tim smith - transcanada turbines - common failures on the lm6000 and key service bulletin discussion

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• LM6000 Operation Data

• Field Events and Service Bulletins

• HPC Stage 3-5 Blades (SB-310)

• D&E Sump Coking

• Sump Evacuation System (SES)

• Compressor Rear Frame (CRF) Oil Manifold

• LP Sprint Damage

• MCD/Lube Oil Analysis

AGENDA

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LM6000 Ops Data

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LM6000 Engine Fleet Statistics

© General Electric Company. All rights reserved

(as of July 14th, 2014)

0

200

400

600

800

1000

1200

2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014

570 599 620 633 665 693735 761 787 806 829

112120

140 150177

207

231254

280322

356

LM6000 Fleet Growth

DLE

SAC

55

LM6000 Operating Schemes

66

LM6000 Field Events

(Issued/ Revised 2014/2015)

77

Service Bulletins

88

HPC Blade Events

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Coating Wear Induced Edge of Contact.

• Investigation findings of these events indicate that there is a correlation between dovetail coating deterioration and EOC (Edge of Contact Cracking).

• Coatings investigated thus far did not yield apparent quality deficiencies, and as such the cause for coating depletion remains “Indeterminate”.

• Additional events around this mode have been identified since last year.

• So what’s being done?

© TransCanada Turbines


HPC Blade Events

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Coating Wear Induced Edge of Contact.

• SB 310 is being introduced which has a Dual Intensity Peening applied to the dovetail roots on stage 3 – 5 blades.

• Pre-Ground kits available for field replacements.

• Repair for older “K” blades expected to be available by Q4 2015.

• New blades are marked with an “H” on the platform.

• K blades still ok for Base Loaded units and can be used in Peakers but will need coating repairs at lower than normal intervals (i.e. prior to normal overhaul)• H blades recommended for Peakers and Load followers.



HPC Blade Events

1111

SB310 – Soon?

1212

SB310 – Soon?

1313

What is after SB-310?

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D&E Sump Coking

15

D&E Sump Coking

16

D&E Sump Coking

17

D&E Sump Coking

18

D&E Sump Coking

19

D&E Sump Coking

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D&E Sump Coking

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Sump Evacuation System (SES)

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Sump Evacuation System (SES)

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CRF Oil Leaks

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CRF Oil Leaks

2010© MTU Maintenance Berlin-Brandenburg© MTU Maintenance Berlin-Brandenburg

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CRF Oil Leaks

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© IHI Corporation

Observed Condition• Abnormally Heavy erosion seen in the VIGV and LPC modules.

Background/New Development• Higher than normal sprint erosion damage seen on Leading Edge of VIGV vanes, Leading of Stage 0 Blades and on rub lands of LPC stator cases.

• LP Sprint rates ranged between 14gpm to 20 gpm for units observed.

• O&M manual reference Sprint schedule as a function of T2 having a water flow range of 5 gpm at T2<40°F and 13.1 gpm at T2 >80°F

LP Sprint Damage

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© IHI Corporation

Recommended Action/Timing• Monitor condition of Sprint Nozzles and repair when tips are showing signs of wear/erosion.

• Ensure water quality is within OEM specifications.

• Monitor water flow rates and reduce where able.

• Repair/Replace parts once identified as unserviceable either at overhaul or field inspections.

LP Sprint Damage

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© IHI Corporation

© IHI Corporation

MCD/Lube Oil Analysis

Dear ASP:

While inspecting my finger screens and MCD’s today we found the following. Is my engine sick? What do I do?

Thanks,Concerned Operator

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© IHI Corporation

© IHI Corporation

Dear Concerned Operator:

Your screwed! Just kidding, please send the samples out to a local lab and have those trusted scientist carry out an analysis and send us the report so we can help you determine best course of action.

Thanks,Helpful ASP


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© IHI Corporation

© IHI Corporation

Dear ASP:

Ok, I got that report they sent me but those scientist wrote it in code. What does all this crap mean?

Thanks,Concerned Operator


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Silver – Typically associated with silver plating from spanner nuts and bearing races. Quite soft and generally does not pose an immediate concern.

Aluminum– Typically can be associated with contamination, housing materials and/or some coatings/seal material


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Chromium– Normally associated gears, gear shafts, bearings and some seals in these oil/MCD reports

Iron– Major alloying element in most components and is inconclusive in itself.


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Molybdenum– Primary indicator of a bearing issue. Do not operate without further investigation

Sodium, Silicon, Zinc–Normally associated with some form of air/oil/water contamination


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GE allows up to 1000 ppm for water in oil per WP 4016, however, anything over 300-400ppm it is recommended you identify and remove the source of water ingress into the oil system in advance of hitting the max allowable. High levels of water can lead to corrosion issues on engine hardware that can lead to costly repairs.

NAS rating for Particle count. WP 4016 calls for rating of NAS 7 (or less) which is 17/16/13. Bigger is not better here!! The higher the numbers the more particles of contamination you have.


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Thank You...Questions?

tim smith - transcanada turbines - common failures on the lm6000 and key service bulletin discussion

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