2012 WTUI Conference LM2500 Breakout Session B k tS i March 18-21, 2012

,

Agenda
• Independent Depots • Engine Fleet Statistics • Recent Service Bulletins & Letters • CWC Breakdown • Depot Findings • Critical Parts Life Management • Engine Preservation, Handling and Transportation • Expected Maintenance Intervals • The Depot Experience

2012 WTUI Presentation LM2500 Breakout Session

2

Authorized Service Providers
Independent LM2500 Level 4 OEM Authorized Depots participating
Trans Canada Turbines (TCT), (TCT) Canada MTU Maintenance, Germany Steve Willard steve_willard@tcturbines.com Ph: +001 (403) 420 4290 Christian Czmok christian.czmok@mtu.de Ph: +49 (0) 3378 824-277

Avio, Italy Claudio Vinci cvinci@aviousa.com Ph: +001 201 625 3766

Air New Zealand Gas Turbines (ANZGT), New Zealand Chris Martin christopher.martin@airnz.co.nz Ph: +64 (9) 256 3990 64

2012 WTUI Presentation LM2500 Breakout Session

3

What does being Authorized mean?
GE Aero Energy authorizes a number of independent Authorized Service Providers for Level 4 engine maintenance service in specific locations. See Service Letter SL2500-11-02 for details. Level 4 Depots receive the following from the OEM: • Access to GE technical documents: • Access to GE parts and service support as defined in their license • Approved Vendor List for Component Repairs
• Departure Records (DR’s)/Deviation requests from GE to cover minor deviations (DR s)/Deviation

to the O&M and IRM’s.

All of the above helps ensure the performance and safety of the Equipment However Authorized Service Providers are fully Equipment. However, responsible for their own workmanship and for the decisions of how to apply GE’s maintenance, repair, overhaul, and test technology to their customer’s engines.

2012 WTUI Presentation LM2500 Breakout Session

4

Engine Fleet Statistics
(as of Dec 30, 2011)

Combustion System

ALL *

SAC 1156 55,862,543

DLE 403 9,791,607

Augmented/ Sprint (SAC) 20 1,852,443

Total Engines Total Operating Hours

1559 65,654,150

High Time Engine Engines In Service Total Operating Engines

230,377 1,499 1 499 1,006

230,377 1,102 1 102 735

120,055 397 271

167,579 20 13

* Approx 557 engines are LM2500+ and +G4

2012 WTUI Presentation LM2500 Breakout Session

5

Recent Service Bulletins and Service Letters

2012 WTUI Presentation LM2500 Breakout Session

6

Latest Service Bulletins
IND • • • • • • • • • • 230 233 232 229 231 117 158 228 225 221 Rev 01 00 00 00 00 02 CANX 00 01 02 Class C O O R C O O C C O Date 02/23/12 02/17/12 02/08/12 01/26/12 11/11/11 10/07/11 08/04/11 05/17/11 04/11/11 01/06/11 Description T5.4 Harness Support EU Pressure Equipment Directive Compliance HPC CDP Seal – Thin Ribbon Honeycomb y TMF Liner Improvement Electrical Harness Bracket Improvement Individually Replaceable t5.4 Probes Indi id all t5 4 P obes and Harnesses Acoustic Baffle Seal Simplification HPC Stage 0 Shroud bolted joint g j improvement Compressor Discharge Pressure Seal HPT Stage 1 Nozzle Outer Seal

2012 WTUI Presentation LM2500 Breakout Session

7

Recommended Service Bulletins
(LM2500 Base)

• •

For overhaul workscope the following Service Bulletin are recommended to provide best reliability on LM2500 Base (SAC/DLE) engines p y ( / ) g SB recommendation always depends on engine operation, customer, workscope

CFF 085 108 152 205 20

GBX 050 063 093 102 02 160

HPC 094 132 137 144 174 180 199 208 225

CRF 098 105 168 170 0 181 194 200 211 227

HPT 079 087 125 201 20 221

TMF 080 092 099 108 08 115 167 175 187 190/197 215 (202)

PT 024 065 092 099 165 183

Ext. 091 116 149 157 217 219 226

Acc. 082 173 179 198 98 213 222

2012 WTUI Presentation LM2500 Breakout Session

8

Recommended Service Bulletins
(LM2500 Plus)

• •

For overhaul workscope the following Service Bulletin are recommended to p provide best reliability on LM2500 Plus (SAC/DLE)/+G4 engines y ( / )/ g SB recommendation always depends on engine operation, customer, work scope
CFF 113 152 205 GBX 157 160 193 HPC 106 132 134 137 145/146 161 162 174 192 196 199 225 CRF 168 170 188 194 195 181 211 227 HPT 087 120 131 150 206 221 TMF 215 (216) PT 128 136 165 183 Ext. E t 154 155 185 186 217 219 Acc. A 107 173 179 213 222

2012 WTUI Presentation LM2500 Breakout Session

9

Recent Service Letter
SL
• • • • • • LM2500-IND-11-003 LM2500-IND-04-003 LM2500-IND-11-002 LM2500-IND-11-001 LM2500-IND-09-005 LM2500-IND-09-001

Rev.
R0 R1 R0 R0 R3 R1

Date
11.18.11 11.14.11 11.14.11 11.08.11 11 08 11 10.28.11 02.17.11

Description
Pressure settings for HP recoup and PT Thrust Cancelled Authorized Service Providers Authorized GE Service Providers EU Regulatory – Thermal Insulation Blanket Restart Procedure after a Hot Shutdown Elimination of Mechanical Protractor

2012 WTUI Presentation LM2500 Breakout Session

10

CWC Breakdown
• So what’s inside?

2012 WTUI Presentation LM2500 Breakout Session

11

CWC Breakdown
• So what’s inside?

2012 WTUI Presentation LM2500 Breakout Session

12

CWC Breakdown
• LM Tech Docs

2012 WTUI Presentation LM2500 Breakout Session

13

CWC Breakdown
• LM Tech Docs

2012 WTUI Presentation LM2500 Breakout Session

14

CWC Breakdown
• LM Tech Docs

2012 WTUI Presentation LM2500 Breakout Session

15

CWC Breakdown
• My Compliance Info

2012 WTUI Presentation LM2500 Breakout Session

16

Depot Findings
• CFF No. 3 Bearing Stationary Seal (ANZ) • CFF Front Frame Paint Peeling (Avio) • HPCR Spline Adapter Wear (TCT) • IGB Horizontal Gear Shaft Wear (Avio) • HPCR 14-16 Spool Rub (Avio) • HPCR Stage 16 Blades (TCT) • HPCR Blades Release (Avio) • HPCS VSV Off-Schedule Wear (TCT) • HPCS Lever Arm Wear (ANZ) • HPCS VSV Control Issue (ANZ) • CRF Expandable Bolts ( p (TCT) ) • CRF Mid Flange Cracking/Wear (TCT) • CRF DLE Vent Tube (MTU) • CRF Event (ANZ) b i ) • Combustor Burning ( (ANZ) • Combustor DLE Heat Shield (MTU) • HPTN1 Outer Leaf Seals (MTU) • HPTN2 Air Tube Issue (ANZ) • HPTR Stage 1 Blades (TCT) • HPT Damper Seal Corrosion(TCT) • Xtend Hot Section (TCT)/(ANZ) • Nozzle Ejector Tube (MTU) • TMF Hub IND-197 (MTU) • TMF Liner Wear (TCT) ( ) • TMF Leaf Seal Liberation (TCT) • TMF Strut Wear (SB 215) (AVIO) • TMF Cast Case (MTU) • LPTS Cover D C Damage (ANZ) • LPTS Honeycomb Damage (ANZ) • TRF Chafing Damage (TCT) • Misc - Starter Issue (ANZ) • Misc - Bearing Corrosion (TCT)

2012 WTUI Presentation LM2500 Breakout Session

17

Compressor Front Frame

2012 WTUI Presentation LM2500 Breakout Session

18

No. 3 Brg. Stationary Seal
Observed Condition
• • Delamination of the teflon type seal Completely delaminated in extreme cases

BASE
SAC DLE

PLUS
SAC DLE

© Air New Zealand Gas Turbines

Background/New Developments B k d/N D l t
• • • • •

Oil leaks present in the compressor flow path. Oil flowing from HPCS bushings seen in extreme cases. The operating temperatures within the A-sump are too high for the capability of the Teflon seal and adhesive (LM2500IND-085). 085) Teflon seal replaced with Metco 601 type per LM2500-IND205. New seal type with body made of stainless steel. Increased resistance against cracking and general damage.
© Air New Zealand Gas Turbines

2012 WTUI Presentation LM2500 Breakout Session

19

No. 3 Brg. Stationary Seal
Recommended Action/Timing
• Field
  Monitor for oil leaks, borescope HPCR if leak is present. , p p Field replacement possible per WP 218 and WP 221.

BASE
SAC DLE

PLUS
SAC DLE

Depot
 Embody LM2500-IND-205 with Metco 601 seal coating when required. h i d

© Air New Zealand Gas Turbines

© Air New Zealand Gas Turbines

2012 WTUI Presentation LM2500 Breakout Session

20

Front Frame Paint Peeling
Observed Condition
• During the Front Frame inspection, the item showed missing or peeling paint. Results of peeling paint was:  micro FOD/DOD by flaking  rust development on casting surface

BASE
SAC DLE

PLUS
SAC DLE

Background/New Developments
• In accordance with GE, a repair procedure for full repainting of Front Frame assembly has been implemented • IRM to be updated with paint procedure
Avio

Recommendations / Timing
• Field
 Paint condition: Check and monitor

• Depot

Full Paint removal by chemical process and full recoat of the part

Avio

2012 WTUI Presentation LM2500 Breakout Session

21

High Pressure Compressor Rotor

2012 WTUI Presentation LM2500 Breakout Session

22

Spline Adapter Wear
Observed Condition
• Red paste/sludge deposits are blocking Compressor

BASE
SAC DLE

PLUS
SAC DLE

Rotor(Stage 2 Disk) mounted Spline Adapter oil galleries. • Heavy spline wear to both Spline Adapter and mating IGB horizontal gearshaft. • More commonly seen on LM2500+ models.

Background/New Developments

• SB LM2500-IND-160 introduced a new “ruggedized” oil
nozzle with an improved oil jet impingement. • SB LM2500-IND-199 introduced a new Spline Adapter with extra Qty. x 4 drain holes to improve the flow of Qty lubrication through the spline interface. • Per SL2500-10-03R1 usage of HTS oil is not recommended by GE

2012 WTUI Presentation LM2500 Breakout Session

23

Spline Adapter Wear
Recommended Action/Timing
• Field
 Monitor oil pressure, A-sump scavenge oil temperature and filter check on regular basis  For LM2500+ engines, perform visual inspection of spline at every SAI  Switch to STD or C/I oils which are included in the latest revision of QPL

BASE
SAC DLE

PLUS
SAC DLE

• Depot

 Replace worn parts  Embody SB-160 and SB-199 if not already accomplished.

2012 WTUI Presentation LM2500 Breakout Session

24

IGB Horizontal Gearshaft Wear
Observed Condition
• • Light wear on Horizontal Gearshaft due to friction of Ring Seal Oil Inlet Gearbox P/N 9671M82P01/P02 Slight signs of oil on inner diameter of Air Duct

BASE
SAC DLE

PLUS
SAC DLE

Background/New Developments
• • New Seal Plain Encased P/N 9032M78P05 has been introduced. The new seal material is changed from bronze to Teflon Encased Viton O-Ring New seal provides better sealing and a improved temperature/oil resistance capability

Ring Seal Oil

Recommended Action/Timing
• Field

• Depot

Check ring seal condition onsite and replace as required

WEAR

 Replace Ring Seal P/N 9671M82P01 or P02 with Seal Plain Encased P/N 9032M78P05

2012 WTUI Presentation LM2500 Breakout Session

25

HPCR 14-16 Spool Rub
Observed Condition
• Abradable coating found with light wear. • It has been processed as per standard repair for the coating refurbishment  After the aluminum coating has been removed the area underneath revealed the exposed material with unexpected damage The inspection of the inner spool surface has shown the material discoloration

BASE
SAC DLE

PLUS
SAC DLE

Recommended Action/Timing
• Field
 Review operational procedures, if full load trip occurs BSI spool for damage

• Depot

 Comply with SB 144 (spool shaft configuration)  May be required to replace rotor spool  Inspect inside surface for discoloration when the external surface looks suspect  Recovery repair development program underway by OEM.

2012 WTUI Presentation LM2500 Breakout Session

26

Stage 16 HPC Blades
Observed Condition
 

BASE
SAC DLE

PLUS
SAC DLE

• Platform Trailing Edge Cracking

Recent incidents of platform cracking/liberation have been reported All reports have been on engines that are post SB 161/162

Background/New Developments
• At this time no solution has been presented
 GE states the Stage 16 blade has a 2nd torsional resonance frequency in platform and a 1st flex resonance in the engine operating range.  SB-161/SB-162 released for Plus units to correct the cracking of blade tip corners, but instances of platform cracking have still been noted.  SB-180 released for Base units as solution to blade airfoil & platform cracking, but is ONLY APPLICABLE to Stage 10-13 Spool/Shaft configuration compressor rotors.  SB 162 & SB 180 increase the quantity of Stage 15 Vanes (by one on SB-162 SB-180 one, upper stator case only) to reduce the dynamic stresses on the blades.  NEW stage 16 blade Inco 718 introduced. SB to be released Q2 2012.

Recommended Action/Timing
• Fi ld Field • Depot
 Monitor issue during BSI  Embody SB-161 & SB-162 on Plus units.  Embody SB-180 on Spool/Shaft config Base units  NDT Stage 16 Blades whenever exposed St Bl d h d

2012 WTUI Presentation LM2500 Breakout Session

27

HPCR Blades Release
Observed Condition
• Heavy damage on the compressor blades and vanes due to dovetail separation • Three blades of the 10th stage have been released g
Avio

BASE
SAC DLE

PLUS
SAC DLE

Background/New Developments

• Previous maintainence history of these blades were not known • Some historical dovetail separations due to H.C.F. [High Cycle Fatigue] have occurred in the fleet • Blades found with crack on dovetail; due to not having history, blade inspections did not occur

Avio Avio

CRACK ON DOVETAIL

Recommended Action/Timing
• Field
 Track time between maintenance of compressor blades RELEASED BLADE

• Depot

 Perform NDT as per IRM (Ultrasonic inspection, FPI etc.)

Avio 2012 WTUI Presentation LM2500 Breakout Session

28

High Pressure Compressor Stator

2012 WTUI Presentation LM2500 Breakout Session

29

VSV System Wear “Off-Schedule” Condition
Observed Condition
• • • • • • Missing or degraded/brittle actuation arm Sleeve “top hat” bushings. Worn actuation Ring segment/”bridge” Connector holes. Worn/loose vane actuation Arm pins. General wear and tear causing “play” in VSV actuation system system. Dirty condition will contribute to wear and tear. Dirty condition makes thorough inspection difficult.

BASE
SAC DLE

PLUS
SAC DLE

Background / New Developments

• Vane Actuation Arm bends in excess of 4 degrees “off-schedule” will cause that vane to create enough localized aerodynamic disturbance in relation to general airflow through compressor, that a once per evolution excitation to passing blades will eventually lead to a blade failure event due to HCF (high cycle fatigue). • E i ti Existing t li tooling i d i is designed t measure actuation A d to t ti Arm bend only, b d l whether installed (sight gauge) or piece-part (go/no-go gauge). • Piece-part inspections per manual requirements are to be applied to other VSV system components, ensuring a potential “off-schedule” condition does not exist due to excessive wear (e.g. elongated hole wear to Actuation Ring or worn/loose vane actuation Arm pin Ring, pin, etc).

2012 WTUI Presentation LM2500 Breakout Session

30

VSV System Wear “Off-Schedule” Condition
Recommendations / Timing
• Field  Keep VSV system clean. Replace defective parts immediately.

BASE
SAC DLE

PLUS
SAC DLE

• Depot

I Inspect vane actuation Arms using sight gauges for i A i i h f “off-schedule” condition.  Piece-part inspections to be applied to remaining VSV hardware.

 Inspect vane actuation Arms in-situ using sight gauge set to check for bend damage and potential “off schedule” condition “off-schedule” condition.  Use Go/No-Go Gauges when vane actuation arms are removed.  Inspect for general VSV system wear, specifically vane actuation Arms for loose or worn pins, actuation Ring segments for missing “top hat” bushings and elongation wear to pin/bushing holes, etc.

2012 WTUI Presentation LM2500 Breakout Session

31

VSV Lever Arm Wear
Observed Condition
• Visual gap observed between Lever Arms and Half Rings. • Both IGV and a few Stage 1 VSV Lever Arms appeared to be not fully seated against the Sleeve Bushings (Top Hats), Half Rings and/or Bridge Connectors, leaving a visual gap Connectors gap. • Further site inspections reported individual Actuation Ring Spacer ‘button’ to case clearances were not ideal with some clearances greater than IRM limits.

BASE
SAC DLE

PLUS
SAC DLE

Background/New Developments

• Not an unusual condition but concern that if disengagement was extreme, premature wear of the Top Hats could result due to reduced surface contact area/higher load concentrations. • This ‘disengagement’ condition is not generally over the full travel range of the VSV system stroke, due to flexing of the Half g y , g Ring/Bridge Connector combination and how the button clearance adjustments are made. • Possible that Half Rings or Bridge Connectors are distorted whilst meeting the IRM serviceable requirements. Also incorrect fitment of Lever Arms possible.

© Air New Zealand Gas Turbines

© Air New Zealand Gas Turbines

Recommended Action/Timing
• Field
 Confirm components have the correct P/N

• Depot

 Check P/N’s, inspect, function test and replace parts as required.
2012 WTUI Presentation LM2500 Breakout Session

32

VSV Control Issue
Observed Condition
• VSV Control would not function at site following a routine shut down.

BASE
SAC DLE

PLUS
SAC DLE

Background/New Developments

• VSV Control removed and the drive spline found to have excessive movement. • No oil leak noted on this occasion. • Modified to P/N L34379P04 via LM2500-IND-198. • Previous VSV Control issue was linked to oil leak and carbon face seal assembly found to be stuck open allowing an oil passage via the ‘o-ring’. • Under investigation.

Recommended Action/Timing
• Field
 If VSV Control does not function trouble shoot.  If VSV Control continues not to function remove and exchange. Changing the outer ‘o-ring’ seal will have no effect. effect
© Air New Zealand Gas Turbines

• Depot

 Send to authorized repair vendor for internal repairs.

2012 WTUI Presentation LM2500 Breakout Session

33

VSV Control Issue
© Air New Zealand Gas Turbines

BASE
SAC DLE

PLUS
SAC DLE

Inner Shaft

‘O-ring’ Seal Outer Body Spring Washer

Mounting Flange

Carbon Face Seal

Carbon Face Seal Assembly Pump Body Drive Shaft
© Air New Zealand Gas Turbines

Drive Spline (Knuckle)

2012 WTUI Presentation LM2500 Breakout Session

34

Compressor Rear Frame

2012 WTUI Presentation LM2500 Breakout Session

35

CRF Expandable Bolts
Observed Condition
• Relative motion between diffuser, CRF and mounting pins resulting in reduced service life.

BASE
SAC DLE

PLUS
SAC DLE

Background / New Developments

• GE introduced SB 153 which replaces the expandable bolts with PN 1753M57P01, however it is intended that these bolts continuously be replaced every 4000 hrs or ½ year interval. Can be done in the field. • GE introduced SB 170 which introduces a CRF change that allows replacement of expandable bolts with bolt PN L56202P01 which thread into the diffuser. To be done in the depot.

Recommendations / Timing g
• Field
 If Pre-SB 170 CRF installed, continue to inspect and replace bolts as required every 4000hrs or ½ year interval per SB 153.

• Depot
 Consider upgrade of CRF to incorporate SB-170 which removes the need to replace the bolts per SB-153.

2012 WTUI Presentation LM2500 Breakout Session

36

Mid Flange Damage
Observed Condition
• Radial cracks tend to propagate from “unused” mid flange bolt holes and extend outward through the edge of the flange and inward through the radius and into the case wall. • Elongated holes due wear from loose bracket bolts bolts. • Bend distortion due rough handling/incorrect positioning.

BASE
SAC DLE

PLUS
SAC DLE

Background / New Developments

• GE say alternating stresses in the boltholes are highest in the G a te at g st esses t e bo t o es a e g est t e 7,000 – 8,000 RPM range, hence Marine LM2500 programs introduced SB’s to install bolts/nuts in unused mid flange bolt holes to improve the structural integrity and the HCF (high cycle fatigue) margin by changing the stress pattern in the area around the holes • Industrial applications do not operate in same critical 7,000 – 8,000 RPM range so GE say no benefit in fitting bolts in unused bolt holes. • SB LM2500-IND-191 released to allow improved redesigned mid flange part (LM2500+ SAC) to be installed on SAC Base CRF as an upgrade Same SPAD mid flange replacement upgrade. repair nominated in GE Authorised Repair Manual EK112834 can be used to rectify an out-of-limit mid flange condition. • NOTE: Crack weld repairs on mid-flange (or case) no longer permissible.
 MTU M i  B li B d b © MTU Maintenance Berlin‐Brandenburg

2012 WTUI Presentation LM2500 Breakout Session

37

Mid Flange Damage
Recommendations / Timing
• Field
 Inspect mid-flange for bends, undue loading forces and cracks, especially at unused bolt hole locations during SAI and when exposed during maintenance events.  Check tighten mid-flange bolts for tightness at the same opportunity.

BASE
SAC DLE

PLUS
SAC DLE

• Depot

 Recommend SB-191 mid-flange SPAD replacement for major level work scope.  Replace mid-flange SPAD to rectify out-of-limit conditions per GE Authorised Repair Manual repair.

2012 WTUI Presentation LM2500 Breakout Session

38

Mid Flange Damage

BASE
SAC DLE

PLUS
SAC DLE

© Component Repair Technologies

2012 WTUI Presentation LM2500 Breakout Session

39

Mid Flange Damage

BASE
SAC DLE

PLUS
SAC DLE

© Component Repair Technologies

LM2500 CRF with replacement Mid-flange EB welded to forward ld d t f d casing and tack welded to aft casing

2012 WTUI Presentation LM2500 Breakout Session

40

Mid Flange Damage

BASE
SAC DLE

PLUS
SAC DLE

© Component Repair Technologies

• Complex repair • Can take longer than standard CRF repairs p

© Component Repair Technologies

2012 WTUI Presentation LM2500 Breakout Session

41

DLE CRF Oil Scavenge Tube
Observed Condition
• During incoming inspection of CRF determined contact between DLE CRF and Oil Scavenge

BASE
SAC DLE

PLUS
SAC DLE

Background / New Developments B k d N D l t

• Discovered in approximately four engines during disassembly in depot • Discovered wear/sharp edge at oil scavenge tube • So far no oil leakages have been caused by this issue • Highlighted to GE
© MTU Maintenance Berlin‐Brandenburg

Recommendations / Timing
• Field
  Can only be borescoped in field through the PS3 port No repair possible in field

• Depot
 

Check area during inspection process Smooth blending of chafed frame

© MTU Maintenance Berlin‐Brandenburg
2012 WTUI Presentation LM2500 Breakout Session

42

CRF Event
Observed Condition
• High ‘B-sump’ temperatures noted during operation. • A borescope inspection confirmed heavy coking indicating internal damage/wear within the CRF.

BASE
SAC DLE

PLUS
SAC DLE

Background/New Developments

• GG removed and sent to the depot for disassembly. • Disassembly confirmed that the rotating CDP seal had separated from the HPCR and was found seized in the CRF stationary vent seal. t ti t l • Ships de-icing system used but not modulated. • Thought that thrust balance/HPCR axial position affected due to de-icing system and shrinkage of stationary seal due to cold air. • Under investigation investigation.

© Air New Zealand Gas Turbines

Recommended Action/Timing
• Field
 Monitor sump temperatures carefully especially in conditions. extreme (cold) operating conditions

• Depot

 Send to authorized depot for investigation and internal repairs.

© Air New Zealand Gas Turbines

2012 WTUI Presentation LM2500 Breakout Session

43

CRF Event

BASE
SAC DLE

PLUS
SAC DLE

© General Electric

© Air New Zealand Gas Turbines

2012 WTUI Presentation LM2500 Breakout Session

44

Combustor (SAC)

2012 WTUI Presentation LM2500 Breakout Session

45

Combustor Burning
Observed Condition
• Missing (burnt) material from the splash plates observed. • TBC loss and associated base material loss due to burning in isolated positions observed. • Premature b burning rate suspected. d • Burning first noted to lease engine. • Then to Combustor, PN 9010M29G77 (TBC). Fuel nozzles changed ~2 000 hrs. Burning continued but at a reduced rate ~2,000 hrs rate. • Combustor replaced after ~7,000 hrs with PN L43663G01 (LM2500+, non TBC) as well as OEM overhauled fuel nozzles. • Burning continued. New OEM fuel nozzles installed. Combustor replaced with PN 9010M29G77 (TBC) after ~3,000 hrs. • Combustor replaced with PN L43663G02 (TBC) after ~8,500 hrs. p ( ) , • Thought to be due to water injection, water/fuel flow rate and/or combustor compatibility – under investigation.

BASE
SAC DLE

PLUS
SAC DLE

© Air New Zealand Gas Turbines

Background/New Developments

Recommended Action/Timing
• Field • Depot
 C fi Confirm NO requirements and/or fl NOx i t d/ flow rates. t  Contact CSM or ASP.  Check PN’s, repair/replace as required.  Review history and advise.

© Air New Zealand Gas Turbines

2012 WTUI Presentation LM2500 Breakout Session

46

Combustor Burning
© Air New Zealand Gas Turbines © Air New Zealand Gas Turbines

BASE
SAC DLE

PLUS
SAC DLE

© Air New Zealand Gas Turbines © Air New Zealand Gas Turbines

© Air New Zealand Gas Turbines

2012 WTUI Presentation LM2500 Breakout Session

47

Combustor (Dry Low Emissions)

2012 WTUI Presentation LM2500 Breakout Session

48

Heat Shields (DLE)
Observed Condition
• Burning/TBC loss detected in general after 50k hrs life. • Non-repairable conditions noted during visual inspection. p g p • Cracks in heat shields

BASE
SAC DLE

PLUS
SAC DLE

Background / New Developments
•P d i Per design, h t shield is brazed and not replaceable as heat hi ld i b d d t l bl single parts • Complete set of heat shields (75ea) need to be removed/ reinstalled • Only B-ring cut back heat shields for scrap replacement available • Cast Dome Plate design developed by OEM • OEM developed bolted heat shield design for single replacement • LM2500 +G4 DLE combustor removes wings from heat shields

2012 WTUI Presentation LM2500 Breakout Session

49

Heat Shields (DLE)
Recommendations / Timing
• Field
 Liberated heat shields require depot visit for repair repair.

BASE
SAC DLE

PLUS
SAC DLE

cut back heat shield design – B-ring with shorter wings

• Depot

 Rotable dome or rotable combustor is reasonable to keep high cost (long TAT) repair  Update to cut-back heat shield combustor will improve life

G4-design – B-ring without wings
2012 WTUI Presentation LM2500 Breakout Session

50

High Pressure Turbine Stage 1 Nozzle

SAC

DLE

2012 WTUI Presentation LM2500 Breakout Session

51

Nozzle Stg. 1 Outer Seal
Observed Condition
• Increased NOx emissions observed • Temperature spread observed • After removal of Nozzle 1 assembly for HS exchange, segments were found with damaged or missing outer seals

BASE
SAC DLE

PLUS
SAC DLE

Background/New Developments
• Sealing plates break due to high cycle fatigue or high temperature stress • Air leakages will cause hot spots • SB IND-221 will rework nozzle segments with improved outer seal support

Recommendations / Timing
• Field
 Replace nozzle stage 1 assembly per applicable work k package  Replace nozzle stage 1 assembly  Remove nozzle segments and rework per SB-IND-221

• Depot

2012 WTUI Presentation LM2500 Breakout Session

52

High Pressure Turbine Stage 2 Nozzle

2012 WTUI Presentation LM2500 Breakout Session

53

HPTN2 Air Tube Issue
Observed Condition
Retaining Ring

BASE
SAC DLE

PLUS
SAC DLE

• Disintegrated, missing and turned Cooling Air Tubes/‘spoolies’ and missing retainers and washers are common across engine lines. • ‘ ‘Spoolies’ f l ’ found worn, broken, damaged or turned. d b k d d d • Missing ‘spoolies’, retainers and washers and/or fragments found inside Nozzle Segments.

Air Cooling Tube

Spring Washer

Background/New Developments

© General Electric

• Turned ‘spoolies’ do not seem to have any affect on degradation of NGV airfoil. • Vibration and the temperature difference between nozzles and cooling air from the HPC are thought to be amongst the main reasons. • A study is ongoing at the moment across all engine lines.

Stage 2 NGV

Recommended Action/Timing
• Field
 Monitor via periodic inspections inspections.

• Depot

 Repair/replace when module exposed.
© Air New Zealand Gas Turbines

2012 WTUI Presentation LM2500 Breakout Session

54

High Pressure Turbine Rotor

2012 WTUI Presentation LM2500 Breakout Session

55

Damper Seals - Wear
Observed Condition
• Wear and corrosion to damper weight slot, retention wire and damper weight tang surfaces. • Damper weight becoming detached due wear and causing damage downstream (e.g. TMF liner puncture damage, etc.)

BASE
SAC DLE

PLUS
SAC DLE

Background / New Developments B k d N D l t
• Xtend Hot section has different design on damper seals

Recommendations / Timing
• Field
 N/A unless removing HPT blades for any reason.

• Depot

 Careful inspections required to determine wear to damper weight slot, retention wire and adjacent surfaces  Recommend replacement if reached 50,000 hrs.

© TransCanada Turbines

2012 WTUI Presentation LM2500 Breakout Session

56

LM2500 Hot Section Life Extension Programs

BASE
SAC DLE

PLUS
SAC DLE

XtendTM

Custome er Value C

ELHSTM
Twin Shank to Single Shank Single Shank HPT
• LM2500+ Technology… – 50,000 Hr HS Life – 25,000 Hr Combustor • 25,000 Hr HS Life • 25,000 Hr Combustor • LM2500+G4 Technology… – 50,000 Hr HS Life

1983
2012 WTUI Presentation LM2500 Breakout Session

2002

2006
57

Description
• The XtendTM and ELHS are only available for SAC engine configurations.

BASE
SAC DLE

PLUS
SAC DLE

• Although the ELHS is no longer available, both the Xtend and existing ELHS fleets will be supported.
•GE’s Extended Life Hot Section (ELHS) incorporated hot section components GE s from the LM2500+ gas turbine. Operating these improved materials at BASE LM2500 gas path temperatures enabled extended hot section life. • The XtendTM kit contains advanced hot section components developed for the LM2500+ G4 gas turbine. The kit also includes special fuel nozzles also designed to provide 2X life over the BASE LM2500. d i l i d li l • Ad Advanced materials, coatings, and component cooling i improvements result in the first 50,000** hour hot section.

2012 WTUI Presentation LM2500 Breakout Session

58

LM2500 Hot Section Upgrades – Configuration
S1 & S2 Shrouds

BASE
SAC DLE

PLUS
SAC DLE

•Component Xtend •HPTR (Blades) Plus •HPT S1 N G4 •HPT S2 N G4 •Shrouds G4

S1 Nozzle

S1 Blade

S2 Nozzle

S2 Blade Thermal Shield

•Component •S1 Blade

Base R80/PtAl X40/VPA R80/PtAl R80/PtAl Mar509/TBC R41/Bradealloy

Xtend N5/PtAl N5/TBC R80/PtAl N5/PtAl N2 N5
59

* XtendTM
Incorporates the Latest Design Improvements & Materials from the LM2500+ G4 the LM2500+ G4

•S1 Nozzle •S2 Blade •S2 Nozzle •S1 Shroud •S2 Shroud

2012 WTUI Presentation LM2500 Breakout Session

Hadward Modifications

BASE
SAC DLE

PLUS
SAC DLE

• Both XtendTM and ELHS Hadward Modifications consist of the following:
• • • • • • Increased cooling air flow from the stage 13 compressor bleed air manifold in order to provide increased cooling to the stage 2 HPT nozzle assembly New HPT cooling tubes (with increased orifice size) are required any time ELHS or XtendTM products are installed installed. Improved material properties, and coating capabilities Proven materials and coatings HPT stage 1 blade cooling increased T5.4 control limit increase of 25°F

** Operators should expect to see 2x their normal expected life based on their particular site conditions. Combustor may still require replacement prior to the rest of the hot section components.
2012 WTUI Presentation LM2500 Breakout Session

60

T5.4 Profile Shift
Observed Condition
• Plus hot section components result in a gas path temperature profile shift that causes the T5.4 probes to see 25 F before. “see” a temperature that is 25°F hotter than before • The 25°F increase that is seen by the T5.4 sensor drives the fuel valve to close.

BASE
SAC DLE

PLUS
SAC DLE

Recommendations

• An adjustment to the continuous indicated temperature control to compensate for the 25°F profile shift can be made in the control system with GE notification only. • This is not “over firing” the engine, rather just compensating for the shift in the profile shift.

2012 WTUI Presentation LM2500 Breakout Session

61

Nozzle Ejector Tube
Observed Condition
• Completely broken ejector tube during operation • Customer run the engine without problems

BASE
SAC DLE

PLUS
SAC DLE

© MTU Maintenance Berlin‐Brandenburg

Background/New Developments
• Sump pressurization insufficient • Sisk of coking the sumps

Recommendations / Timing g
• Field • Depot
 Perform periodic hardware inspections  Replace immediately if ejector tube is damaged  Replace/Repair ejector tube p p j  Check sumps for oil coking

© MTU Maintenance Berlin‐Brandenburg g

2012 WTUI Presentation LM2500 Breakout Session

62

Nozzle Ejector Tube
© General Electric Company © General Electric Company

BASE
SAC DLE

PLUS
SAC DLE

© MTU Maintenance Berlin‐Brandenburg

© MTU Maintenance Berlin‐Brandenburg

2012 WTUI Presentation LM2500 Breakout Session

63

Turbine Mid Frame

2012 WTUI Presentation LM2500 Breakout Session

64

TMF Hub IND-197
© General Electric Company

BASE
SAC DLE

PLUS
SAC DLE

Forward side © MTU Maintenance Berlin‐Brandenburg

Observed Condition
• • • • TMF hub with incorrect holes Causes insufficient cooling air to PT disk bore Results in disk overheating and growth Results in high PT vibrations

Aft side

Background/New Developments
• In 2006 Alert SB issued to check the hub through strut #3 • Check in field possible
 G l El i  C © General Electric Company

2012 WTUI Presentation LM2500 Breakout Session

65

TMF Liner Wear
Observed Condition
• The Oblate seal dislodges during movement between the liners due to thermal growth g • This causes the liner fairing to bind and wear on the struts and the inner liner bends under leaf seal load and wears on the strut fairing

BASE
SAC DLE

PLUS
SAC DLE

Background / New Developments

• The original liner design was a 2 piece inner and outer liner • One piece liner now available to replace the 2 piece liner.

© TransCanada Turbines

Recommendations / Timing d i i i
• Field • Depot
 Inspect liner for wear at hot section replacement  If worn, replace TMF  Repair at component repair vendor (if repairable)  Replace liner with new one piece liner

© TransCanada Turbines

2012 WTUI Presentation LM2500 Breakout Session

66

TMF Leaf Seal Liberation
Observed Condition
• Leaf seals found missing on frames • Some cases have not produced secondary damage as the leaf seals fall off into the TMF aft cavity y • Some cases have produced damage in the power turbine

BASE
SAC DLE

PLUS
SAC DLE

Background / New Developments

• Wear is being excited by vibratory load • Leaf seals are to be redesigned with a shorten length and a preload on all dimensional combinations • Changes will be incorporated with liner improvements (one piece liner)

Recommendations / Timing
• Field • Depot
 Inspect Seals at hot section replacement  If missing, complete a field repair or replace TMF  Repair at component repair vendor  Replace seals and liner when products become available

2012 WTUI Presentation LM2500 Breakout Session

67

Strut Oval Sleeves/SB-215
Observed Condition
WEAR • Excessive wear at No. 2 (C-Sump vent) and No.6 (9th stage cooling air and oil scavenge tube) locations between strut cap oval sleeve and tube.

BASE
SAC DLE

PLUS
SAC DLE

Background/New Developments

• GE studies show wear mechanisms are a combination of vibratory impact and sliding due to relative thermal growth between case and strut. • GE testing has shown improved wear characteristics when oval sleeve material was changed from 347SS to L605. • SB LM2500-IND-215 released to introduce improvement.

• Field

Recommendations/Timing R d ti /Ti i
 Specifically inspect areas during Periodic Inspection or when exposed. (Refer Service Letter No. 2500-I-04-07)  Replace both No. 2 and No. 6 oval sleeves with latest L605 material parts per SB-215 at TMF overhaul or heavy repair visit.

•D Depot t

WEAR

2012 WTUI Presentation LM2500 Breakout Session

68

BASE

PLUS
SAC DLE

TMF Cast Case IND-202
Background/New Developments
• Fabricated case has experienced cracking near to aft flange due to temperatures and stress • Cast Case Design, one piece case • Thickness increase in areas that require reduction in stress • SL SL2500-I-02-01 is not necessary anymore

SAC DLE

Recommended Action/Timing
• Field
 Complete exchange of TMF is possible per WP 208 00or WP 208 01  Introduction requires Retaining Ring L50630P01/P02  Outer Seal 9084M71P02 required  Fabricated TMF can be reworked to Cast TMF configuration by authorized service provider  Introduction requires Retaining Ring L50630P01/P02  Outer Seal 9084M71P02 installed on G-Series

• Depot

2012 WTUI Presentation LM2500 Breakout Session

69

Low Pressure Turbine Stator

2012 WTUI Presentation LM2500 Breakout Session

70

LPTS Cover Damage
Observed Condition
• Cover (LPT Stage 1 Nozzle Insulation Cover Segment) forward surface and corner chafing/fretting wear due to contact with LPT Stage 1 Nozzle outer lip. • Cover cracks/breaks up into sections creating damage to LPTS vanes and/or LPTR blades. • Worn LPTS vanes and outer sealing strips. • Worn LPTS case forward ring (rail) from chafing and fretting contact by Cover forward edge.

BASE
SAC DLE

PLUS
SAC DLE

Background/New Developments

• Due to the LPTS Case design, field replacement of damaged cover segments is difficult - a field type repair is available. • Weld repairs to LPTS case available per CF6-6 manual. • ‘Thick’ flange/SB-099 conversion/LM2500+ configuration g / / g LPTS case still retain similar Cover design thus, potential wear to ring.

© Air New Zealand Gas Turbines

Recommended Action/Timing

• Field  Inspect Covers/Nozzles for damage whenever exposed  Talk to Depot if unserviceable. • Depot  Inspect Covers/Nozzles for damage whenever exposed.  Replace Covers with new at depot level.

© Air New Zealand Gas Turbines

2012 WTUI Presentation LM2500 Breakout Session

71

LPTS Cover Damage

BASE
SAC DLE

PLUS
SAC DLE

© Air New Zealand Gas Turbines

© Air New Zealand Gas Turbines

© Air New Zealand Gas Turbines © Air New Zealand Gas Turbines

© Air New Zealand Gas Turbines

2012 WTUI Presentation LM2500 Breakout Session

72

LPTS Honeycomb Damage
Observed Condition
• Case fretting wear/honeycomb imprint from HCB (honeycombbacked) insulation left on case.

BASE
SAC DLE

PLUS
SAC DLE

© Air New Zealand Gas Turbines

Background/New Developments

• LPT Stage 1 honeycomb backed insulation was introduced as an improvement to replace foil bag type insulation for ‘thick’ flange Industrial configuration. •H Honeycomb backed insulation is also applicable to bb k di l ti i l li bl t Commercial Marine ‘thin’ flange configuration which had specific flange area cracking issues. • Honeycomb backed insulation is NOT APPLICABLE to ‘thin’ flange Industrial configuration.
© Air New Zealand Gas Turbines

Recommended Action/Timing
• Field
 None  Inspect area whenever exposed for this type of damage.  Send Cases to GE authorized Repair Vendor for repairs.  Replace insulation with new whenever area exposed.

• Depot

2012 WTUI Presentation LM2500 Breakout Session

73

Turbine Rear Frame (TRF)

2012 WTUI Presentation LM2500 Breakout Session

74

TRF Frame Chafing Damage
Observed Condition
• Strap located incorrectly  Fretting/Chafing wear to adjacent ground handling clevis mount structure.

BASE
SAC DLE

PLUS
SAC DLE

Background/New Developments

• External Insulation Kit developed • Frame  IRM serviceable limit is 0.016 inches deep following removal of high metal to TRF frame in clevis mount areas, otherwise full blending repair is required per GE Standard Practices Manual.

Recommended Action/Timing d d i / i i
• Field
 Check correct strap locations during periodic inspections  Adjust if required to give clearance.  Check correct strap locations during kit installation and during inspections

•D Depot t

2012 WTUI Presentation LM2500 Breakout Session

75

Misc – Starter Issues
Observed Condition
• Continuous start attempts/failures. • Flames emitted from the exhaust stack whilst starting the GG. • Multiple Starter events. l l

BASE
SAC DLE

PLUS
SAC DLE

© Air New Zealand Gas Turbines

Background/New Developments

• The correct restart procedure was reported as not being followed (no dry motor) motor). • Internal components of the Starters showed; signs of overheating, bearing failures, gear failures and seized components which, could be attributed to a lack of oil to the internal components. • Under investigation.

© Air New Zealand Gas Turbines

Recommended Action/Timing
• Field
 Carry out the correct start/restart procedures IAW the OEM manuals manuals.  Inspect/investigate the removed Starters.

• Depot

2012 WTUI Presentation LM2500 Breakout Session

76

Misc - Bearing Corrosion
Observed Condition

BASE
SAC DLE

PLUS
SAC DLE

Corrosion to Mainline and Gearbox Bearings  Abnormal corrosion and pitting noted to all parts of the bearings  Some cases have caused an increase metal particle count

Background/New Developments

Improper drying techniques and long periods without operation  Noted in marine/offshore environments  Units are being water washed and then dried and not operated or ranked for long periods of time. The moisture that remains in the sump is attacking the bearing surfaces

Recommended Action/Timing
• Field • Depot  Inspect and replace bearings as required
 Routinely crank engine to oil wet bearings y g g  Ensure engine is dried after water washing

2012 WTUI Presentation LM2500 Breakout Session

77

Critical Parts Life Management (CPLM)

2012 WTUI Presentation LM2500 Breakout Session

78

Critical Parts Life Management
(LM2500 Base)

2012 WTUI Presentation LM2500 Breakout Session

79

Critical Parts Life Management
(LM2500 Plus/+G4)

2012 WTUI Presentation LM2500 Breakout Session

80

Critical Parts Life Management
Observed Condition
• Experiencing difficultly getting full GG/GT and individual Critical Life

Parts (e.g. Hot Section) operating history required to calculate Accumulated Cycles used/remaining for each each.

Background/New Developments

• Operating stresses / cycles result in Thermal Mechanical

Fatigue and dimensional “Creep” changes Creep • Critical Parts are those that under sudden fracture can threaten the structural integrity of the engine/package. (Typically, major rotating parts, excluding airfoils). • Aero engines first to adopt Life Limits for Critical parts. • Commercial Marine introduced CPLM then Industrial Base

Recommended Action/Timing
• Field
 Customer/Operator responsible to record operating

hours partial cycles, full cycles, etc. cycles cycles etc hours,

• Depot  Have an obligation to assist in calculating Accumulated Cycles for each Critical Life Part and tracking sheets.

2012 WTUI Presentation LM2500 Breakout Session

81

Critical Parts Life Management
What to do in the absence of information?
• If you have total hours on engine and the number of fired starts, an estimate of cycles can be done  as shown in the below example on a HPC 3 – 9 spool. Table 6 -1 provides declared life for critical rotating components. The cycle life of a 3-9 spool is 14,200 along with the K factors of Kf = 1, Kp = 0.5, Kt = 0.5. (Note Kp and Kt are N/A in table 61. Values used here are to give a conservative estimate) The 3-9 spool had ~100,000 TSN and 3350 fired starts. The following assumptions were used to determine a conservative estimate of the cycles: • • • • • Total hours on spool are 100,000 (known) + 20,000** = 130,000 hrs TSN Fired starts 2500 (known) + 250** For every full cycle there existed 1 partial cycle All partial cycles assumed to be X>75 and <100 (worst case) Assume 1 trip cycle every 500 hrs of operation

** - these hours and starts were used to account for any error in the historical data. (~20% more hours for every 50,000 hrs run time and ~10% more starts for every 1000 fired starts)

Using the above data and assumptions you get the following: Number of full cycles = 2750 Number of partial cycles = 2750 Number of trip cycles = 260 Total cycles = Kf(2750) + Kp(2750) + Kt(260) = 4255 Cycles

< 14 200 Cycles 14,200

* Results based on ideal estimates that do not account for unscheduled or abnormal operation deviations.   Data is for reference purposes only.  Individual operators responsible to collect and track site specific data.
2012 WTUI Presentation LM2500 Breakout Session

82

Engine Preservation Engine Handling Engine Transportation

2012 WTUI Presentation LM2500 Breakout Session

83

Engine Preservation
Typical Considerations
• Duration  Short term is defined as less than 30 days.  Long term is anything greater than 30 days days. • Environment  Engine can be stored either in package or alternatively in a Shipping & Storage Container which can be pressurized.  High humidity is the greatest threat to engine bearings

Preservation in Package

• Short Term  If engine is going to sit idle for more than 15 days, operators should oil wet bearings using Brayco 483 or equivalent.  Recommended to cover inlet, exhaust and VBV. • Long Term  Oil wet bearings using Brayco 483 or equivalent.  Recommended to cover inlet and exhaust  Oil wet bearings again every 30 days.

Lube Oil Preservation Unit

2012 WTUI Presentation LM2500 Breakout Session

84

Engine Preservation
Preservation in Container
• Short Term  Oil wet bearings using Brayco 483 or equivalent.  Install desiccant into container.  Seal container. • Long Term  Same as short term except desiccant must be inspected every 30 days days.  If indicator is blue, no action required.  If indicator is pink, replace desiccant and oil wet bearings within 14 days.  Recommended to oil wet bearings every 60 days regardless of condition of desiccant/indicator.

Recommended Action
• REFERENCE O&M MANUAL, VOLUME 2, WORK PACKAGE (WP) 501-00 • KEEP A LOG !!!! • High Humidity Environments  If engine is stored in an environment with high humidity, oil wet bearings every 30 days and verify desiccant every 15 days.

2012 WTUI Presentation LM2500 Breakout Session

85

Engine Handling
Observed Condition
• Handling Issues  Confusion over correct container lifting points with GG/GT inside

Background/New Developments • Lift Points

Top – Engine / container is designed to be lifted from the 4 lifting rings at corner areas of the lid providing all T-bolts are installed. Tie Down Bars – These are NOT be used for lifting the container Bottom – There are fork lift slots that can be used to lift container with GG/GT inside off ground and transported over short distances. Placard - GE planning to add the following in red paint on all shipping containers:

“Warning TRANSPORT ONLY ON AIR RIDE EQUIPPED TRUCK AND TRAILER”. TRAILER”

Recommended Action/Timing
• Field
 Check T-bolts and container “lifting points” for serviceability

• Depot  As above

2012 WTUI Presentation LM2500 Breakout Session

86

Engine Transportation
Observed Condition
• Bearing Damage  Brinelling to bearing surfaces  Probable vibration step indication in operation  Bearing metal (M50 steel) on Mag Plugs / Scavenge Screen

Background / New Developments

• GE recommends the use of tractor and trailers that have

• Recommended corrective action for engines shipped on non • GE have developed an retro-fit air ride suspension kit for Shipping &

p pneumatic “air ride” suspension to prevent bearing damage. p p g g

pneumatic suspension, is to replace all main line bearings.

Storage Containers, allowing a gas generator/gas turbine to be transported safely in remote areas of the world where no “air ride” truck/ trailer unit is available . Blue painted base denotes container • modified for kit retro-fit. Train trials to be conducted soon by GE.

Recommendations / Timing
• Field

g y p , p y y  Investigate any vibration step indications, especially if recently installed following transportation  Organize approved transporting methods to and from site.

• Depot  Promote correct handling and transportation methods.  Main Bearings must be accessed and inspected if engine mishandled.

2012 WTUI Presentation LM2500 Breakout Session

87

Expected Maintenance Intervals

2012 WTUI Presentation LM2500 Breakout Session

88

Expected Maintenance Intervals
Background / New Developments
• General Electric has designed the LM2500 Gas

Turbine t reach 50,000 operating hours, and itis T bi to h 50 000 ti h d iti generally understood from a budgeting/planning perspective that a Depot “overhaul” visit would be required by that time or earlier, depending on specific site operating conditions. when a major overhaul should performed
• Generally there is no instruction from the manual, • In earlier presentation there was only a rough

workscope recommendation given from GE

2012 WTUI Presentation LM2500 Breakout Session

89

Expected Maintenance Intervals

2012 WTUI Presentation LM2500 Breakout Session

90

Expected Maintenance Intervals
Basically, maintenance intervals depend on engine operation operation, handling and also preventive maintenance

• There is no standard workscope

engine incoming condition

• Workscope always depends on

2012 WTUI Presentation LM2500 Breakout Session

91

Depot Experience

2012 WTUI Presentation LM2500 Breakout Session

92

The Depot Experience
Tips for a Successful Depot Experience
• • • •

Open a dialogue with your depot to create an effective workscope Combine disassembly level with related Service Bulletin Incorporation Notice effort of disassembly for incorporation of some SB´s “only” Avoid “Hold Days” due to detailed defined workscope

2012 WTUI Presentation LM2500 Breakout Session

93

The Depot Experience
Tips for a Successful Depot Experience

Customer to provide engine history to Depot (i.e. Ques o a e) Questionnaire)
 TSN, TSR, critical parts life hours  Provide last borescope report  Provide specific component history (i.e. operational hours on key components: Combustor, HPT, etc.) Combustor HPT etc )  Describe any operational event history or known issues  Provide Service Bulletin history and vouchers  Provide last Depot report

© MTU Maintenance Berlin‐Brandenburg

2012 WTUI Presentation LM2500 Breakout Session

94

The Depot Experience
• • • •

Discuss expectations for future life (“workscoping to a budget”) Discuss YOUR reliability/availability and performance needs Consider an incoming test for engine repair What are your “hot” buttons? at a e you ot butto s
 

Cost vs. turnaround time Replacement parts

© Air New Zealand Gas Turbines

 (used serviceable vs. new/overhauled) vs  Usage of rotable parts

2012 WTUI Presentation LM2500 Breakout Session

95

The Depot Experience
What should you receive from your Depot visit?
• • • •

Incoming report (photograph & record of missing parts) I i ( h h d f i i ) Inspection report and cost estimate Weekly status reports Final report
  

Inspection findings On-off log SB compliance

Test report

2012 WTUI Presentation LM2500 Breakout Session

96

The Field Service Experience
Tips for a Successful Field Service Experience

Open a dialogue with your field service provider to create an effective workscope and parts supply list
  

Combine outage with Service Bulletin (Field Level) Incorporation Identify available resources at site including manpower, parts, dollies and tooling y g p ,p , g Identify resources required by field service team including manpower (technical, controls expert, mapper), parts and tooling Avoid d l A id delays b h i by having equipment, package, parts and man power available at ti i t k t d il bl t time of f outage Establish site specific HSE requirements up front:  Confined space training?  H2S Training?  Site specific PPE requirements?

2012 WTUI Presentation LM2500 Breakout Session

97

The Field Service Experience
Tips for a Successful Field Service Experience

Customer can expect to provide the following:
 

TSN, TSR, critical parts life hours Site specific orientation  Site Emergency Response plan (including contacts)  First Aid Facility and equipment locations  Emergency escape routes  Lunch/Break rooms

 

Load testing and inspection certificates for lift equipment Clean and safe work environment  Slip hazards contained  Isolations in place (confirm with field team)  LOTO’s in place LOTO s

2012 WTUI Presentation LM2500 Breakout Session

98

The Field Service Experience
Tips for a Successful Field Service Experience

Customer can expect the following from its ASP: C h f ll i f i ASP

ASP certifications including, but not limited to the following:  ISO 9001 (Quality Management Certification)  ISO 14001 (Environmental Management Certification)  OHSAS 18001 (Health and Safety Management Certification)

Trained and Professional Field Service Representatives  Ask for OEM training certificates

  

Site visit report including findings and recommendations Depot level Engineering support (if needed) Access to the right Parts and Tooling necessary to complete the work

2012 WTUI Presentation LM2500 Breakout Session

99

Thank You...Questions?

2012 WTUI Presentation LM2500 Breakout Session

100