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LM6000 GENERATOR PACKAGE

BASIC OPERATORS COURSE

SECTION 1
COURSE INTRODUCTION

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SYSTEM PACKAGE OVERVIEW

OVERVIEW OF GE AERO ENERGY PRODUCTS


GE Aero Energy Products is a leading supplier of diesel and aeroderivative gas turbine
packages for industrial and marine applications with many units operating throughout the
world.
We take single-source responsibility for the total equipment package, and we provide field
service for the equipment once it has been installed.
We put our best into each unit that we buildall our skill and field experience. We meet our
customers needs with standardized designs, which have been proved and reproved in tropic
heat, desert sand, and arctic cold.
For our customers special requirements, we add features from our list of pre-engineered
options. Then we build the unit with care in a modern factory and test it rigorously, under
load, before shipment.
Our obligation doesnt end when the unit rolls out our door. We provide job-site supervision
and operator training. We offer total plant operation and maintenance, if desired. Then we
back up our customers with a multimillion-dollar inventory of turbine parts and a service
department ready to perform field service anywhere in the world24 hours a day, 365 days a
year.
Meeting our customers requirements for quality, dependability, and outstanding service has
been the basis of the GE Aero Energy Products reputation since day one.
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PURPOSE OF THE COURSE


This training course will familiarize system operators with the basic operation of the gas
turbine-generator (GTG) set, alternating current generator, and subsystems that make up the
GTG set package. The integration of these subsystems into an operational unit represents the
value-added engineering contributed by GE Aero Energy Products.

COURSE DESCRIPTION
This training course will provide adequate system and subsystem operational information to
achieve maximum equipment efficiency. The correct interpretation of this information will
lead to safe, reliable operation and extended equipment life.
This course will cover the following:
Gas turbine fundamentals, theory of operation, and details of construction
Gas turbine support systems and equipment flow and instrument diagrams (F&ID)
Generator fundamentals, theory of operation, details of construction
Control system fundamentals, theory of operation, details of construction
This course should be considered a mandatory prerequisite to maintenance training, which is a
separate discipline requiring disassembly and reassembly instructions, as well as
troubleshooting techniques using special tools and test equipment.

CLASS HOURS
The minimum course length is five calendar days, eight hours per day with a one-hour lunch
break and a fifteen-minute break every one and one-half hours. The class start time is
normally 8 a.m., and the finish time is 4 p.m.

PROGRESSIVE AND FINAL EXAMINATIONS


Progressive examinations are given after each major subsection. The examinations are
intended to be part of the learning process. The examinations are open book, and help from
other class members is allowed.
A final, comprehensive examination is given at the conclusion of the course. During the final
examination, students may not communicate with others when answering the questions. The
final examination allows GE Aero Energy Products and your employer to measure the
effectiveness of the training and your understanding of the material and concepts presented.
A course completion certificate will be given to qualified students.

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Additional courses are available:


Level I maintenance- The training will cover LM6000 engine routine, periodic, and
unscheduled maintenance and Boroscope training.

Advance Control Systems


1. Millennium Control- The training will cover the generator equipment
description, operations, and calibration.
2. Woodward- The training will cover the Woodward governor equipment
description, operations and calibration.

TYPICAL LM6000

SAFETY
The following are general safety precautions that are not related to any specific procedures
and do not appear elsewhere in this manual. Personnel must understand and apply these
precautions during all phases of operation and maintenance.

HEALTH HAZARDS
Use all cleaning solvents, fuels, oil adhesives, epoxies, and catalysts in a well-ventilated
area. Avoid frequent and prolonged inhalation of fumes. Concentrations of fumes of
many cleaners, adhesives, and esters are toxic and will cause serious adverse health effects
and possible death if inhaled frequently. Wear protective gloves and wash thoroughly

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with soap and water, as soon as possible, after exposure to such materials. Take special
precautions to prevent materials from entering the eyes. If exposed, rinse the eyes in an
eyebath fountain immediately and report to a physician. Avoid spilling solvents on the
skid. Review the hazard information on the appropriate Material Safety Data Sheet and
follow all applicable personal protection requirements.

ENVIRONMENTAL HAZARDS
The disposal of many cleaning solvents, fuels, oils, adhesives, epoxies, and catalysts is
regulated and, if mismanaged, could cause environmental damage. Review Material
Safety Data Sheets, product bulletin information, and applicable local, state, and federal
disposal requirements for proper waste management practices.

FIRE HAZARDS
Keep all cleaning solvents, fuels, oil, esters, and adhesives away from exposed-element
electric heaters, sparks, or flame. Do not smoke when using flammable materials, in the
vicinity of flammable materials, or in areas where flammable materials are stored.
Provide adequate ventilation to disperse concentrations of potentially explosive fumes or
vapors. Provide approved containers for bulk storage of flammable materials, and
approved dispensers in the working areas. Keep all containers tightly closed when not in
use.

ELECTRICAL HAZARDS
Use extreme care when working with electricity. Electricity can cause shock, burns, or
death. Electrical power must be off before connecting or disconnecting electrical
connectors. Lethal output voltages are generated by the ignition exciter. Do not energize
the exciter unless the output connection is properly isolated. Be sure all leads are
connected and the plug is installed, or that all personnel are cleared to at least 5 feet before
firing the exciter.

COMPRESSED AIR HAZARDS


Air pressure used in work areas for cleaning or drying operations shall be regulated to 29
psi or less. Use approved safety equipment (goggles or face shield) to prevent injury to
the eyes. Do not direct the jet of compressed air at yourself or other personnel so that
refuse is blown onto adjacent work stations. If additional air pressure is required to
dislodge foreign materials from parts, ensure that approved safety equipment is worn, and
move to an isolated area. Be sure that the increased air pressure is not detrimental or
damaging to the parts before applying high-pressure jets of air.

PROCEDURAL HAZARDS
Observe all specified and logical safety practices when assembling or disassembling the
engine. Wear safety glasses or other appropriate eye protection at all times. Do not allow
safety wire or wire clippings to fly from the cutter when removing or installing wire. Do
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not use fingers as guides when installing parts or checking alignment of holes. Use only
correct tools and fixtures. Avoid shortcuts, such as using fewer-than-recommended
attaching bolts or inferior-grade bolts. Heed all warnings in this manual and in all vendor
manuals, to avoid injury to personnel or damage to gas turbine parts.

TOOLING HAZARDS
Improperly maintained tools and support equipment can be dangerous to personnel, and
can damage gas turbine parts. Observe recommended inspection schedules to avoid
unanticipated failures. Use tooling only for the purpose for which it was designed, and
avoid abuse. Be constantly alert for damaged equipment, and initiate appropriate action
for approved repair immediately.

GAS TURBINE OPERATIONAL HAZARDS


The outside surfaces of the engine are not insulated; therefore, adequate precautions shall
be taken to prevent operating personnel from inadvertently coming into contact with these
hot surfaces.
The gas turbine is a source of considerable noise. It is necessary for personnel working on
the gas turbine or in its vicinity to wear proper ear protection equipment when it is
operating.
The gas turbine is a high-speed machine. In case of component failure, the skid housing
would contain compressor and turbine blade failures, but might not contain major
compressor or turbine disk failures. Operating personnel shall not be permanently
stationed in or near the plane of the rotating parts.
Low-pressure, high-velocity airflow created by the compressor can draw objects or
personnel into the engine. Although an inlet screen is used, personnel should not stand in
front of the inlet while the engine is operating.
When entering the gas turbine enclosure, the following requirements must be met:
The gas turbine will be shut down or limited to core idle power.
The fire extinguishing system will be made inactive.
The enclosure door shall be kept open. If the gas turbine is operating, an observer shall be
stationed at the enclosure door, and confined space entry procedures will be followed.
Avoid contact with hot parts, and wear thermally insulated gloves, as necessary.
Hearing protection (double) will be worn if the gas turbine is operating.
Do not remain in the plane of rotation of the starter when motoring the gas turbine.

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When performing maintenance on electrical components, turn off electrical power


to those components, except when power is required to take voltage
measurements.
Lock out all controls and switches, if possible; otherwise, tag electrical switches Out of
Service to prevent inadvertent activation. Tag the engine operating controls Do Not
Operate to prevent the unit from being started during a shutdown condition.
Cleanliness and FOD/DOD
FOD/DOD foreign object damage/domestic object damage is the single major cause of
premature gas turbine failure. Prevention is the only practical means of protecting against
FOD, and adherence to the following guidelines cannot be over-emphasized.

Empty pockets of all lose objects.


Keep maintenance area clean and organized.
Keep FOD containers in the work area to receive bits of safety wire, used gaskets, Orings and other similar types of debris. USE THEM.
Do not use the gas turbine as a shelf to hold parts and tools during maintenance.
Install protective covers and caps on all exposed openings during maintenance.
Remove protective caps and covers only when required to install a part or make a
connection.
After protective caps and covers are removed, inspect all openings and cavities for
foreign objects and cleanliness.
After maintenance, thoroughly clean and inspect work area. Account for all tools,
parts, and materials used during maintenance.

Product Bulletins
Product Bulletins are issued by SSEP to inform customers of changes to and improvements in
the gas turbine product. All Product Bulletins issued by SSEP and cross-reference of Product
Bulletins, are available on the SSEP Bulletin Board System (BBS).
The files on the BBS are compressed, self-extracting, Microsoft Word document files. In
addition to Product Bulletins, other technical information is available, and there are extended
BBS features such as e-mail available for your use. If you require further information
concerning BBS operation or account status, please fax your inquiry to BBS operation or
account status, please fax your inquiry to BBS System Operator, SSEP at (281) 457-8412.

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LM6000 TYPICAL PRE-START


WALK AROUND

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1.

BASIC OPERATORS COURSE

INTRODUCTION

If followed good engineering practices dictates that three different types of walk-around by
conducted on the package, a pre-start walk around, a running walk around, and a post
shutdown walk around. The following are some typical checks to be conducted during each
of these types of walk-around.

2.

PRE-START WALK AROUND:

Pre-start walk around is to be conducted with no machinery running. Starting at the left door
of the generator end of the package.

2.1. GENERATOR END LEFT END DOOR

CHECKED BY

Open door.
Check enclosure lights are working correctly.
Check condition of jacking oil pump.
Check for standing oil around jacking oil pump.
Check the lube oil reservoir for standing oil.
Check overhead tanks for oil leaks.
Check duplex filters are set to one side or the other.
Check duplex filters for leaks.
Check lube oil thermostatic control valve for leaks.
Check jacking oil pump filters for leaks.
Check that all instrumentation is in place and securely mounted.
Check exciter bearing for leakage.
Check exciter-cooling airway is clean and clear of any debris.
Close door and check door is secure.

2.2. GENERATOR END ENCLOSURE LEFT SIDE

CHECKED BY

Check hand fire station is in good condition.


Check generator oil level.
Check all jacking oil pump gauges are reading 0, not above or
below.
Going to next door on left, check enclosure roof is in good
condition.

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GENERATOR END LEFT SIDE DOOR

CHECKED BY

Open door.
Check drive end bearing for leakage.
Check that all instrumentation is in place and securely mounted.
Check coupling guard is in place and secure.
Check overhead tanks for oil leaks.
Close door and check door is secure.

2.3. GENERATOR ENCLOSURE LEFT SIDE

CHECKED BY

Check hand fire station is in good condition


.

2.4. GAS TURBINE LEFT SIDE DOOR

CHECKED BY

Open turbine enclosure door.


Check for standing oil or liquid fuel.
Check that all instrumentation is in place and securely mounted.
Check overall condition of gas turbine.
Check Emergency Stop button is in correct position.
Check enclosure lights are working correctly.
Check condition of Fire-Eye.
Check Fire-Eye for correct position.
Check turbine fire dampers are open.
Close door and check door is secure.

2.5. GAS TURBINE ENCLOSURE LEFT SIDE

CHECKED BY

Check all turbine gauges for calibration

2.6 GAS TURBINE RIGHT SIDE DOOR


Open turbine enclosure door.
Check for standing oil or liquid fuel.
Check that all instrumentation is in place and securely mounted.
Check overall condition of gas turbine.
Check variable geometry filter for leaks.
Check Emergency Stop button is in correct position.
Check enclosure lights are working correctly.
Check condition of Fire-Eye.
Check Fire-Eye for correct position.
Check turbine fire dampers are open.
Close door and check door is secure.

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LM6000 GENERATOR PACKAGE

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2.6. GENERATOR ENCLOSURE LEFT SIDE

CHECKED BY

Check hand fire station is in good condition.

2.7. GENERATOR END RIGHT SIDE DOOR

CHECKED BY

Open door.
Check drive end bearing for leakage.
Check that all instrumentation is in place and securely mounted.
Check coupling guard is in place and secure.
Check all generator oil pump gauges are reading 0, not above or
below.
Check overhead tanks for oil leaks.
Check Emergency Stop button is in correct position.
Close door and check door is secure.

2.8. GENERATOR END RIGHT END DOOR

CHECKED BY

Open door.
Check enclosure lights are working correctly.
Check condition of auxiliary oil pump.
Check for standing oil around auxiliary oil pump.
Check condition of attached oil pump.
Check for standing oil around attached oil pump.
Check the lube oil reservoir for standing oil.
Check overhead tanks for oil leaks.
Check that all instrumentation is in place and securely mounted.
Check exciter bearing for leakage.
Check exciter-cooling airway is clean and clear of any debris.
Check condition of Fire-Eye.
Check Fire-Eye for correct position.
Close door and check door is secure.

2.9. SYSTEMS CHECKS


GAS TURBINE LUBE OIL SYSTEM

Checked By

Check lube oil level in reservoir.


Check lube oil reservoir for leaks.
Check lube oil reservoir drain valve is locked shut.
Check duplex supply filters are set to one side or the other.
Check duplex supply filters for leaks.
Check duplex supply filter P gauge is reading 0, not above or
below.
Check duplex scavenge filters are set to one side or the other.
Check duplex scavenge filters for leaks.
Check duplex scavenge filter P gauge is reading 0, not above
or below.
Check lube oil coolers for leaks.
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Check lube oil cooler valve alignment to ensure proper water and
oil flow.
Check lube oil thermostatic control valve for leaks.
Check lube oil coolers for leaks.
Check lube oil cooler valve alignment to ensure proper water and
oil flow.

2.9.1. HYDRAULIC START SYSTEM

CHECKED BY

Check hydraulic start oil level in reservoir.


Check hydraulic oil reservoir for leaks.
Check hydraulic start pump assembly for leaks.
Check condition of hydraulic start pump assembly.
Check condition of hydraulic start motor
Check condition of hydraulic start hoses.
Check hydraulic start cooler for leaks.
Check hydraulic start cooler airways are clear.

2.9.3. WATER INJECTION SKID

CHECKED BY

Check water injection pump assembly for leaks.


Check condition of water injection pump assembly.
Check condition of hydraulic start motor
Upon completion of walk-thru notify supervisor of results for any recommended actions
prior to start.

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GAS TURBINE TECHNICAL MANUAL


Operation &Maintenance 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 and


Operating Instructions

This section is divided into four subsections, providing an introduction and a


detailed description of each system that 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

Parts

Drawings

Vendor Publications

Lubricant Specifications

Fuel Water
Specifications
Abbreviations and
Acronyms

Factory Test Procedure

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.
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.
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.
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.
The appendix contains the lubricant requirements necessary to operate and
maintain the GTG set.
This section contains information and specifications of particular importance to
the operator, such as fuel and water requirements for the engine.
This is a listing of abbreviations and acronyms commonly used in the powergeneration field.

This section contains the published Factory Test Report as issued by 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.

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TABLE OF CONTENTS
Description

Chapter-Section

Title Page

Front Matter

Record of Ownership
Record of Revisions
List of Effective Pages
Table of Contents
Notice of Liability
Introduction
Warning and Caution Summary
Site-specific Warnings and Cautions
Product Bulletins
Metric and SI Conversions

Front Matter
Front Matter
Front Matter
Front Matter
Front Matter
Front Matter
Front Matter
Front Matter
Front Matter
Front Matter

General Information and Operating Instructions


Introduction and Description of System
Specifications
Controls and Indicators
Operation
Operating Instructions:
LM6000 Water Wash System (Pump System)

1
1-1
1-2
1-3
1-4

Maintenance
General Information
Servicing
Troubleshooting
Engine Alignment, Repairs, and Adjustments

2
2-1
2-2
2-3
2-4

Parts
Spare Parts
Recommended Spare Parts

3
3-1
3-2

Drawings
Drawings
Drawing Lists

4
4-1
4-2

I thru IV

Vendor Publications
Vendor Information
List of Vendor Publications

5
5-1
5-2

V thru XVII

Lubricant Specifications
Fuel-Water Specifications
Abbreviations and Acronyms
Factory Test Procedures

Appendix A
Appendix B
Appendix C
Appendix D

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