Professional Documents
Culture Documents
GE ALTERATION
REVISION LETTER
NOTICE NUMBER
GE PURCHASE ORDER #: 180667255
GE MLI/CC #: GR0922
GE DWG NUMBER MFI DWG NUMBER DESCRIPTION DIS REQ REV LEVEL SHEET QTY
THIS DOCUMENT SHALL BE REVISED IN ITS ENTIRETY. ALL SHEETS OF THIS DOCUMENT AT THE SAME REVISION
LEVEL AS INDICATED IN THIS VENDOR SUPPLIED DRAWING APPLIQUE.
2000 Military Rd
Tonawanda, NY 14150
Phone: 716-873-9300
Fax: 716-873-7538
May 2004
LFAA MODULE GR0922
TITLE SHEET
SKIKDA
DATE: 05/25/04
HEBELER CORPORATION
GR0#922
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TABLE OF CONTENTS
TAB 3 OPERATION
TAB 4 MAINTENANCE
TAB 5 TROUBLESHOOTING
TAB 6 TEST
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I. GENERAL
The liquid fuel atomizing air module is a combination of several systems and sub-systems that provide
compressed air and liquid fuel to the eighteen turbine combustion chambers.
These systems are shown in the following schematic diagrams, located in the Reference Drawings
Section of this manual:
Fuel oil is filtered, pressurized, controlled and equally distributed between the 18 turbine
combustion chambers.
Compressor discharge air is cooled, moisture separated, filtered, re-compressed and equally
distributed between the 18 turbine combustion chambers during liquid fuel operation.
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The atomizing air compressor gearbox receives cooled lubricating oil from the lubricating oil system.
The liquid fuel stop valve trip relay valve receives pressurized trip oil to allow fuel oil flow to the
turbine.
Cooling water is supplied to the atomizing air pre-cooler to reduce the inlet temperature of air
entering the compressor.
The fire protection system provides CO2 in the event of flame detection by the fire detectors.
Strobes and horns are located within the module for personnel warning just prior to initial CO2
discharge.
The hydraulic oil system provides muscle pressure to actuate the liquid fuel flow control valve
and the liquid fuel stop valve.
Module heating is provided for humidity protection. Module ventilation is provided for cooling air
for the liquid fuel pump motor and the atomizing air compressor motor.
The fuel purge air regulators and solenoid valves are located in the module for a cooler
environment than within the turbine enclosure.
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I. GENERAL
The liquid fuel (distillate oil) system filters, pressurizes, controls, and equally distributes fuel flow to the
eighteen turbine combustion chambers. Flow is regulated by controlling the position of 3–way valve
VC3-1.
The entire liquid fuel system must be pressurized, with all valves in the open position, before starting
the gas turbine.
Refer to “Gas Turbine Liquid Fuel Recommendations GEI-41047H" in the FLUID SPECIFICATIONS
section of this manual for the liquid fuel system requirements.
Refer to “Leak Test and Blow-down Procedure 361A5550” in the FLUID SPECIFICATIONS section of
this manual for the liquid fuel system requirements.
Refer to “Air Venting Procedure 360A6343” and “TIL 1250-2: Air Venting Procedure for F/FA Gas
Turbine Liquid Fuel Systems” in the FLUID SPECIFICATIONS section of this manual for the liquid fuel
system requirements.
Refer to “TIL 1107-3: Operational Reliability on Oil Fuel in Dual Fuel (Gas/Liquid) Gas Turbines” in the
FLUID SPECIFICATIONS section of this manual for the liquid fuel system requirements. For a dual fuel
(gas/liquid) turbine, the liquid fuel system should be operated for a minimum of one half hour every week
to prevent binding of the components. This is best achieved by operation of the turbine on liquid fuel for a
minimum of one half hour per week with either 100% fuel oil or fuel gas mixed mode with fuel oil.
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The fuel system shown in the MLI-0424 schematic diagram located in the Reference Documents section of
this manual is comprised of the following major components:
1. Duplex low–pressure fuel filter FF1-1, -2 with transfer valve VM5-1 and thermal pressure
relief valves VR41-1, -2.
2. Fuel pump PF-1-1 with driving motors 88FP-1 and motor heater 23FP-1 and discharge pressure
relief valves VR4-1.
Except for the fuel nozzles all components are mounted in the off–base liquid fuel/atomizing
air module.
Fuel oil forwarded to the liquid fuel module within specified pressure and temperature ranges enters
the low-pressure filter FF1-1 or FF1-2 via transfer valve VM5-1 prior to entering the fuel pumps.
The low–pressure filter consists of multiple synthetic elements, with oversize contamination capacity.
These elements retain contaminants, which could damage downstream components.
The filter vessels are protected from thermal overpressure by relief valves VR41-1, -2.
Differential pressure switch 63LF-5 gives a signal when the pressure drop across the filter
reaches the set point. The dirty filter should then be serviced by replacing the dirty elements
with clean ones.
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B. Fuel Pumps
Fuel pumps PF1-1 is of the axial flow, positive displacement, rotary, screw type with one power rotor
(driven screw) and two intermeshing idler rotors. The single ball bearing positions the power rotor for
proper operation of the mechanical seal. The bearing is permanently grease packed and external to the
pumped fuel.
The motor driven fuel pump 88FP/PF1-1 is rated at hundred percent capacity of the maximum turbine
fuel requirement The pump motors is equipped with an integral heater 23FP-1 respectively.
The pump is protected from insufficient suction pressure by permissive–to–start pressure switch
63FL-2. During normal operation this switch functions as a low–pressure alarm. The fuel system
is protected from excessive pressure by pump discharge relief valve VR4-1 that relieves pressure
back to filter inlet.
The servo controlled three-way control valve assembly VC3-1 modulates pump discharge flow.
Components of this assembly include the valve body, electro-hydraulic servovalve 65FP-1,
hydraulic oil filter FH3-1 and the cylinder. Refer to the Trip Oil (hydraulic control and trip)
system description. The valve controls the flow to the turbine by throttling the main port while
opening the bypass port, returning the bypass flow to pump suction.
Hydraulically operated three–way fuel oil stop valve VS1-1 shuts off the supply of fuel to the
turbine during normal or emergency shutdowns. During normal turbine operation, the valve is
held open (bypass closed) by high–pressure hydraulic oil that passes through a hydraulic trip relay
(dump) valve VH4-1. Refer to the Trip Oil
(hydraulic control & trip) system description. Trip oil acting through solenoid valve DCV5050
hydraulically operates this dump valve, located between the hydraulic supply and the stop valve
hydraulic cylinder. During a normal shutdown or emergency trip, low trip oil pressure will cause
valve VH4-1 to shift position, dumping high–pressure hydraulic oil from the stop valve actuating
cylinder, allowing the stop valve spring to close the valve. During an electrical trip, solenoid valve
DCV5050 causes the dump valve to shift with the same results as above. The stop valve will be
fully closed within 0.5 second of the trip signal. Limit switch 33FL-1 signals stop valve-closed
position.
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E. Flow Divider
Flow divider FD1-1 equally distributes filtered fuel to the eighteen combustors. It is a continuous
flow, free wheeling device consisting of fourteen gear pump elements in a circular or linear
arrangement having a common inlet with a single timing gear or shaft. This timing (sun) gear
or shaft maintains the speed of each flow element synchronous with all the other elements.
The speed of each flow divider gear element is directly proportional to the total flow through the
flow divider. Magnetic pickup assemblies 77FD-1, -2 and -3, fitted to the flow divider, produce
a flow feedback signal at a frequency proportional to the fuel delivered to the combustion chambers.
This signal is fed to the SPEEDTRONIC™ control panel where it is used in the fuel control system.
An eighteen ported pressure selector valve VH17-1 allows monitoring of individually selected line
pressures on a local gauge. These include any one of the eighteen combustor fuel lines.
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The Atomizing Air system for the MS9001FA gas turbine provides compressed air for atomization of liquid
fuel in the combustion system. The Atomizing Air is introduced through supplementary orifices in the
fuel nozzles. The discharge from these nozzles impinges directly upon the liquid fuel oil spray as it enters the
combustion chambers. The high velocity Atomizing Air stream shears the droplets of fuel into very
small pieces, yielding a fine mist. The fine mist of fuel burns more completely in the combustion chamber,
yielding significantly higher combustion efficiency, and lower levels of combustion particles discharging to
atmosphere through the exhaust.
In addition to supplying air for atomization of liquid fuel, the Atomizing Air system also supplies purge air to the
liquid fuel and water injection nozzles when the gas turbine is operating on gas fuel (refer to Fuel Purge system
description). Immediately following shut down, the Atomizing Air Compressor can be run to purge and cool the
Atomizing Air, Water Injection, and Liquid Fuel nozzles. Provisions can also be made to use the Atomizing Air
module to purge the Atomizing Air and Liquid Fuel piping during off-line water washes.
The Atomizing Air system components are located in the Liquid Fuel/Atomizing Air Module (MLI A162),
which is an enclosed off-base skid. This module also houses components of the liquid fuel system
(refer to Liquid Fuel System description - MLI 0424). The components of the Atomizing Air system are
shown in the Atomizing Air Piping Schematic Diagram Drawing (MLI 0425), which is included in the
reference drawings section of this manual.
COMPONENTS
The major Atomizing Air System components are as follows:
1. Atomizing Air Compressor/Motor assembly, with Compressor Vibration Transmitters (CA1-2, 88AK-1,
39VS-AA-1)
2. Inlet Air Heat Exchanger or Precooler, (HX1-1)
3. Cooling Water Control Valve and Electro-pneumatic Temperature Controller arrangement (VA32-2,
90AT-1, VPR68-2) (On Cooling Water Schematic – MLI 0420)
4. Cooling Water Electro-pneumatic Temperature Controller Thermocouple (AAT-HXD-1A)
5. Dual Inlet Air Temperature Switches (26AA-1A, 26AA-1B)
6. Moisture Separators (PDS1-1, PDS1-2)
7. Air Filter and Air Filter Differential Pressure Switch (FA5-1, 63AF-1)
8. Motor Actuated Atomizing Air Compressor Bypass Valve with Limit Switches
(20AA-1, 33AA-1, 33AA-2)
9. Motor Actuated Atomizing Air D/S Throttling Valve with Limit Switches (20AA-2, 33AA-3, 33AA-4)
10. Motor Actuated Atomizing Air Scavenging Valve with Limit Switches (20AA-5, 33AA-7, 33AA-8)
Compressor Differential Pressure Switches (63AD-1A, 63AD-1B, 63AD-1C)
11. Compressor Discharge Temperature Switch (26AA-2)
12. CDP – Atomizing Air Manifold Differential Pressure Transmitters (96AA-1A, 96AA-2B, 96AA-1C)
(See MLI 557T)
13. Cooling Water Bypass Solenoid, Control Valve and Limit Switches (20WC-50, VA34-1, 33WC-50A,
33WC-50B) (On Cooling Water Schematic - MLI 0420).
GE DRAWING NUMBER REV.
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OPERATIONAL/FUNCTIONAL DESCRIPTION
I. General
Air is supplied to the Liquid Fuel/Atomizing Air (LF/AA) Module from an extraction manifold at the
Gas Turbine Compressor Discharge (see Cooling and Sealing Air Piping Schematic MLI 0417). This air is
approximately at CDP (pressure) and CDT (temperature). The actual pressures and temperatures are dependent on
the Gas Turbine operating conditions. This air enters the LF/AA Module, and passes through the Atomizing Air
Precooler (HX1-1). The supply of cooling water to the Precooler is controlled by the Cooling Water Control
Valve arrangement (VA32-2, VPR68-2, 90AT-1, AAT-HXD-1A). (see Cooling Water Piping Schematic MLI
0420). The temperature of the air leaving the Precooler (HX1-1) is controlled to 225°F (107°C) at high air mass
flow conditions, but may be lower at part-load air flow conditions. Downstream of the Precooler, the air passes
through a Moisture Separator (PDS1-1) with a continuous blowdown drain. This device separates out most of the
entrained moisture droplets in the atomizing air stream. Two identical temperature switches (26AA-1A, 26AA-
1B) and the Cooling Water Temperature Control Thermocouple (AAT-HXD-1A) are provided in the line
downstream of the Moisture Separator. The switches have a 275°F (135°C) set point, and are intended to signal
an alarm if the Precooler fails to adequately cool the incoming air. Further downstream of the Moisture Separator,
the air passes through a 2 micron Filter arrangement (FA5-1). The Filter should be checked annually for integrity
and should be replaced when the AA Filter Differential Pressure Switch (63AF-1) alarms at between 3 and 4
PSID. The 0-300 PSIG Panel Mounted Pressure Gauge downstream of the Filter (FA5-1) can also be monitored.
Upstream of the Filter, the air proceeds to the purge air “tee”, where it splits into one of two paths. One path
enters the atomizing air compressor inlets, (Atomizing Air, Liquid Fuel mode), as described in more detail in
section B2. The alternate path bypasses around the air compressor (Purge Air, Gas Fuel mode), described in more
detail in section III.
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connection “AAO1”. Interconnecting piping conducts the Atomizing Air to connection AAI1 at the turbine base.
The air then enters the Atomizing Air Manifold, which supplies air to the combustion chambers via 18 flexible
hose “pigtails”. The absolute pressure at the connection to the combustion chamber end-cover is
approximately 1.35 to 1.4 times Gas Turbine Compressor Discharge Pressure (CDP).
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The actuation air for this Ball Valve (IA) is turned on and off by a ½" Dia. Solenoid Valve (20WC-50)
controlled by the Speedtronic Control Panel. The normally closed Ball Valve (VA34-1) has a Limit Switch
to signal fully closed (33WC-50A) and fully open (33WC-50B) positions. (See the Cooling Water
schematic MLI 0420 for the VA34-1; 20WC-50; 33WC-50A; and 33WC-50B devices). This air is at
approximately Gas Turbine Compressor Discharge Pressure (CDP) and 225 degrees F. After the air passes the
purge “tee”, it then passes through fully opened Atomizing Air Bypass Valve (20AA-1), which serves to open and
close the bypass air route depending on which fuel is powering the gas turbine.
The air then splits into two paths, supplying air to the Liquid Fuel and Water Injection Purge piping and to the
Atomizing Air nozzles. The piping to the Liquid Fuel and Water Injection Purge systems pass out of the
Liquid Fuel/Atomizing Air Module via connections PA2. The purge air is carried via interconnecting piping
to the turbine base (see MLI 0477 Fuel Purge Schematic). The Atomizing Air flow stream exits the Liquid
Fuel/Atomizing Air module via connection AAO1. Interconnecting piping conducts the air to connection
AAI1 at the turbine base. The air then enters the Atomizing Air Manifold, which supplies air to the
combustion chambers via 14 flexible hose “pigtails”. The pressure at the connection to the
combustion chamber end-cover is approximately 0.985 times Gas Turbine Compressor Discharge
Pressure (CDP).
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CAUTION
ISOLATION VALVES ARE PROVIDED AT THE INLET AND DISCHARGE OF THE ATOMIZING AIR
COMPRESSORS. RUNNING EITHER COMPRESSOR WITH ONE OR BOTH OF ITS ISOLATION VALVES
CLOSED MAY SERIOUSLY DAMAGE THE COMPRESSOR.
TAB 3 OPERATION
3.1 INSTALLATION
The liquid fuel/ atomizing air module is shipped as a single package. All components of the module are
mounted on a steel platform. All components are piped per prepared mechanical drawings and all
electrical components except the fuel pump motors and atomizing air compressor motors are wired to
junction boxes.
3.1.1 Foundation
The module including six pedestals should be mounted on a level concrete base or pad, and bolted
securely in place. The module should be shimmed as required so that undue strain will not be placed on
the skid when secured. Anchor bolt locations are provided on the foundation interface drawing as well as
the outline drawing provided in Section 3. Ground skid to plant ground using the two-hole NEMA
grounding pads provided on the skid base. Two grounding pads are located at opposite corners as shown
per the outline drawing.
Hydrostatic test, and flush (with the same fluid type as to be used in service) all interconnecting piping
prior to attachment to the module in accordance with Liquid Fuel Leak Test and Blowdown Procedure
located in the Gas Turbine Manual Reference Drawing Section.
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ll interconnect piping should be fitted, bolted or welded to the skid and care must be taken not to stress the
piping connections. Attach ANSI B16.5 bolted flanges using Flexitallic spiral wound gaskets and ASTM
A193 Gr B7 and ASTM A194 Gr 7 or Gr 2H corrosion resistant fasteners. Refer to the Outline and P&ID
drawings located in the Gas Turbine Manual Reference Drawing Section for the fluid type, connection
sizes, pressures, temperatures and flow rates. Install the shipped loose isolation butterfly valve for the
liquid fuel supply LF1 connection in the interconnecting piping in an open location adjacent to the module
suitable for firemen use including appropriate marking identification in accordance with site local the fire
code. Pressurize each system and check all external connections and module internal piping connections
for leakage.
For an outdoor module, install the enclosure ventilation fan, gravity damper and the CO2 damper assembly
(ies) on the roof of the module. Connect tubing from the module roof initial discharge coupling(s) FP53
(A, B) to the CO2 damper latch (es).
The base includes a floor drain coupling that may be piped to an unpressurized tank. This would require
installation of a trap and an isolation valve.
Remove the plug from the atomizing air blow down silencer discharge coupling where it exits the module
wall.
3.1.3 Electrical
All inter-skid wiring is completed at the factory in accordance with the electrical elementary
located in the Gas Turbine Manual Reference Drawing Section. Customer shall connect signal, fire
protection, power and control wiring to skid junction boxes, as specified by the MLI-0445
interconnection diagram.
JB77F Level 2S Fire protection Direct wire the liquid fuel pump motor(s), atomizing
air compressor motor(s), and the ventilation fan(s) to their motor starter(s) and motor switch gear(s).
Continuity should be checked at the motor switchgear, motor control center and the turbine control panel.
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The C-face flange mounting accommodates the fuel oil pump to motor alignment. Align the atomizing air
compressor to the motor and couple in accordance with the compressor manufacturer instructions
included in Section 8.
Verify that the FD1-1 liquid fuel Flowdivider magnetic speed pickups, 77FD-1, 2,3, gaps meet set point
calibration in accordance with the Device List located in the Gas Turbine Manual Reference Drawing
Section. Adjust if necessary. Drain the Flowdivider of preservative oil, connect the inlet manifold and
discharge tubes, fill with distillate fuel oil, and vent air from the high point as necessary.
Fill the lube oil system supply piping and the compressor gearbox with lube oil. Check the sight glass for
appropriate flow.
Fill the cooling water system piping and atomizing air heat exchanger with cooling water. Vent air
from the high points as necessary.
Fill the hydraulic system and trip oil system piping with lube oil. Vent air as necessary.
Analyze the light distillate fuel in the storage tanks to ensure compliance with Gas Turbine Liquid Fuel
Specification located in the Gas Turbine Manual Reference Drawing Section.
When the fuel-forwarding module has been properly installed and checked, flush the fuel lines and the
fuel oil may be brought into the liquid fuel module. All fuel oil components and piping should be
completely filled and all air vented at each high point in accordance with the Liquid Fuel Air Venting
Procedure located in the Gas Turbine Manual Reference Drawing Section. This venting process
may have to be repeated several times.
Start the PF1-1/88FP-1 fuel oil pump and motor assembly and verify that it is performing correctly while
running with the VS1-1 stop valve closed (re-circulation line is always open to the liquid fuel filter inlet to
prevent dead heading the pump).
Verify that the instrumentation pressure, differential pressure, and temperature switches meet set point
calibration requirements in accordance with the Device List located in the Gas Turbine Manual
Reference Drawing Section.
Verify that instrumentation pressure gauges, differential pressure gauges, and thermometers are within
calibration limits.
Verify that the liquid fuel purge system pressure regulators meet set point calibration in accordance with
the Device List located in the Gas Turbine Manual Reference Drawing Section.
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Verify that the atomizing air cooling system temperature controller pressure regulator meet set point
calibration requirements in accordance with the Device List located in the Gas Turbine Manual
Reference Drawing Section.
Verify fire protection system strobe/horns, detectors, and CO2 piping nozzles function properly.
The liquid fuel/ atomizing air module is now ready for start-up by the turbine control panel
and is ready to provide fuel oil, atomizing air and purge air to the turbine base combustion nozzles
and manifolds.
Verify atomizing air system continuous blow down function and moisture removal.
Orifices in the atomizing air discharges FO-9, FO-10 and FO-11 sizes are to be checked during
performance testing to meet operating requirements of the combustion system.
TAB 4 MAINTENANCE
4.0 GENERAL
The liquid fuel system and the cooling water system should be purged of air once per week to prevent
excessive low frequency pressure dynamics during operation. Periodically check systems for leaks,
excessive vibration or damaged components.
A duplex filter with rating β25 =200, low-pressure filter is provided to remove particles from the distillate
fuel. A differential pressure gauge is used to monitor the differential pressure across the strainer to
indicate when cleaning is required. A clean out drain is connected to the LF9 purchaser’s connection.
Cleaning can be performed during turbine operation only for the duplex. Turn the filter transfer valve
to the opposite vessel and close the crossover fill valve to operate on the clean filter set. On the
dirty filter vessel, open the drain valve and open the vent valve on the cover. Unlock the cover and
remove, being careful with the O-ring. Remove the dirty filter elements, clean the vessel with solvent,
and install clean replacement elements. Replace the cover and O-ring and close the drain valve.
Using the crossover fill valve, fill the vessel with fuel oil until fluid exits the vent.
Close the vent valve. Clear the alarm. The filter is now ready for subsequent turbine operation.
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Periodically check servo valve calibration. Examine 3-way valve for fuel leakage. Examine hydraulic
actuator for lube oil leakage. Service filter when visual dirty indicator has popped-up.
Periodically check 3-way valve for fuel leakage. Examine hydraulic actuator for lube oil
leakage. Examine trip relay valve for lube oil leakage. Service filter when visual dirty indicator has
popped-up.
Periodically check for fuel leakage. Check MAGNETIC SPEED PICKUP calibration.
Periodically check for air leakage. Check continuous blowdown for proper drainage of
condensed water.
Periodically check for air leakage. Check continuous blowdown for proper drainage of condensed
water. When the differential pressure switch alarms the turbine control panel, plan to service the
filter element during the next turbine planned shutdown. With the vessel adequately cooled,
remove the dirty filter element and install clean filter element. Reset the alarm. The
filter is now ready for subsequent turbine operation.
Periodically check for excessive vibration and coupling alignment. The motor couplings should be
visually inspected for excessive wear, which would indicate that the alignment has drifted.
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Periodically check for control air and water leakage from 3-way valve and actuator.
Check temperature control system pressures and calibration.
Periodically check for air leakage. Check air pressure regulator calibration.
4.12 Instrumentation
Periodically check for fluid leakage. Check switch set point calibrations in accordance with the
Device List located in the Gas Turbine Manual Reference Drawing Section.
Check gauge calibrations. Isolation valves and test ports for the pressure switches and gauges are
provided for this purpose so that calibration can be performed as installed during turbine
non-operational periods.
Periodically check CO2 piping per local fire codes to keep nozzles clear. Check calibration
of fire detectors and operate strobes and horns.
4.14 Idle
Idle is defined as a period of time less than or equal to six weeks. During a shutdown special
maintenance procedures are required to prevent deterioration of system components.
The following are recommendations for system shutdown:
Operate the fuel oil/atomizing air system for at least ½ hour per week. This will help flush
settled water. Also, operation of the fuel oil pumps will circulate oil throughout
the piping system ensuring a protective coat of oil on the oil pipes to prevent corrosion.
Vent air in accordance with the procedure located in the Gas Turbine Manual
Reference Drawing Section.
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Extended idle is defined as a period of time longer than six weeks. During an extended idle special
maintenance procedures are required to prevent deterioration of fuel oil system components.
If the fuel oil is removed from the system the following applies: It is imperative that the quality
of the system components be maintained. The pump should be filled with a corrosion inhibiting vapor
phase inhibitor type oil, fully compatible with the turbine fuel oil.
If the fuel oil is removed from the system the following applies: It is imperative that the quality of the
system components be maintained. The Flowdivider should be filled with a corrosion inhibiting
vapor phase inhibitor type oil, fully compatible with the turbine fuel oil.
If the lubricating oil is left in the gearbox, operate the lube oil system for at least ½ hour per week.
This will allow settled water to be flushed. Analyze the oil for water and deterioration every
six months.
If the lubricating oil is removed from the gearbox the following applies: It is imperative that the
quality of the oil be maintained. The gearbox should be filled with a corrosion inhibiting
vapor phase inhibitor type oil, which is fully compatible with the turbine lube oil.
Motor and pump assemblies should be rotated by hand every two months. Motor bearings
should be greased once per year.
The heat exchangers should be drained immediately of all water. Tube or plates exposed to
stagnant water are subject to failure.
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4.16.1 General
Obtain maintenance manuals and wiring diagrams for all the plant machinery and equipment.
Set up maintenance data cards for each machine, or purchase a computer-aided program.
Assign and place identifying numbers on all plant machines.
Develop a frequency schedule for machine lubrication based on actual use and vendor data.
Make a lubrication card for any component that requires routine lubrication, and locate it in a
conspicuous area on the unit. Remember to complete the lubrication card after a lubrication
cycle has been completed.
4.16.2 Lubrication
Lubrication is one of the most important aspects of a maintenance program. Over greasing of
motor bearings may cause them to overheat. The coils may also overheat due to grease being
forced into the windings collecting dust and reducing the cooling effect. Bearing housings are
generally arranged to introduce new grease and to purge the old grease from the bearing, allowing
it to discharge through a partially restricted escape port or relief hold. This generally allows filling
to the desired level, which is one third to one-half full, leaving ample space for expansion. Over
greasing also causes churning and internal friction resulting in heating, oxidation of the grease
and possible leakage through the retaining seals.
Dirt should be wiped away from the lubrication fittings prior to adding fresh lubricant.
All lubricants should be stored in a dry place in clean covered containers, and that lubricants
used in your maintenance program are used as recommended or equal.
For lubrication schedule recommendations refer to the vendor data sheet for the specific
component in question.
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Check the overall system for possible under voltage and for efficiency of all switching controls.
Check the motors for unnecessary starting and stopping and reversing, and for excessive
idling when they should be turned off.
Repair and replace any worn or damaged parts. Re-adjust any out-of adjustment components
as per vendor recommendations.
The information provided in this section is general in nature. For specific information
regarding the maintenance of specific components, refer to Section 8.0 Vendor Data Publications.
Scheduled routine inspection and service will minimize motor problems. It is important to plan and
document your maintenance program. This includes the use of prepared forms for recording such
data as the date of inspection, items inspected, service performed, and general motor condition.
Keep these records aids in the identifying of specific problems to help avoid breakdown, and
production losses. Routine inspection and service to the motors can usually be done
without disconnecting or disassembling the motors.
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Lubricate the bearing of this motor type only when scheduled. Do not over lubricate.
Excessive grease creates heat due to churning and can damage motor bearings. It can also
find its way into the motor where it collects dirt and causes insulation deterioration. Follow
the manufacturer’s recommendation for frequency and amount of lubrication.
Whenever motors are disassembled for service, check the bearing housing.
Wipe away any old grease. If there are any signs of grease contamination or breakdown,
clean and re-pack the bearing system. Previously make sure that the inlet and outlet
passages are free of dirt or chips.
Generally, fractional horsepower motors with a wick lubrication system should be oiled
every 2000 hours of operation, or at least annually. Dirty, damp, or corrosive locations or
heavy loading may require oiling at 3-month intervals or more often. Follow the
manufacturer’s recommendations for quantity, frequency and type of oil.
Many larger motors are equipped with oil reservoirs and usually a sight gage to check proper
level. As long as the oil is clean and light in color, the only requirement is to fill the cavity to
the proper level with the oil recommended by the manufacturer. Do not overfill the cavity.
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LFAA MODULE GR0922
If the oil appears discolored, dirty or contains water, remove the drain plug. Flush
the bearing with clean solvent until it comes out clear. Coat the plug threads with a
sealing compound, replace the plug, and fill the cavity to the proper level. If the oil
discolors frequently or becomes unusually dark, it is advisable to disassemble and
inspect the bearing parts. Possible causes or dark oil are:
Wiping or melting of babbit bearing face, caused by improper scrapping, dirt, heat, or
vibration.
Thrusting the shaft shoulder into the end face of the bearing, caused by improper
alignment of the motor to the driven equipment, improper internal motor axial clearances,
and end float.
Improper or insufficient sealing of bearing housing bolted surfaces can allow contaminated
air to be drawn into the bearing reservoir.
When motors are disassembled, wash the housing with a solvent. Discard any used packing.
Replace badly worn bearings. Coat the shaft and bearing surfaces with oil and reassemble.
Be sure that the new bearings are properly scraped and fitted.
Fuel oil requires continual care, observation and treatment. If properly filtered and cared for,
the system can be used for long periods of time, depending upon the fuel oil supply quality,
the supply system and the filters. Refer to fuel oil recommendations, provided separately by
the GE company - GEI-41047H located in the Gas Turbine Manual Reference Drawing
Section.
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LFAA MODULE GR0922
TASK INTERVAL
Maintenance
Test fuel oil quality Monthly GEI 41047
Vent air from fuel oil system Weekly 360A6343
Check filter differential pressure gages Weekly
Check all gages Daily
Fuel Oil Filter Change out When differential pressure limit reached
Fuel Oil Pump Seal and Bearings See Section 8 for manufacturer instructions
Fuel Oil Flowdivider Bearings See Section 8 for manufacturer instructions
Fuel Oil Bypass Valve Seals See Section 8 for manufacturer instructions
Fuel Oil Stop Valve Seals See Section 8 for manufacturer instructions
AA Compressor Seals See Section 8 for manufacturer instructions
AAHX Bundle Cleaning See Section 8 for manufacturer instructions
AA Stop and Recirculation Valve Seals See Section 8 for manufacturer instructions
AA Air Filter Change out When differential pressure limit reached
AA CW Control Valve Seals See Section 8 for manufacturer instructions
Instrumentation Settings Every year
Flush During Startup and as needed
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TROUBLESHOOTING
5.1 SYSTEM
The Gas Turbine Control Panel performs troubleshooting of the liquid fuel and the
atomizing air systems.
5.2 COMPONENTS
Troubleshooting of the components in the Liquid Fuel/ Atomizing Air Module is detailed in the
vendor bulletins located in Tab 8.
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TAB 6 TEST
Testing of the components in the Liquid Fuel/ Atomizing Air Module may be accomplished
in accordance with the attached vendor manufacturing test procedure.
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GE Outline/Arrangement GE # 120E2906
Note: GE documents are located in the Gas Turbine Manual Reference Drawing Section.
05/25/04
May 2004
LFAA MODULE GR0922
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GE – LF/AA Module – Skikda
Hebeler Job #22400A
TABLE OF CONTENTS
1. General Information
2. Equipment / System Description
3. Operation
4. Maintenance
5. Troubleshooting
6. Test
7. Reference Drawings & Data
A. General Assembly Hebeler Dwg. # 211D5621
B. Assembly Details Piping Hebeler Dwg. # N/A
Components
A. Filters
Hilco Liquid Fuel Filter
- Ref. # 1013
Model No. 52HMF-496000036
GE # 377A9820P102
B. Valves
B1. Jamesbury
Butterfly Valve
- Ref. # 9026, 9027
GE# 377A9593P015
GE – LF/AA Module – Skikda
Hebeler Job #22400A
3- Way Valve
- Ref. # 9044
Model No. 6Z-B6XSPKR-SSP-V-SSP-C
GE # 361A6239P008
Manifold Valve
- Ref. # 9016
Model No. HLS2PM ¼ NDTPPD
GE # 354A3280P001
- Ref. # 9017
Model No. LS3PM 1/4 NDTPPD
GE # 354A3280P002
Flowtek
- Ref. # 9031
GE # 354A3275P056
Model No. Triad FP3205
- Ref. # 9021
GE # 354A3275P002
Model No. Triad FP2105
KTM
- Ref. # 2615
Model No. 2.00”-150#
GE # 361A6224P275
GE – LF/AA Module – Skikda
Hebeler Job #22400A
B15. Woodward
Fuel Oil Stop Valve
- Ref. #0511
Model No. 8413E200C-G002
GE# 358A8884P003
GE – LF/AA Module – Skikda
Hebeler Job #22400A
Bypass Valve
- Ref. # 0516
Model No. 8365EI00G002
GE # 358A8883P003
C. Instrumentation
C1. Ashcroft Thermometer
- Ref. # 9035
Model No. 50-EI-60-E-060-50/300F-XCS
GE # 354A3285P002
- Ref. # 9004
GE # 354A3285P003
Model No. 50-EI-60-E-060-50/400F-XCS
C2. Gauges
Ametek Pressure Gauge
Model No. 1911
- Ref. # 9023
GE # 315A2970P725
- Ref. # 9007
GE # 315A2970P720
- Ref. # 9008
GE # 315A2970P722
- Ref. # 9019
GE # 315A2970P719
Mid-West Differential Pressure Gauge
- Ref. # 9020
Model No. 120-SC-10-OO
GE # 272A6132P057
- Ref. # 9010
GE # 272A6132P051
Model No. 120-SC-10-PO
C3. Switches
Crouse Hinds
3-Way Switch
- Ref. # 6017
GE # 360A7433P003
GE – LF/AA Module – Skikda
Hebeler Job #22400A
ITT Neo-Dyn
Pressure Switch
- Ref. # 9065
Model No. 132P4S408-002
GE # 363A5542P002
- Ref. # 9064
Model No. 132P4S408-003
GE # 363A5542P003
- Ref. #6070
Model No. 152P8S42-001
GE# 586A2226P001
Temperature Switch
- Ref. # 9062
Model No. 132TC5S410-010
GE # 363A5544P010
- Ref. # 9063
Model No. 132TC5S410-012
GE # 363A5544P012
GE # 361A5553P022
Model No. 131 – 1.5”
Jacoby Tarbox
- Ref. # 9038
GE # 361A5553P005
Model No. 935-FA
D. Miscellaneous
D1. Anderson Moisture Separator
- Ref. # 2603
GE – LF/AA Module – Skikda
Hebeler Job #22400A
GE # 382A6715P002
E2. Compressors
Atlas Copco
Ref: #0607
- GE# 382A6714P002