is random and has little or no information to aid you during
the inspection. As operating time increases on the assembly, you will observe significant
deterioration at the edges of the streaking patterns. Cracking will begin in the forward inner
liner panels and will propagate aft. The axial cracks tend to follow the light streaks. Panel
overhang cracking and liberation usually occur at the edge of the streaks.
Riveted Joints(LM2500 Series Engines)

The dome band and the inner and outer liner assemblies are joined by rivets as shown in
figure below. The presence and condition of the rivet heads and rivet holes are easily assessed
because of their position in relationship to the borescope ports. Record any missing rivets and
torn or cracked hole edges.
Pg 7-36 Rev 1
Borescope
06/26/2012
Combustion Liner Dome Rivet Joint.
Dome Assembly
Distortion of the trumpets and/ or swirl cups is random and occurs on high-time assemblies.
Record the distortion (in percent) of the edge and/ or span of the trumpet and the percent of
circumference versus diameter of the swirl cups.
Combustion Liner Dome Band And Plate Cracks.
Cracking in the dome band area occurs at relatively low operating time. Record the number
of cracks and their relationship to one another. Indicate if these cracks are parallel, T-shaped,
circumferential or angled to connect and separate part of the band, and so forth.
Rev 1 Pg 7-37
Borescope
06/26/2012
All the missing metal areas or burn-through must be recorded. For the dome bands, estimate
the magnitude by the number or partial/ circumferential span of the dimples and axially by
percent of span of the band overhang to the trumpet. Record the trumpet areas of burn-away
and burn-through of the dome plate around the swirl cups. Burn-through in the combustor
dome will reduce cooling flow to the HP turbine vanes. Monitor the HP turbine vane
condition as burn-through progresses.
Igniter Tubes And Ferrules

Inspect the two-igniter locations for the condition of the weld at the cutaway of the trumpet
and the dome band. The ferrules are visible from these ports. Record the condition for
evidence of cracking, loss of ferrule metal, or both. Cracking from the igniter tube aft to the
panel overhang is common.
Combustion Liner Dome Igniter Tube.
Pg 7-38 Rev 1
Borescope
06/26/2012
Inner And Outer Liner Assemblies

You can inspect all areas of the inner and outer liner assemblies aft of the fuel nozzles by
rotating and tilting the probe, and by varying the immersion depth. Some of the damage that
you may find is described in the following paragraphs.
Circumferential Cracks
The figure below shows an example of circumferential cracking on a high-time combustion
liner. This type of cracking occurs over the area of the inner liner stiffening bands. The bands
are viewed through the borescope inside the combustor assembly. Before actual cracking, the
thermal working of the liner shows stress lines. These lines will be visible in all panels. Take
care to inspect for the presence of cracks, not merely lines. A crack will be open and the
separation will show an edge. The distortion occurs so that the inner liner lifts up into the flow
path and the outer liner bends down into the flow path. These irregularities are usually
obvious when the liners are viewed through wide angle probe No. 2. When circumferential
cracking is observed, record the band number and the span of the cracking relative to the
number of cooling/ dilution holes. Use the diameter of the cooling holes as a comparative
measurement gauge.
Inner/ Outer Liner Cracks
Rev 1 Pg 7-39
Borescope
06/26/2012
Axial Cracks
Axial cracking usually starts at band No. 3 on the inner liners and propagates aft and forward.
As operating time is accrued, these axial panel cracks grow into three-legged cracks as seen in
figure above. The edges of these cracks will separate and the corners will lift into the flow
path. Inspect the areas aft and forward of these cracks, recording the axially separated cracks
that show a tendency to grow together.
DOD is the primary cause of damage to the HP nozzle and turbine rotor elements. It is caused
by pieces from the combustor liners cracking out of the panel overhangs and impacting with
the rotating turbine elements. The most serious problem is the separation of a large section of
liner that could cause significant damage. This usually occurs as a result of axial and
circumferential cracks growing together as shown in the figure above. It is important to record
the damage to adjacent areas of about 5 inches to either side of the damaged area. These areas
can grow together and liberate large pieces of material. These circumferentially spaced,
cracked areas are usually separated at every other fuel nozzle spacing along with axial color
streaking.
Inner/ Outer Liner Burns and Missing Metal
Pg 7-40 Rev 1
Borescope
06/26/2012
Missing Metal And Burn-Through

Inspect for the loss of metal at the panel overhang and the area between dimples. Bum-
through of the liners is not common. What is common are the bluish-black slag areas that
show roughness and appear to be oxidized. Inspect these areas carefully for T cracks because
they will propagate and open up.
Distortion
Distortion or bowing of the liner assemblies is extremely difficult to assess when viewed
through the borescope. If an axial streak (gutter) is observed to be out of contour, estimate the
relative distortion in terms of dimples spanned or in relation to the diameter of the dilution
holes. If the distortion is present at the No. 1 band, estimate the contour change at the dome
band relative to the panel.
Rev 1 Pg 7-41
Borescope
06/26/2012
HP TURBINE
Inspect the HP turbine for eroded or burned areas, cracks or tears, nicks or dents, and missing
blades. Knifing (erosion resulting in sharp edges) can occur on first-stage blades. The severity
will vary according to the cleanliness of the turbine inlet air. Check for pitting on the leading
edge near the root of the second-stage blading.
Cracking of the first-stage nozzle guide vanes is not very common, but photograph and report
any suspected cracks. First-stage vane surfaces at the juncture of the inner and outer platforms
have a tendency to corrode or erode. It would not be unusual for you to find several small
penetrations in a vane platform during its service life. Most of these penetrations remain small
and are not usually severe enough to warrant engine replacement. Record any such
penetrations and regularly inspect them for any changes in size or quantity.
Vane HP (concave) surfaces will show gradual erosion with time, and the trailing edge slots
will become elongated. When this degradation reaches maximum service limits, as noted on
the PMS card or in the manufacturer's technical manual, the engine must be replaced.
HP turbine second-stage blades have a service life that is dependent upon operating
conditions. Cracks are the major inspection criteria listed. You should document and report
any confirmed cracks. The most common form of degradation is deposit buildup and erosion;
this is not usually as severe as on the first-stage blades. The most serious form of damage that
you may find in this area is pitting in the root area, which you must document and report.
Hp Turbine Nozzle Damage

The first-stage turbine nozzle vanes are inspected simultaneously with the combustor and fuel
nozzles. The following paragraphs describe the common damage you may find during the
borescope inspections.
Discoloration
Normal aging of the HP turbine nozzle stage 1 vanes will result in coloration changes as
operating time is accrued. There is no limit relative to discoloration of HP turbine nozzle
vanes. Oxidation and/ or burning of the vane areas is accompanied by dark areas silhouetting
the initial distress. Cracks are shrouded in dark patches adjacent to the defect. Usually the
distress starts as a crack, followed by oxidation of the shroud adjacent to the crack. Impact
damage usually shows as a dark spot on the leading edge.
Leading Edge Damage

This type of damage can be found between the forward gill holes on the concave and convex
side of the leading edge.
Pg 7-42 Rev 1
Borescope
06/26/2012
Axial cracks form around the leading edge. Estimate the percent of span of the leading edge
or span relative to the nose cooling hole rows to determine the crack length.
Burns and spalling on the leading edge should not be construed as coloration only, but must
have actual metal oxidized (surface metal loss), but no holes through the leading edge.
Estimate the area boundaries by the nose cooling holes spanned both radially (up and down
the leading edge) and axially (around or across the leading edge). Record the number of vanes
affected.
Blocked cooling air passages on the leading edge is another type of damage. If multiple hole
blockage is observed, record the separation of the open cooling holes and the number of
adjacent plugged holes.
Airfoil Concave Surface

Radial cracks run spanwise in the vane airfoil surface (up and down the vane). Record the
relative chord position of the cracks. Record the relation of axial cracking versus radial
cracking, such as axial and radial cracks that intersect or join at the second row of gill holes.
The intent of the service limits are to preclude the liberation (break-out) of pressure face
pieces.
Other Airfoil Area Defects

The following paragraphs describe other airfoil area defects that you may find during the
inspections.
Burns and cracks on concave and convex sides (charred). Record the area and length, estimate
the length relative to the leading edge area (gill hole to gill hole and spanwise by span of
cooling or gill holes). Estimate the surface damage relative to separation of gill hole rows and
radially by gill or cooling holes.
Craze cracking. These cracks are superficial surface cracks, caused by high temperature. They
are random lines that are very thin in appearance with tight lines (no depth or width to the
cracks). There is no limit against this condition.
Nicks, scores, scratches, or dents. These defects are allowed by the service limit and may "be
present on any area of the nozzle vanes.
Cracks in the airfoil fillet at the platform - there is no limit restricting these cracks, except at
the leading edge area.
Metal splatter. Aluminum and combustor liner metal, when liberated by the compressor or
combustor, frequently splatter the surface areas of the stage 1 HP turbine nozzle vanes. There
is no limit for these deposits; however, abnormal amounts of this splatter is reason to inspect
the compressor.
Rev 1 Pg 7-43
Borescope
06/26/2012
Platforms
Cracking in the HP turbine nozzle stage 1 platforms is difficult to see from the combustor
borescope ports. When this area is viewed through the port, extreme magnification is afforded
even with probe No. 2. This is due to the closeness of the surface to the distal end of the
probe. Record the origin and end of the cracking and assess the magnitude using trailing edge
slots and gill hole rows for radial and axial dimensions.
Nicks, scores, scratches, and dents on platform surfaces are again masked from the combustor
ports, except for the forward areas. Viewed via borescope, the area is magnified. Record the
magnitude of the defect using the geometry of the trailing edge, gill hole rows, and gill hole
separation for comparative dimensions.
You must record burns on vane platform areas and use probe No. 1 to assess the conditions. If
a burn-through occurs, the inner and outer surface edge of the platform should be seen. This
difficult assessment can be done with the aid of a fiberscope. Any incomplete or doubtful
evaluation should be the subject of a followup check after a specified amount of operating
time.
HP TURBINE BLADE DAMAGE

When inspecting the HP turbine blades, you should use probe No. 2 with the 150-watt light
source. The following paragraphs describe some of the damage you may find.
Cracks In The Leading Edge

The leading edge of the stage 1 turbine rotor blades is the area forward of the gill holes.
Cracks in the leading edge can be caused by DOD impact (combustion liner pieces) or
thermal stress. An indication on the leading edge open enough to show depth is defined as a
crack. Some conditions may mislead you in the determination of the presence of cracks. Dirt
and debris buildup in layers on the leading edge, as shown in figure below, are not cracks. As
this buildup begins to flake off, the edge of the area where the flake came off causes visible
lines. These lines are irregular and appear to be cracks. The other common point of confusion
on leading edge cracks is on the convex side of the leading edge tip area. This area is subject
to "scratching" by the small pieces of combustor metal that pass through the HP turbine.
Cracks in the Trailing Edge

The trailing edge is the flat surface with cooling holes that forms the after edge of the blade
airfoil. Trailing edge cracks are difficult to see, but if a crack is suspected, use probe No. 1 for
increased magnification. Record the location relative to a cooling hole and the magnitude of
the crack. Record any plugged trailing edge cooling holes.
Pg 7-44 Rev 1
Borescope
06/26/2012
Cracks in Concave and Convex Surfaces

The airfoil surfaces are the areas aft of the gill holes back to the trailing edge. The tip area is
further restricted to that area above the tip cap. When you evaluate the airfoil serviceability,
do not consider the tip as a part of that area. Cracks in the airfoil surfaces are very tight, but
can readily be seen with probe No. 2. Airfoil surface cracks are irregular in edge appearance
and are not usually confined with streaks, which are usually straight in appearance. Record
the area by the percent of span or gill hole spacing equivalent for location and magnitude of
the cracking. For axial position, use an estimate of percent chord and the position relative to
the tip cooling film cooling holes.
Cooling Hole Blockage

The HP turbine rotor stage 1 blades are film cooled by air that flows out of the cooling holes.
Report plugged holes relative to the number of blades affected and the position and number of
plugged holes. Ensure the correct callout of the holes (such as the nose cooling, convex gill,
tip film cooling holes, and so forth.)
Distortion
Heavy impact damage to the leading edge of the blade usually results in distortion. When the
impact is severe enough, cracking and/ or tearing of the leading edge, adjacent to the impact
area, occurs. Record the magnitude and span location relative to the number of gill holes
spanned. Estimate the out of contour as percent of the leading edge frontal area width or
relative to the lateral spanning of the leading edge cooling hole rows.
Rev 1 Pg 7-45
Borescope
06/26/2012
HP Turbine Blade Flaking And Buildup.
Blade Tip Nibbling

The HP turbine rotor stage 1 blade tip nibbling is associated with hot running engines.
Momentary overtemperature operation (such as experienced during compressor stalls) has
exhibited this type of deterioration. This area of the blade is above the tip cap and located
about two-thirds of the chord aft from the leading edge. The Figure below shows a typical
"nibbled tip" as a result of a severe stall.
Blade Leading Edge Impact Damage

The two figures below show an impacted and distorted leading edge of a stage 1 HP turbine
rotor blade. (Note the cracking condition leading from the impact area into the airfoil surface.)
The critical part of this type of damage is the axial or chord wire cracking. If this cracking
progresses from the impacted damaged area into the convex or concave airfoil surface, the
damage can be severe.
Pg 7-46 Rev 1
Borescope
06/26/2012
HP Turbine Blade Tip Nibbling
HP Turbine Blade Impact Damage
Hp Turbine Blade Coating Failure

The HP turbine protective coating is the key factor in the service life of an LM Series engine.
The combined effect of film cooling and protective coating will extend the service life.
Coatings are thinly and uniformly applied by a vacuum film deposition process.
Coatings do not usually cause problems by chipping, peeling, or flaking. The normal failure
mode is usually by pitting, rub-off, or nicks and scratches. Occasionally a bubble will occur in
the surface coating during the coating process. If a bubble occurs, it will be tested at the
coating facility to ensure that it cannot be rubbed off the surface. These bubble imperfections
pose no problem to the engine. If the bubble area of the coating fails, you should monitor that
area to determine any further deterioration.
Rev 1 Pg 7-47
Borescope
06/26/2012
HP Turbine Rotor Stage 1 Blade -

Areas Of Severe Corrosion After Extensive Operating Time.
Hp Turbine Blade Failure Modes

Failures that you may observe during a borescope inspection include the following types:
1. Corrosion of the coating. This appears as pitting of the coating primarily in the 80-
percent span mid-chord region of the concave airfoil (thumbprint) side and the 20-
percent span mid-chord region (root print). This corrosion/erosion has not been found
on blades coated with BC23.
HP Turbine Leading Edge Impact Damage.
2. Cracks in all areas of the blade, including radial cracks in the tips. Cracks generally
start at the cooling holes.
3. FOD/ DOD, including nicks and dents. Aluminum spattering that appears as metallic
deposits on the blade. This results from compressor tip rubs.
4. HP turbine blade tip rubs. This results in coating removal and tip damage.
Pg 7-48 Rev 1
Borescope
06/26/2012
CORROSION
Characteristics
The appearance of corrosion will vary with the metal involved. The following discussion
includes brief descriptions of typical corrosion product characteristics. These descriptions are
only for the most common materials used in gas turbine propulsion and support equipment.
Iron and Steel

Possibly the best known and most easily recognized of all forms of metal corrosion is the
familiar reddish-colored iron rust. When iron and its alloys corrode, dark iron oxide coatings
usually form first. These coatings, such as heat scale on steel sheet stock and the magnetite
layer that forms on the inside of boiler tubes, protect iron surfaces rather efficiently. However,
if sufficient oxygen and moisture are present, the iron oxide is soon converted to hydrated
ferric oxide, which is conventional red rust. Hydrated ferric oxide, red rust, does not protect
surfaces. It destroys surfaces.
Aluminum
Aluminum and its alloys exhibit a wide range of corrosive attacks, varying from general
etching of surfaces to penetrating attacks along the internal grain boundaries of the metal. The
corrosion products of aluminum are seen as white-gray powdery deposits.
Copper And Copper Alloys

Copper and its alloys are generally corrosion resistant, although the products of corrosive
attack on copper are commonly known. Sometimes copper or copper alloy surfaces will
tarnish to a gray-green color, while the surface will remain relatively smooth. This
discoloration is the result of the formation of a fine-grained, airtight copper oxide crust, called
a patina.
Patina offers good protection for the underlying metal in ordinary situations. However,
exposure of copper alloys to moisture or salt spray will cause the formation of blue or green
salts called verdigris. The presence of verdigris indicates active corrosion.
Cadmium and Zinc

Cadmium is used as a coating to protect the area to which it is applied and to provide a
compatible surface when the part is in contact with other metals. The cadmium plate supplies
sacrificial protection to the underlying metal because of its great activity. During the time it is
protecting the base metal, the cadmium is intentionally being consumed. Zinc coatings are
used for the same purpose, although to a lesser extent. Attack is evident by white-to-brown-
to-black mottling of the surfaces. These indications do NOT indicate deterioration of the base
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metal. Until the characteristic colors peculiar to corrosion of the base metal appear, the
coating is still performing its protective function.
Nickel and Chromium Alloys

Nickel and chromium alloys are also used as protective agents. They are used as electroplated
coatings and as alloying constituents with iron in stainless steels and with other metals such as
copper. Nickel and chromium plate provide protection by the formation of an actual physical
non-corrosive barrier over the steel. Electroplated coatings, particularly chromium on steel,
are somewhat porous. Eventually, corrosion starts at these pores unless a supplementary
coating is applied and maintained.
TYPES OF CORROSION
As stated previously, corrosion may occur in several forms, depending upon the metal
involved, its size and shape, its specific function, the atmospheric conditions, and the
corrosion-producing agents present. Those corrosion types described in this section are the
most common forms found on gas turbine engines and machinery structures.
Direct Surface Attack

The surface effect produced by reaction of the metal surface to oxygen in the air is a uniform
etching of the metal. The rusting of steel, tarnishing of copper alloys, and the general dulling
of aluminum surfaces are common examples of direct surface attacks. If such corrosion is
allowed to continue unabated, the surface becomes rough, and in the case of aluminum, frosty
in appearance. Direct surface attack is sometimes referred to as uniform etch corrosion.
Galvanic Corrosion
Galvanic corrosion is the term applied to the accelerated corrosion of metal caused by
dissimilar metals being in contact in a corrosive medium.
Dissimilar metal corrosion is usually a result of faulty design or improper maintenance
practices which result in dissimilar metals coming in contact with each other. This is usually
seen as a buildup of corrosion at the joint between the metals. For example, when aluminum
pieces are attached with steel bolts and moisture or contaminations are present, galvanic
corrosion occurs around the fasteners.
Pitting
The most common effect of corrosion on aluminum alloys is pitting. It is caused primarily by
variations in the grain structure between adjacent areas on the metal surfaces that are in
contact with a corrosive environment. Pitting is first noticeable as a white or gray powdery
deposit, similar to dust, that blotches the surface. When the superficial deposit is cleaned
away, tiny pits or holes can be seen in the surface. These pits may appear either as relatively
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06/26/2012
shallow indentations or as deeper cavities of small diameters. Pitting may occur in any metal,
but it is particularly characteristic of aluminum and aluminum alloys.
Inter-granular Corrosion
Inter-granular corrosion is an attack on the grain boundaries of some alloys under specific
renditions. During heat treatment, these alloys are heated to a temperature that dissolves the
alloying elements. As the metal cools, these elements combine to form other compounds. If
the cooling rate is slow, they form predominantly at the grain boundaries. These compounds
differ electrochemically from the metal adjacent to the grain boundaries. These altered
compounds can be either anodic or cathodic to the adjoining areas, depending on their
composition. The presence of an electrolyte will result in an attack on the anodic area. This
attack will generally be quite rapid and can exist without visible evidence.
As the corrosion advances, it reveals itself by lifting up the surface grain of the metal by the
force of expanding corrosion products occurring at the grain boundaries just below the
surface. This advanced attack is referred to as EXFOLIATION. Recognition and necessary
corrective action to immediately correct such serious instances of corrosion are vital. This
type of attack can seriously weaken structural members before the volume of corrosion
products accumulate on the surface and the damage becomes apparent.
Fretting
Fretting is a limited but highly damaging type of corrosion caused by a slight vibration,
friction, or slippage between two contacting surfaces that are under stress and heavily loaded.
Fretting is usually associated with machined parts such as the contact area of bearing surfaces,
two mating surfaces, and bolted assemblies. At least one of the surfaces must be metal.
In fretting, the slipping movement at the interface of the contacting surface destroys the
continuity of the protective films that may be present on the surfaces. This action removes
fine particles of the basic metal. The particles oxidize and form abrasive materials that further
accumulate and agitate within a confined area to produce deep pits. Such pits are usually
located where they can increase the fatigue potential of the metal.
Fretting is evidenced at an early stage by surface discoloration and by the presence of
corrosion products in any lubrication. Lubricating and securing the parts so that they are rigid
are the most effective measures for the prevention of this type of corrosion.
Stress
Stress, evidenced by cracking, is caused by the simultaneous effects of tensile stress and
corrosion. Stress may be internal or applied.
Internal stresses are produced by non-uniform deformation during cold working conditions,
by unequal cooling from high temperatures during heat treatment, and by internal-structural
rearrangement involving volume changes. Stresses set up when a piece is deformed.
Examples of internal stresses include those induced by press-and-shrink fits and those in
rivets and bolts.
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Concealed stress is a more dangerous condition than design stress. Concealed stress corrosion
is difficult to recognize before it has overcome the design safety factor. The magnitude of the
stress varies from point-to-point within the metal. Stresses in the neighborhood of the yield
strength are generally necessary to promote stress corrosion cracking, but failures may occur
at lower stresses.
Fatigue
Fatigue is a special type of stress corrosion. It is caused by the combined effects of corrosion
and stresses applied in cycles. An example of cyclic stress fatigue is the alternating loads to
which the connecting rod of a double-acting piston in an air compressor is subjected. During
the extension (up) stroke a compression load is applied, and during the retraction (down)
stroke a tensile or stretching load is applied. Fatigue damage is greater than the combined
damage of corrosion and stresses. Fracture of a metal part due to fatigue corrosion generally
occurs at a stress far below the fatigue limit in a laboratory environment, even though the
amount of corrosion is very small. For this reason, protection of all parts subject to alternating
stress is particularly important wherever practical, even in environments that are only mildly
corrosive.
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Borescope Definitions
Condition of Part Code Definition Related Terms

Acceptable 01 Satisfactory for use OK, Checked OK
Battered 02 Damaged by repeated blows or impacts
Bent 03 Sharp deviation from original line or plane, Creased, Folded,
usually caused by lateral force Kinked
Example: Creased or folded sheet metal
Binding 04 Restricted movement such as tightening or Sticking, Tight
sticking condition, resulting from high or
low temperatures, foreign object jammed in
mechanism, etc.
Bowed 05 Curved or gradual deviation from original
line or plane usually caused by lateral force
and/or heat
Broken 06 Separated by force into two or more pieces Fractured
(Complete destruction of cohesion)
Bulged 07 Localized outward or inward swelling, Ballooned,
usually caused by excessive local heating Swelling
and/or differential pressures
Burned 08 Destructive oxidation, usually caused by
higher temperature than parent material can
withstand
Burred 09 A rough edge or sharp projection on the
edge of the surface of the parent metal
Carboned 10 Accumulation of carbon deposits Carbon Covered,
Coked
Chafing 11 A rubbed action between parts having Abrasion, Fretting
limited relative motion (as in vibration)
Chipped 13 A breaking away of the edge, corner, or
surface of the parent material, usually
caused by heavy impact (not flaking)
Corroded 14 Gradual destruction of the parent material Rusted, Oxidation
by chemical action. Often evidenced by
oxide buildup on the surface of the parent
material
Cracked 15 Visible partial separation of material which
may progress to a complete break
Curled 16 A condition where the tip(s) of compressor
blades or turbine blades have been curled
over due to rubbing against engine casing
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06/26/2012
Dented 17 A surface indentation with rounded bottom, Peened

usually caused by impact of a foreign
object. Parent material is displaced, seldom
separated
Deposits 18 A buildup of material on a part either from
foreign material or from another part not in
direct contact.
Distorted 19 Extensive deformation of the original Buckled,
contour of a part, usually due to impact of a Deformed,
foreign object, structural stresses, excessive Depressed,
localized heating, or any combination of Twisted, Warped
these.
Eroded 20 Carry away of material by flow of a fluid or
gasses, accelerated by applied pressure
Flake 21 A thin chip-like or scale layer of metal
Fretting 22 Wear in a ripple pattern, caused by friction Chafing,
Abrasion
Frosted 23 A dull, roughened surface finish
Fused 24 Joined together by two materials, usually
caused by heat or friction
Gall 25 A defect caused by movement of two See Pickup
surfaces in contact with each other. In most
cases an accumulation of foreign material is
deposited on the parent material.
Gouged 26 A scooping out of material, usually caused Furrowed
by foreign material
Grooved 27 Smooth, rounded furrow or furrows of wear,
usually wider than scouring with rounded
corners and smooth on the groove bottom.
(Example: A ball bearing wearing into a
ring could cause a grooved condition)
Indications 28 Cracked, inclusion, fracture, etc. Not visible
without fluorescent or magnetic penetrates.
Knifing 29 Erosion resulting in sharp edge.
Loose 30 Separation of a part from another part to Separated,
which it is normally affixed. Disengaged
Melted 31 Deformation from original configuration
due to heat, friction, or pressure as with
melted bearings or insulation
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Mismatched 32 Improper association of two or more parts
Mispositioned 33 Improper installation of a part, resulting in Misaligned,

damage to the installed part or to associated Reversed
part.
Nicked 34 A sharp surface indentation caused by
impact of a foreign object. Parent material
displaced, seldom separated
Obstructed 35 Prevention of free flow of a fluid (air, oil, Clogged,
fuel, water) because of foreign material in contaminated,
the flow path or malfunction in the flow Plugged,
member. Restricted
Over- 36 Subjected to excessive temperature, usually Heat discolored
Temperature evidence by change in color and appearance
of the part.
Oxidation 37 A surface deterioration by the chemical
reaction between oxygen in the air and the
metal surface. Attack is manifested as red
rust in iron and low-alloy steels when
formed at ambient temperature. The
oxidation which forms on super alloys are
complex and can be green or black,
depending on material composition and
temperature at which it is formed.
Part Missing 38 The absence of a required part. Loss
Peeled 39 A breaking away of surface finish such as Blistered, Flaked
coating, plating, etc. Peeling would be
flaking of large pieces. A blistering
condition usually proceeds or accompanies
flaking.
Pickup 40 Transfer of one material into or upon the Burr, Gall, High
surface of another, caused by contact spot, Imbedment,
between moving parts or deposits of molten Inclusion,
material on a cooler material. protrusion,
Metalization
Pinched 41 Distortion of one or more surfaces of the Bound, Tight,

parent material, caused by pressure Compressed,
Flattened, Seized,
Smashed,
Squashed,
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Pitted 42 Small irregular shaped cavities in the

surface of the parent material, usually
caused by corrosion, chipping, or heavy
electrical discharge
Rolled-over 43 Lipping or rounded of metal edge Lipped, Turned
metal
Rubbed 44 To move with pressure or friction against
another part, such as compressor rub.
Scuff 45 A surface roughened by wear Scrap, Scratch
Seizure 46 A welding or binding of two surfaces which Bound up, tight,
prevent further movement. Frozen, Wedged,
welded
Scored 47 Deep Scratch or scratches made on the part
surface by sharp edges of foreign
particulates
Scratched 48 Light, narrow, shallow mark(s) caused by
movement of a sharp object or particulate
across a surface. Material is displaced, not
removed
Sheared 49 Dividing a body by cutting action i.e.,
division of a body so as to cause its parts to
slide relative to each other in a direction
parallel to their plane of contact
Shingling 50 The effect of two adjacent surfaces
overlapping, usually caused by wear to one
edge of the lapping planes.
Spall 51 Broken or crushed material due to heat, or Chip
structural causes. Chipping off of small
fragments under the action of abrasion
Stall 52 A disruption of the normally smooth airflow
through the gas turbine. The compressor
blades stall in much the same manner as the
wings of an aircraft. A high-speed stall is
indicated by a rise of t4.8, with
corresponding reduction in XN2.5 and P3.
A sub-idle stall is indicated by a rapid rise
in T4.8 and hang-up of XN2.5. Personnel in
the immediate area of the base enclosure
may hear a chugging or a rumble during a
stall.
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Sulfidation 53 A form of hot corrosion in heat-resistant

alloys by the reaction at the metal surface of
sodium chloride (sea air) and sulfur (from
fuel). Attack usually over a broad front and
can be identified as gray or black blisters
(early stages) or surface delamination
(advanced stages).
Tip Clang 54 The banging together of the leading edge of
one blade and the trailing edge of the
adjacent blade during stall. Tip clang results
in trailing edge fretting.
Torn 55 Separation by pulling apart
Varnish Film 56 A hard surface film on metal, straw color to Banded,
very dark brown, buildup by exposure to Discolored,
dry chemicals or fluids (commonly oil) Oxidation,
while the part is heated above the Stained
breakdown point of the chemical or fluid.
Warped 57 Not true in plane or in line; out of true Distorted, Bent,
shape. Twisted, Buckled,
Contorted
Worn Excessively 58 Material of part consumed as a result of
exposure to operation or usage.
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Drive Motor, 2C14764G05/G06, and Adapter, 1C8208,

installation.
NOTE
 The gas turbine inspection drive motor permits one operator to control the
rotation of the gas turbine high pressure rotors for purpose of inspection. No
other personnel are required. The inspection drive motor will allow the gas
turbine high pressure rotors to be rotated in either direction at a very slow,
variable speed. The drive motor will not rotate the low pressure rotors
 The drive motor may be installed at alternate locations as required. Spline
adapter, 1C8208, is required for all drive motors. Spline adapter, 1C8208, can be
used at various accessory locations.
 The gas turbine can be rotated by hand using a 1/2-inch-drive wrench in the
borescope drive pad.
Remove nuts and washers that secure drive pad cover onto transfer gearbox (figure 1).
Remove cover from gearbox and discard preformed packing. Retain hardware for
reinstallation.
1 NOTE
This drive pad may be utilized as an accessory drive. If so, the accessory must be
removed for access to the pad. Refer to the packager's manual for removal/installation
instructions.
Install adapter plate onto gearbox drive pad (figure 1). Secure with nuts provided with
adapter plate. Tighten nuts to 55-70 lb in. (6.2-7.9 N·m) of torque.
Install drive shaft onto drive motor and tighten setscrew.
Insert drive shaft through hole in center of adapter plate and into spur gear. Ensure drive shaft
splines mesh with spur gear splines.
Secure drive motor to adapter plate with bolts and washers supplied with drive motor. Tighten
bolts to 420-510 lb in. (47.5-57.6 N·m) of torque.
Connect drive motor cord to control unit J3 motor connector.
Connect remote control cord to control unit J2 remote connector.
WARNING
Electrical power shall be off before connecting or disconnecting electrical connectors.
Electricity causes shock, burns, and death.
Connect three-prong power cord to control unit J1 power connector. Plug three-prong
Rev 1 Pg 7-139
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06/26/2012
connector into power source.
Operate drive motor during borescope as follows:
a. Move control unit power switch to ON position.
b. Select direction of rotor rotation for particular borescope inspection.
c. Move switch on remote control to forward or reverse as required. Adjust motor speed
on control unit to achieve desired rotor rotation speed. Operator may perform
borescope inspection as planned, and may vary speed and direction of rotation as
required.
CAUTION
Before reversing direction of rotation, bring rotor to a complete stop. Failure to stop the
rotor before reversing rotation may result in severe damage to the drive motor
mechanism.
d. To reverse direction of rotation, move directional selector to neutral position which

allows gas turbine to free wheel. Wait until rotor completely stops; then move
directional selector to opposite direction.
Drive Motor, 2C14764G05/G06, and Adapter, 1C8208, Removal.

WARNING
Electrical power shall be off before connecting or disconnecting electrical connectors.
Electricity causes shock, burns, and death.
Switch control unit off and disconnect power cord from power source and control unit.
Disconnect remote control and drive motor from control unit.
Remove drive motor from adapter plate by removing drive motor bolts and washers. Loosen
setscrew on drive shaft and remove drive shaft from drive motor.
Remove nuts that secure adapter plate onto transfer gearbox. Remove adapter plate from
gearbox.
NOTE
If drive pad is used for driving an accessory, install the accessory per
the packager's manual.
Install preformed packing, J221P134, and drive pad cover (figure 1) onto transfer gearbox
and secure with nuts and washers removed during drive motor installation. Tighten nuts to 55-
70 lb in. (6.2-7.9 N·m) of torque.
Pg 7-140 Rev 1
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SECTION 8A
LEVEL 1 MAINTENANCE
WORK PACKAGES
Rev 1 Pg 8A-1
Level 1 Gas Turbine Maintenance
06/26/2012
Pg 8A-2 Rev 1
06/26/2012
Level 1 Maintenance
Work Package Description Maint.

Level
WP 0001 00 Numerical List of Support Equipment, Consumables, and 1&2
Expendables
WP 1110 00 Axial Inlet Centerbody Assembly Replacement 1
WP 1111 00 Low Pressure Compressor Inlet Temperature Pressure (T2P2) Sensor 1
Replacement
WP 1112 00 Variable Inlet Guide Vane (VIGV) Actuator Replacement 1
SWP 1112 01 Variable Inlet Guide Vane (VIGV) Actuator Replacement with Fixed 1
Link
WP 1113 00 Variable Inlet Guide Vane (VIGV) System Check 1
WP 1114 00 Forward Seal Cover Plate Replacement 1
WP 1210 00 Low Pressure Compressor Speed (XN2) Sensor Replacement 1
WP 1310 00 High Pressure Compressor Inlet Temperature-Pressure T25-P25) 1
Sensor Replacement
WP 1311 00 Variable Bypass Valve (VBV) Actuator Replacement 1
WP 1312 00 Variable Bypass Valve (VBV) System Check 1
WP 1313 00 Bypass Valve, Bellcrank, and Actuating Ring Replacement 1
WP 1410 00 Variable Stator Vane (VSV) Actuator Components Replacement 1
WP 1411 00 Variable Stator Vane (VSV) Rigging 1
WP 1412 00 Variable Stator Vane 8VSV) Stages 3 to 5 Bushing Replacement 1
(High Boss HPC Stator Case)
WP 1510 00 Fuel System Replacement 1
WP 1511 00 Dual Fuel System Replacement 1
WP 1512 00 Gas/Water Fuel System Components Replacement 1
WP 1513 00 Liquid Fuel/Water Fuel System Components Replacement 1
WP 1514 00 Gas Fuel System Components Replacement 1
WP 1515 00 Ultraviolet Flame Sensor, L28490, Flame Sensor Sight Glass, and 1
Flame Sensor Bracket Replacement
SWP 1515 01 Ultraviolet Flame Sensor, L44819, Flame Sensor Sight Glass, and 1
Flame Sensor Bracket Replacement
WP 1516 00 Igniter Plug Replacement 1
WP 1517 00 High Pressure Compressor Discharge Temperature (T3) Sensor 1
Replacement
WP 1518 00 Compressor Discharge Pressure (CDP) Bleed Air Manifold And 1
Flange Cover Replacement
WP 1710 00 Low Pressure Rotor Speed (XNSD) Sensor Replacement 1
WP 1711 00 Low Pressure Turbine Inlet Temperature (T48) Thermocouple 1
Replacement-Inspection
WP 1712 00 Low Pressure Turbine Inlet Pressure (P48) Probe Replacement 1
WP 1713 00 Thrust Balance Valve (TBV) Assembly Replacement 1
WP 1810 00 Liquid Fuel Pump Assembly, Fuel Pump Adapter, and Quick 1
Disconnect Adapter Replacement
Rev 1 Pg 8A-3
06/26/2012

Level
WP 1811 00 Hydraulic Control Unit (Hcu) and Hydraulic Filter Assembly 1
Replacement
WP 1812 00 Variable Geometry Hydraulic Pump Replacement 1
WP 1813 00 Lube and Scavenge Pump Replacement 1
WP 1814 00 Pneumatic Starter Replacement 1
WP 1815 00 Hydraulic Starter and Distributor Assembly Replacement 1
WP 1816 00 High Pressure Compressor Speed (XN25) Sensor Replacement 1
WP 1817 00 Lube Resistance Temperature Detector (RTD) Replacement 1
WP 1910 00 Magnetic Chip Detector Replacement 1
WP 1911 00 Accelerometer Replacement 1
WP 1912 00 Liquid Fuel Manifold Temperature Sensor Replacement 1
WP 1913 00 External Piping, Hoses, and Electrical Harness Replacement 1
SWP 1913 01 Front Frame Module External Tubing, Harnesses, and Clamping 1
SWP 1913 02 Core Module External Tubing, Electrical Leads, and Clamping 1
SWP 1913 03 Low Pressure Turbine (LPT) Module External Tubing, Harnesses, 1
and Clamping
SWP 1913 04 Engine Assembly External Tubing, Harnesses, and Clamping 1
WP 1914 00 Fuel Pressurization Valve Replacement 1
WP 1916 00 High Pressure Compressor Water Injection (Sprint®) Kit Removal 1
and Installation
WP 3010 00 Gas Turbine In Enclosure Replacement 1
WP 3011 00 Preservation-Depreservation 1
WP 3012 00 Gas Turbine Maintenance Dolly Removal and Installation 1
WP 3013 00 Gas Turbine-Support Pedestal Removal and Installation 1
WP 3015 00 Gas and Dual Fuel Manifold Support Fixture Replacement 1
WP 4010 00 Gas Turbine Inlet Inspection 1
WP 4011 00 External Engine Cleaning 1
WP 4012 00 Gas Turbine External Inspection (Visual) 1
WP 4013 00 Gas Turbine Exhaust System Inspection 1
WP 4014 00 Gas Turbine Water-Wash 1
WP 4015 00 Borescope Inspection 1
WP 4016 00 Lube Oil Sampling 1
WP 4017 00 Lube and Scavenge Pump Chip Detector Inspection 1
WP 4018 00 Main Fuel Filter replacement 1
WP 4019 00 Fuel Pump Filter Check 1
WP 4020 00 Lube and Scavenge Pump Screen Check 1
WP 4021 00 Variable Geometry Pump-Hydraulic Control Unit Filter Check 1
WP 4022 00 Pneumatic Starter Servicing 1
WP 4023 00 Ignition System Functional Check 1
WP 4024 00 Vibration Monitoring System Functional Check 1
WP 4025 00 Overspeed Inspection 1
WP 4026 00 Over-temperature Inspection 1
WP 4027 00 Bearing Sump Flow Tests 1
WP 4028 00 Variable Stator Vane Off-Schedule Inspection 1
Pg 8A-4 Rev 1
06/26/2012
Level 2 Maintenance

Level
WP 0001 00 Numerical List of Support Equipment, Consumables, and 1&2
Expendables
Level
WP 2110 00 Variable Inlet Guide Vane (VIGV) Assembly Replacement 2
SWP 2110 01 Inlet Frame Replacement 2
WP 2210 00 Low Pressure Compressor (LPC) Module Replacement 2
WP 2211 00 Low Pressure Compressor (LPC) Stage 0 Rotor Blades Replacement 2
WP 2212 00 Low Pressure Compressor (LPC) Stages 0-3 Upper and Lower Stator 2
Case Replacement
WP 2213 00 Low Pressure Compressor (LPC) Stages 0-3 Stator Vanes 2
Replacement
WP 2214 00 Low Pressure Compressor (LPC) Stages 1-3 Rotor Blades 2
Replacement
WP 2215 00 Low Pressure Compressor (LPC) AFT Fan Case Replacement 2
WP 2216 00 Low Pressure Compressor (LPC) Stage 4 Stator Vanes Replacement 2
WP 2217 00 Low Pressure Compressor (LPC) Stage 4 Rotor Blades Replacement 2
WP 2310 00 Front Frame Air Collector Replacement 2
WP 2411 00 High Pressure Compressor (HPC) Upper and Lower Stator Case 2
Replacement
SWP 2411 01 High Pressure Compressor Upper-Lower Stator Case Opening- 2
Closing
WP 2412 00 High Pressure Compressor (HPC) Stator Vanes Replacement 2
WP 2413 00 High Pressure Compressor (HPC) Rotor Blades Replacement 2
WP 241400 High Pressure compressor (HPC) Stator Outlel Guide Vanes 2
Replacement
WP 2510 00 Combustion Chamber Replacement 2
WP 2511 00 Stage 1 High Pressure Turbine (HPT) Nozzle Replacement 2
WP 2610 00 High Pressure Turbine (HPT) Module Replacement 2
WP 2611 00 Stage 2 High Pressure Turbine (HPT) Nozzle (On Engine) 2
Replacement
WP 2612 00 Stage 2 High Pressure Turbine (HPT) Nozzle (Off Engine) 2
Replacement
WP 2613 00 Stage 1 High Pressure Turbine (HPT) Rotor Blades Replacement 2
WP 2614 00 Stage 2 High Pressure Turbine (HPT) Rotor Blades Replacement 2
WP 2710 00 Low Pressure Turbine (LPT) Module Replacement 2
WP 2711 00 Rear Drive adapter or Aft Seal Spacer Replacement 2
WP 2810 00 Radial Drive Shaft Replacement 2
WP 2811 00 Transfer Gearbox Assembly Replacement 2
WP 2812 00 Spur Gearshaft Assemblies Replacement 2
WP 2813 00 Accessory Gearbox Carbon Seals Replacement 2
WP 3014 00 Gas Turbine In Shipping Container Replacement 2
WP 3017 00 Low Pressure Turbine (LPT) Module In Shipping Container 2
Replacement
Rev 1 Pg 8A-5
06/26/2012
Pg 8A-6 Rev 1
06/26/2012
ICM, Interim, Letter, Paper
Rev 1 Pg 8B-1
06/26/2012
Pg 8B-2 Rev 1
06/26/2012
ICM – Installation and Commissioning Manual

This manual consists of all the requirements and procedures for installing and commissioning
the LM6000.
Interim – Interim Change Notice
Interim Change Notices are changes to the manual that have yet to be incorporated but are
still required actions.
Figure 1, Typical Interim Change Notice
Rev 1 Pg 8B-3
06/26/2012
Letter – GE Letters (Product & Service)
GE issues letters to make their customers aware of certain concerns, product specific or
service specific, experienced by users that may be of interest to other users. Typically
customer issues of minor importance.
Figure 2, Typical Product Letter
Pg 8B-4 Rev 1
06/26/2012
Papers - Position Papers (LM Series, LM6000, IEC NEC TCP 50/60 Hz)
A position paper is an essay that presents an opinion about an issue, typically that of the
author or another specified entity. Position papers are used by GE to make public the official
beliefs and recommendations of the group.
Figure 3, Typical White Paper
Rev 1 Pg 8B-5
06/26/2012
Pg 8B-6 Rev 1
06/26/2012

Maintenance Course

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Maintenance Course

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Solidaris LLC

1700 Rockville Pike, #535

LM6000 Gas Turbine

Presented by: S&W Energy Solutions, Inc.

Solidaris LLC advises that plant personnel read

This manual is not a replacement for experience

06A - Maintenance Administration

08A - Level 1 and Level 2 Work Packages

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MAINTENANCE MANAGEMENT SYSTEMS

Planned Maintenance System (PMS)

1. Define the minimum planned maintenance required to schedule and control

Benefits Planned Maintenance System

MAINTENANCE INFORMATION SYSTEMS

3. A persistent follow-up or tracking system to ensure that proper inspection and

4. An equipment repair and maintenance task priority assignment system that

7. Programs to analyze the effectiveness and cost of inspection and maintenance

8. Written notification to management and other affected departments so they will be

In most organizations, the maintenance information system uses computers to assist in

Maintenance Data System (MDS)

1. Maintenance Action Form (MAF) is used by maintenance personnel to report deferred

3. Parts Report is a listing of parts utilized for repair and maintenance.

Work Request Form, Operators to Maintenance Department

Maintenance Work Order Produced By The Program

Maintenance Task Assignments

OPERATOR EVENT LOGS

General Log Construction

Minimum information required:

1. The designated supervisor reviews the operations logbook.

3. On-coming shift supervisors to get overall picture of plant operation.

INDIVIDUAL EQUIPMENT OPERATING LOG

A typical operating log may contain entries such as the following:

1. Date and time of readings

Typical Equipment Log

EQUIPMENT HISTORY LOGS

Equipment history log entries may include the following:

Conduct Initial Performance

Conduct employee On the

Continually assess systems

Request technical assistance

Package Maintenance Levels

On-Site (External) - Level I

Off-Site (Medium Shop Repair) - Level II

Off-Site (Extensive Shop Repair) - Level III

MAINTENANCE WORK PACKAGE DEVELOPMENT

1. Engine Maintenance/Repair Work Packages

MAINTENANCE AND REPAIR RESPONSIBILITIES

Materials and Repair Parts

Identification of Repair Parts and Materials

1. Operation & Maintenance Manual

2. Nameplates on the equipment

4. Gas Turbine Serial Number

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Purpose of O&M Manual

Description Chapter-Section Volume

Title Page Front Matter I

Record of Ownership Front Matter I

General Information and Operating Instructions 1 I

Vendor Publications 5 V thru XVI

Lubricant Specifications Appendix A I

General Information This section is divided into four subsections, providing an

Maintenance This section is divided into four subsections, providing general

Parts This section contains recommendations on spare parts, lists of