Solar Turbines Incorporated

215 Centre Park Blvd.

DeSoto, Texas USA
75115-1086

EQUIPMENT
CONDITION REPORT
Transportadora De Gas Del Norte
SO: DOSM00297

Part Number: EM15000-122G

Serial Number: 0496M
Caterpillar: Confidential Green
 OVERHAUL EQUIPMENT CONDITION REPORT

The subject Equipment Condition Report (ECR) serves to document the condition of the
equipment (GP, PT, RGB, AGB, etc.) at the time of disassembly. This report provides an
accurate description and pictures of the "as received condition" as identified during the
repair or overhaul disassembly process. The ECR is not intended as a failure analysis
document and should not be used to directly determine any degree of fault or cause for the
noted condition of the equipment. This document will not make any attempt to assume or
report design inadequacies, design limitations, performance degradation, or short term or
long term reliability issues.

The ECR contains data pertaining to proprietary designs of Solar Turbines

Incorporated. Reproduction, manufacture, or use of any assembly,
subassembly, or part indicated here in or the use of the design of any such
assembly, subassembly, or part is not permissible unless expressly
authorized in advance and in writing by the Vice President of Engineering,
Solar Turbines Incorporated.

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 EQUIPMENT CONDITION REPORT

Customer Transportadora De Gas Del Norte

Package Information

Serial Number MC97D68

Unit Number Puelen Station Unit # 2

Customer PO 4599000543

Location La Pampa, Argentina

Inquiry Number MA3635

Report Information

Report Date October 31, 2003 Received Date October 23, 2003

Model Mars 100 SO Number DOSM00297

Description Gas Producer Operating Hours 30,000

Part Number EM15000-122G Serial Number 0496M

Reason For Return High time

Accessories Received With Unit

Power Turbine P/N 127670-303U S/N TUI97-M8678

Accessory Gearbox P/N 241900-202 S/N ESI97-98918

As-Received Condition The gas producer, power turbine and accessory gearbox were
received on October 23, 2003. Disassemblies were performed on October 31, 2003 and
witnessed by Solar Turbines representatives Jon M. McDonald and Raymond Downey.

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 AIR INLET SECTION

The air inlet housing had contaminates in the air path and surface corrosion on the
unpainted areas.

The air inlet housing seal was worn and corroded.

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 The bearing housing seal was worn and corroded.

The number one tilt pad bearing had rub on the pads.

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 The forward thrust bearing assembly had light pad wear.

The thrust collar had light wear and light oil varnish.

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 Light wear was noted on the aft thrust washer.

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 COMPRESSOR SECTION

The compressor cases had light corrosion and contaminates on the flanges and aft spacers.
The forward stages of fixed stators were lightly contaminated. The aft stators were lightly
corroded, contaminated and had rub wear on the spacers.
Photo 1 of 5

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 The stator case variable vanes had light contamination on the forward stages.
Photo 2 of 5

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 Grooved wear patterns were observed on the case inner rings.
Photo 3 of 5

Photo 4 of 5

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 Photo 5 of 5

The number one bearing journal had light scoring and oil varnish.
The labyrinth seals were worn and corroded.

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 Light scoring and oil varnish were noted on the number two bearing journal.

The number two labyrinth seals were heavily worn, corroded and had oil deposits.

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 The forward stages of the compressor rotor blades displayed light contamination.
Photo 1 of 2

Photo 2 of 2

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 The forward cone had light contamination.

The aft compressor drum and spacers had corrosion, rub wear and light contamination.
The aft stage blades displayed tip rub.
Photo 1 of 3

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 Photo 2 of 3

Photo 3 of 3

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 DIFFUSER SECTION

The compressor diffuser had heavy corrosion on the unpainted surfaces.

The number two tilt pad bearing had light scratches and moderate rub on the pads.

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The number two bearing cap bronze seal was heavily worn and corroded. Wear and corrosion
were noted on the honeycomb seals.

Oil varnish and heavy deposits were noted on the backside of the cap.

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 Moderate pad wear was observed on the number three bearing pads.

The number three bearing cap seal was worn and corroded.

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 The forward face of the cap had moderate oil deposits noted.

COMBUSTION SECTION

Thermal erosion and corrosion were noted on the external surface of the combustion liner.

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 There were cracks and burn through on the cooling holes throughout the liner, in line with the
injector flame path area.
Photo 1 of 4

Photo 2 of 4

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 Photo 3 of 4

Photo 4 of 4

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 The liner exit cones had light thermal erosion and contaminates.

Thermal erosion and contaminates were noted internally on the liner and splash plates.

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 The gas injectors were corroded, and had erosion and carbon buildup on the spray heads.

TURBINE SECTION

Corrosion and discoloration were noted on the nozzle case.

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 The first stage tip shoes exhibited thermal erosion, deterioration, cracks and rub wear.

The first stage nozzle segments had light thermal erosion and contaminates.
Photo 1 of 2

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 Photo 2 of 2

The nozzle case sliding ring had light thermal erosion and contaminates on the ceramic ring.

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 The nozzle case cooling shroud was corroded.

The first stage diaphragm honeycomb seals had wear patterns

and the housing was heavily corroded.

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 On the second stage nozzle assembly, surface corrosion and contaminates were noted.

Wear and corrosion were observed on the honeycomb seal.

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 The second stage nozzle assembly segments had light thermal erosion and contaminates.
Photo 1 of 2

Photo 2 of 2

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 The third stage nozzle assembly displayed heavy surface corrosion.

Seal wear and heavy corrosion were noted on the honeycomb seal.

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 The third stage nozzle segments were moderately corroded.

The first stage disc assembly had light surface corrosion and discoloration.
The rim seals were in good condition.

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 Light tip rub, thermal erosion and contaminates were noted on the first stage turbine blades.

The second stage disc assembly had light surface corrosion and discoloration.
The labyrinth seal and dampers were in good condition.

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 The second stage turbine blades had light tip rub, thermal erosion and
surface contamination.

Surface corrosion and tip rub were present on the second stage tip shoes.

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 Surface corrosion and blade tip buildup were noted on the third stage tip shoes.

The gas producer shaft number three bearing journal exhibited light wear and heavy oil
varnishing. The labyrinth seals were worn, corroded and had oil deposits.

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 POWER TURBINE (PT)

The diffuser housing had moderate surface corrosion.

The forward bearing housing and diffuser had evidence of oil leakage and burnt oil.

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 The third stage power turbine disc assembly had light surface corrosion and discoloration.

Tip rub and light surface contaminates were noted on the third stage turbine blades.

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 The fourth stage power turbine disc assembly exhibited minor surface corrosion and
discoloration.

The fourth stage turbine blades had light surface contaminates.

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The shaft number four bearing journal had light wear and oil varnish. The labyrinth seals were
heavily worn, corroded and had oil deposits.

Light wear and oil varnish were present on the number five bearing journal.

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 The number four bearing exhibited scoring and rub on the pads.

The number four bearing cap bronze seal and honeycomb seal were worn and corroded.

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 Oil deposits and burnt oil were noted on the cap backside.

Scratches and rub were present on the number five tilt pad bearing.

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 The power turbine thrust collar was lightly worn and oil varnished.

Pad wear and light scratches were noted on the aft thrust bearing assembly.

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 Light scratches and rub wear was observed on the forward thrust washer.

The fourth stage diaphragm assembly had heavy surface corrosion.

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 The honeycomb seal had wear patterns and corrosion.

The nozzle segments were moderately corroded.

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 Accessory Gearbox (AGB)

The main housing was received in an acceptable condition.

Photo 1 of 2

Photo 2 of 2

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 The housing support plate was in an acceptable condition.

The pinion gear had fret wear on the bearing journal, and a light
wear pattern on the teeth.
Photo 1 of 2

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 Photo 2 of 2

The upper lube pump drive gear assembly had no defects noted.

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 The lower lube pump drive gear had no defects noted.

The accessory drive gear assembly had no defects noted.

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 The upper accessory drive gear had no defects noted.

The lube pump coupling hub had fret wear on the splines. The accessory drive coupling hub
had no defects noted.
Photo 1 of 2

Lube Pump Accessory drive

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 Photo 2 of 2

The starter gear had fret wear on the aft bearing journal and gear teeth.
Photo 1 of 3

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 Photo 2 of 3

Photo 3 of 3

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 The coupling hub had a light wear pattern on the teeth.
Photo 1 of 2

Photo 2 of 2

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 The coupling retainer had no defects noted.

The drive coupling had no defects noted.

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 The pinion, starter and idler bearing retainers had no defects noted.

The oil rings had no defects noted.

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 The oil dams had no defects noted.

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 SUMMARY

Gas Producer

The engine was removed from service for high time. The operating time was reported
as 30,000 hours since new.
The air inlet assembly displayed contamination in the air path and surface corrosion on
the unpainted surfaces. The inlet and number one bearing housing seals were worn and
corroded, and there was rub on the number one tilt pad bearing.
The stator case had light corrosion and contamination internally, with light
contamination noted on the variable vanes. Grooved wear patterns were observed on the inner
seal rings, and light tip rub was present on the aft spacers. The compressor rotor was free
from structural defects, but did have light contamination on the forward stage blades. Blade tip
rub, drum rub, corrosion and light contamination were noted on the aft stages of the rotor. The
number one bearing journal had light scoring and oil varnish, with wear and corrosion noted on
the labyrinth seals. Number two bearing journal had light scoring and oil varnish, and the
labyrinth seals were heavily worn, corroded and had oil deposits.
In the diffuser section, heavy surface corrosion was noted on the diffuser housing and
the number two tilt pad bearing assembly had light scratches and moderate rub. Moderate rub
was observed on the number three bearing. The number two bearing cap bronze seal was
heavily worn and corroded, and there was oil varnish and heavy oil deposits on the backside.
Wear and corrosion were present on the number three bearing cap, with moderate oil deposits
found on the backside.
In the combustion section, thermal erosion and corrosion were noted on the external
surfaces, and there were cracks and burn through on the cooling holes throughout the liner, in
line with the injector flame path area. The exit cones and internal liner had thermal erosion and
contamination. The fuel injectors were corroded and had erosion and carbon buildup on the
spray heads.
In the turbine section, the nozzle case had corrosion and discoloration. There was light
thermal erosion and contaminates on the first and second stage nozzle segments, and the
third stage nozzle segments displayed moderate surface corrosion.

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 Cracks, rub, deterioration and thermal erosion were noted on the first stage tip shoes.
Rub and surface corrosion was observed on the second stage tip shoes, and surface corrosion
and blade tip buildup were noted on the third stage tip shoes. The number three bearing
journal exhibited light wear and heavy oil varnishing, and the labyrinth seals were worn,
corroded and had oil deposits. The first and second stage turbine disc assemblies displayed
light surface corrosion and discoloration, with light tip rub, thermal erosion and contamination
noted on the first and second stage turbine blades.

Power Turbine

The power turbine diffuser had moderate surface corrosion. The power turbine shaft,
number four and five bearing journals displayed light wear and oil varnishing, and the labyrinth
seals were heavily worn, corroded and had oil deposits. The number four bearing assembly
had scoring and rub on the pads, and the number five tilt pad bearing assembly had scratches
and rub on the pads. There was corrosion and wear on the number four bearing cap, with oil
deposits and burnt oil noted on the backside. The third and fourth stage disc assemblies
exhibited light surface corrosion and discoloration. There was tip rub and light surface
contaminates noted on the third stage turbine blades. Light surface contaminates were present
on the fourth stage turbine blades. Heavy corrosion was observed on the fourth stage nozzle
assembly and the segments were moderately corroded.

Accessory Gearbox

Disassembly of the accessory gearbox revealed the pinion gear had fret wear on the
bearing journal and a light wear pattern on the teeth. The lube pump coupling hub had fret
wear on the splines. There was fret wear on the aft bearing journal and gear teeth of the
starter gear. Additionally, the coupling hub a light wear pattern on the teeth.

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 Prepared By

Jon M. McDonald
Engineering Support
Gas Producer and Power Turbine

Raymond Downey
Support Engineering
Accessories

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