LM6000 Introduccion

LM6000 GENERATOR PACKAGE BASIC OPERATORS COURSE

Newcrest Mining Telfer Project 1-1

SECTION 1 COURSE INTRODUCTION


1-2 Newcrest Mining Telfer Project

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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.



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.



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



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



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.



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, O-

rings 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.



LM6000 TYPICAL PRE-START WALK AROUND



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1. 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.



2.3 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 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 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.



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.



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.



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

This section is divided into four subsections, providing general information on maintenance; maintenance definitions and concepts; maintenance schedules; servicing information; troubleshooting of the prime mover, generator, and ancillary equipment; and repairs and adjustments to the equipment.

Parts

This section contains recommendations on spare parts, lists of required and recommended spare parts, and points-of-contact to order or find information on parts for the gas turbine-generator set.

Drawings

This section contains a listing of mechanical and electrical drawings sent with the manual. The list contains the GE Aero Energy Products engineering document number, the revision level of the drawing, and the title of the drawing.

Vendor Publications

This section contains vendor publications that provide operation, maintenance, and parts information for the equipment and related components in the gas turbine-generator set. The publications include vendor material ranging from catalog data sheets to complete sets of operation and maintenance manuals and parts manuals.

Lubricant Specifications

The appendix contains the lubricant requirements necessary to operate and maintain the GTG set.

Fuel Water Specifications

This section contains information and specifications of particular importance to the operator, such as fuel and water requirements for the engine.

Abbreviations and Acronyms

This is a listing of abbreviations and acronyms commonly used in the power-generation field.

Factory Test Procedure

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.



LM6000 GAS TURBINE-GENERATOR SET TABLE OF CONTENTS Description Chapter-Section Volume Title Page Front Matter I Record of Ownership Front Matter I Record of Revisions Front Matter List of Effective Pages Front Matter Table of Contents Front Matter Notice of Liability Front Matter Introduction Front Matter Warning and Caution Summary Front Matter Site-specific Warnings and Cautions Front Matter Product Bulletins Front Matter Metric and SI Conversions Front Matter General Information and Operating Instructions 1 I Introduction and Description of System 1-1 Specifications 1-2 Controls and Indicators 1-3 Operation 1-4 Operating Instructions: LM6000 Water Wash System (Pump System) 1-5 Maintenance 2 I General Information 2-1 Servicing 2-2 Troubleshooting 2-3 Engine Alignment, Repairs, and Adjustments 2-4 Parts 3 I Spare Parts 3-1 Recommended Spare Parts 3-2 Drawings 4 I thru IV Drawings 4-1 Drawing Lists 4-2 Vendor Publications 5 V thru XVII Vendor Information 5-1 List of Vendor Publications 5-2 Lubricant Specifications Appendix A I Fuel-Water Specifications Appendix B I Abbreviations and Acronyms Appendix C I Factory Test Procedures Appendix D I

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LM6000 Introduccion

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