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Aero Energy

Semi-Annual Inspection

FS Report

31.05/02.06.2015

Unit-1

Customer Representative:

GE Field Service Representative:

All technical recommendations and information contained in this report are based on GE manuals

that have been developed and approved for use with GE engines and parts that have been operated

and maintained in accordance with GE technical documentation and recommendations.

GE has no technical knowledge of, nor obligation for, non GE-approved parts and repairs.

Accordingly, this report is not intended to apply to non GE-approved parts and repairs, nor to any parts

that may be directly or indirectly affected by non GE-approved parts and repairs.

Aero Energy LM6000 PC

Report completed by 2

DETAILS AND DATA

Purpose of visit:

The purpose of this visit was to perform the Semi-Annual Inspections.

Work performed:

Control system part of Semi-Annual Inspections was performed.

SAI Summary:

30.05.2015;

- We arrived to the site at 19:30. But the unit was found in working condition. We had a small meeting with the

customer about stop time of the unit and offline water wash period. Customer informed that, the unit will run until

21:00 due to commercial reason. We had to leave the site. Offline water wash has been started by customer.

31.05.2015;

- We arrived to the site at 01:00

- Offline water wash was completed by customer. (03:45)

- LOTO was applied by customer.

- All engine thermocouples and RTDs were simulated. T48 and T3 thermocouples were measured and found within

limits except T48 A and F thermocouples. T48 A and F were replaced with new ones.

01.06.2015;

- All pressure transmitters were calibrated according to actual ambient pressure. Ambient pressure was measured as

14.45 PSIA during the Semi-Annual Inspection. All pressure transmitter lines have been checked for leakage.

- Turbine and Generator Lube Oil systems pressure transmitter and switch calibrations were checked. Switch setting

values have been set according to site P & ID.

- Over-speed alarm, trip points and external over-speed detection system have been checked. Alarm and trip signals

were appeared on the HMI Screen.

- Magnetic Chip Detectors were checked. Chip Detector A was found damaged. It was replaced with a new one. - 24VDC Control, FPP and 125 VDC Battery Charger Systems have been checked as visually. Electrolyte levels have been

checked and found as normal level. Battery measurements were performed. 24 VDC battery system ground leakage

was found on the (-) polarity. It needs to be investigated next available outage.

- Gap voltage of generator vibration proxy sensors were measured and found as within tolerances.

- Off-engine and on-engine cables have been inspected as visually. Observed no anomalies. All off-engine cable plugs

have been checked for tightness.

- Unit was started by customer due to commercial reasons. Unit was reached up 42 MW without any problem.

02.06.2015

- Gas Fuel system pressure transmitter calibrations were checked. Fuel gas metering valve calibration and shut-off

valves have been checked.

- Generator vent fan (A) air flow switch function checks were performed. Observed no anomalies. - Fire protection system faulty strobe was replaced with new one. All cables have been connected to their terminals.

- FPP Combustible Gas Detectors have been calibrated. Two gas sensor sensitivities were measured out of limit. Only

one gas sensor was provided by the customer and then it was replaced. Other gas sensor needs to be replaced with

new one. Two combustible gas sensor needs to be ordered. Optical flame detectors have been checked for their

functionality. Fire alarm was received and SOVs have been activated by FPP. Horns, strobes have been activated by

FPP.CO2 release stations have been checked and received the alarm from the FPP and HMI.



- Remote emergency stop buttons were not working. Necessary investigations were performed on the Emergency

system. Cabling and their connections were checked. Incorrect connections were found. Faulty connections were

corrected. All Emergency Stop buttons have been checked for their functionality. Observed no anomalies.

- Hydraulic Start System solenoid valve (SOV 1619) was replaced with new one. Demand value has been adjusted back. Replaced solenoid valve is working without any problem.

- Generator Jacking Oil HP pressure gauge calibrations were checked. Pressure gauges were found normal condition.

Troubleshooting need to be performed on the jacking oil system.

- For HMI counter corrections, new control software (Rev: H) which is provided by engineering, has been uploaded to

the controller. However, Linknet N212 fault signal and connected signals were received. Old control software (Rev: F)

has been uploaded to the controller again. However, Linknet N212 fault signal and connected signals were received

again. Faulty Linknet was replaced with new one. New control software which is provided by engineering has not been

uploaded to controller due to lack of enough time. The new software (Rev: H) needs to be installed at the first available

outage.

- Unit has been started by customer due to commercial reasons and reached up 42 MW without any problem.

- Customer ADSL modem configurations were checked for OSM connection issue. ADSL modem was configured as

bridge mode. However internet connection was not established between ADSL modem and Cisco modem. Latest

customer ISP account details have been shared with engineering to check Cisco configuration.



CONCLUSIONS & RECOMMENDATIONS

Open Items: - New control software which is provided by engineering has not been uploaded to

controller due to lack of enough time. The new software (Rev: H) needs to be installed at

the first available outage.

- (-) Polarity ground leakage was measured on the 24VDC system. It needs to be

investigated as soon as possible.

- Water Injection flow meter could not be replaced with new one due to lack of the spare

part on site. It needs to be replaced when the new flow meter delivered to the site.

- Customer ADSL modem configurations were checked for OSM connection issue. ADSL

modem was configured as bridge mode. However internet connection was not established

between ADSL modem and Cisco modem. Latest customer ISP account details have been

shared with engineering to check Cisco configuration.

- Generator Jacking Oil HP pressure gauge calibrations were checked. Pressure gauges

were found normal condition. Troubleshooting need to be performed on the jacking oil

system.

Follow Up Action Items Engineering:

Follow Up Action Items SM/CPM/PM:

Outage Data:

Engine Data:

ESN xxx-xxx Engine Fired Hours - Package Hours 43005

Model LM6000 PC Engine Fired Starts - Package Fired Starts 2513

Maintenance Data:

WP, SB, SL, PB, PL

Performed

Revision/manual reference Date

completed

Comments

WP 1711 00 T48 Thermocouple Inspection 31.05.2015 WP 4024 00 Vibration Monitoring System Check 01.06.2015 WP 4017 00 Chip Detector Check 01.06.2015

Parts Data:

Description PN Removed SN

Removed

Qty Disposition PN

Installed

SN

Installed

STROBE 382A5419P0001 - 1 Replaced 382A5419P0001 -

T48 1962M86P02 - 2 Replaced 1962M86P02 -

CHIP DETECTOR L43563P01 - 1 Replaced L43563P01 -

LINKNET 9905-970 - 1 Replaced 9905-970 -

GAS SENSOR 334A3940P0001 - 2 Replaced 334A3940P0001 -

IGNITER 9392M95P04 - 1 Replaced 9392M95P04 -

SOV1619 382A5502P0001 - 1 Replaced 382A5502P0001 -



UDETAILS AND DATA

Work performed

T48 Thermocouple Inspection

T48 Thermocouple Measurement

T48

Probe

Insulation Resistance

KP-KN

Insulation Resistance

KN-KP

Average

KP-KN(Ohm)

T48A 2.82 2.32 2.57

T48B 2.83 2.14 2.48

T48C 2.85 2.21 2.53

T48D 2.84 2.15 2.50

T48E 2.86 2.13 2.49

T48F 2.81 2.20 2.50

T48G 2.82 2.14 2.48

T48H 2.88 2.22 2.55

As per the GEK 105059 Volume II WP 1711 00; KP to KN circuit resistance should be between

2,4 ohm and 4,1 ohm. Insulation resistance between plug and case should be > 5Mohm.

Tag As Found As Left

-70 ºF 0 ºF 900 ºF 1600 ºF 1900 ºF -70 ºF 0 ºF 900 ºF 1600ºF 1900 ºF

T48 A -70.41 -1.31 902.18 1603.44 1903.21 -69.98 0.04 900.35 1600.65 1899.89

T48 B -71.81 -2.23 901.20 1602.54 1902.52 -69.98 0.04 900.31 1600.43 1899.96

T48 C -72.62 -2.44 901.73 1602.78 1902.05 -69.97 0.03 900.42 1600.33 1900.06

T48 D -73.18 -2.83 900.94 1601.27 1900.76 -70.02 0.08 900.54 1600.52 1900.03

T48 E -72.38 -2.18 900.76 1602.03 1901.51 -69.99 0.02 900.41 1600.45 1900.07

T48 F -69.96 0.06 902.84 1603.67 1903.17 -69.96 0.06 900.23 1600.34 1900.13

T48 G -69.98 0.03 901.45 1604.26 1903.82 -69.97 0.03 900.21 1600.42 1899.96

T48 H -71.21 -1.44 902.31 1603.18 1902.54 -69.96 0.07 900.43 1600.28 1900.04

- Turbine Control system simulated and re- tuned according to T48 low and high set points. Observed no big

differences.

- Between KP/KN and case ohm was > 5Mohm for all the probes.



UDETAILS AND DATA

T3 Calibration Data

T3A

TE-6838A

T3B

TE-6838B

Range -70 to 1200 ºF Range -70 to 1200 ºF

KP-KN KN-KP KP-KN KN-KP

Resistance 5.8 5.2 Resistance 5.8 5.2

Sim.

Temperature

As Found

As Left

Sim.

Temperature

As Found

As Left

-70 -70.54 -69.97 -70 -70.68 -69.99

0 -0.84 0.04 0 -0.57 0.11

400 399.24 399.89 400 399.61 399.85

800 801.84 800.04 800 801.78 799.98

1200 1202.63 1199.97 1200 1203.44 1199.96

As per the GEK 105059, Volume I, between A and B and between C and D pins

Resistance should be between 4,3 ohm and 6 Ohms.

- Turbine Control system simulated and re- tuned according to T3 low and high set points. Observed small differences

(max. 4-5 Fahrenheit) before the simulation.

- On- engine and off-engine cable sockets were cleaned with Contact Cleaner before the re-installation.

T2 Calibration Data

T2A T2B


Sim.

Temp.

As Found

As Left

Sim.

Temp.

As Found

As Left

-70 -69.94 -69.94 -70 -70.01 -70.01

0 0.21 0.21 0 0.32 0.32

120 120.07 120.07 120 120.12 120.12

250 250.12 250.12 250 250.41 250.41

500 500.15 500.15 500 500.18 500.18



DETAILS AND DATA

Work performed:

T25 Calibration Data

T25A T25B


Sim.

Temp.

As Found

As Left

Sim.

Temp.

As Found

As Left

-70 -70.02 -70.02 -70 -69.96 -69.96

0 0.02 0.02 0 0.04 0.04

150 150.11 150.11 150 150.07 150.07

300 300.09 300.09 300 300.14 300.14

500 500.18 500.18 500 500.21 500.21

Calibration Data of Pressure Transmitters

Ambient pressure was measured as 14.45 PSI.

Tag P0

Range 0-16 PSIA

Actual

PSIG

As Found

PSIA

As Left

PSIA

-12.00 2.43 2.43

0 14.44 14.44

1.6 16.04 16.04

P25 Calibration Data

Tag P25A Tag P25B

Range 0 - 100 PSIA Range 0 - 100 PSIA

Actual

PSIG

As Found

PSIA

As Left

PSIA

Actual

PSIG

As Found

PSIA

As Left

PSIA

-12.00 2.46 2.46 -12.00 2.45 2.46

0 14.45 14.45 0 14.48 14.48

50.0 64.46 64.46 50.0 64.46 64.46

75.0 89.45 89.45 75.0 89.47 89.47

85.6 100.04 100.04 85.6 100.11 100.11



DETAILS AND DATA

Work performed:

PS3 Calibration Data

Tag PS3 A Tag PS3 B

Range 0-600 PSIA Range 0-600 PSIA

Actual

%

Actual

PSIG

As Found

PSIA

As Left

PSIA

Actual

%

Actual

PSIG

As Found

PSIA

As Left

PSIA

Vacuum -12.00 2.46 2.46 Vacuum -12.00 2.45 2.45

%0 0 14.46 14.46 %0 0 14.46 14.46

%50 300 314.46 314.46 %50 300 314.46 314.46

%75 400 414.48 414.48 %75 400 414.47 414.47

%100 585.6 600.04 600.04 %100 585.6 600.02 600.02

PTB Calibration Data

Tag PTB A Tag PTB B

Range 0-300 PSIA Range 0-300 PSIA

Actual

PSIG

As Found

PSIA

As Left

PSIA

Actual

PSIG

As Found

PSIA

As Left

PSIA

-12.0 3.44 2.44 -12.0 2.46 2.46

0 15.68 14.46 0 14.45 14.45

150.00 166.52 164.51 150.00 164.44 164.44

285.6 302.31 300.03 285.6 300.02 300.02

P48 Calibration Data

Tag P48

Range 0-150 PSIA

Actual PSIG As Found PSIA As Left PSIA

-12.00 2.43 2.43

0 14.45 14.45

75.00 89.47 89.47

135.6 150.04 150.04



Redundant Over-speed System Check U

Speed signals are simulated from the off-engine cable via signal generator. Speed signals have been monitored

as shown below tables. The alarm and trip points have been appeared on the Alarm Page when we send;

Redundant over speed system check was carried out according to the following set points.

1 Rpm = 0.7491 Hz

Alarm Point: > 10700 Rpm = 8015 Hz

Trip Point: > 10800 Rpm = 8090.3 Hz

For NSD Speed Sensors;

1Rpm = 0.8 Hz

Trip Point > 4050 Rpm = 3240 Hz

XN25A XN25B

Actual

(Hz)

Actual

(rpm)

HMI

(rpm)

Actual

(Hz)

Actual

(rpm)

HMI

(rpm) 2000 2669.89 2670 2000 2669.89 2670 4000 5339.73 5340 4000 5339.74 5340 6000 8009.61 8010 6000 8009.61 8009 8016

(alarm) 10700.84 10701 8016

(alarm)

10700.81 10701

8090

(trip) 10799.72 10800 8090

(trip)

10799.71 10800

NSDA NSDB

Actual

(Hz)

Actual

(rpm)

HMI

(RPM)

Actual

(Hz)

Actual

(rpm)

HMI

(RPM) 1000 1250.01 1250 1000 1250.01 1250 2000 2500.03 2500 2000 2500.02 2500 3000 3749.99 3750 3000 3749.99 3750 3240

(trip) 4050.02 4050 3240

(trip) 4050.02 4050



VIBRATION MONITORING SYSTEM

- Vibration Monitoring System was checked according to WP 4024. Vibration signals were appeared on

the HMI Screen. According to manual “Check accelerometers by tapping it lightly with a small object

(screwdriver handle). Accelerometer is good if control panel shows an indication of tapping “,

- During the taping test, indication was observed on HMI from the both accelerometers.

GENERATOR GAP VOLTAGE

ID NUMBER DESCRIPTION SET POINT UNIT AS FOUND AS LEFT

XE-6807 DE_X

GEN DRIVE END VIB PROBE -10.5 VDC -10.33 -10.33

XE-6808 DE_Y

GEN DRIVE END VIB PROBE -10.5

VDC -9.21 -10.45

XE-6809 NDE_X

NON-GEN DRIVE END -10.5

VDC -10.39 -10.39

XE-6810 NDE_Y

NON-GEN DRIVE END -10.5

VDC -10.46 -10.46

GENERATOR LUBE OIL SYSTEM

Tag

Name

Description

Setpoint

INC

DE

C

FOUND

LEFT

PSL- 6018 GLO Supply Press Low 20 PSIG DEC 20.1 20.1

PSLL-6019 GLO Supply Press LowLow 12 PSIG DEC 19.9 19.9

PSL-6073A GLO AC Pump A Press Low 40 PSIG DEC 40.2 40.2

PSL-6073B GLO AC Pump B Press Low 40 PSIG DEC 37.2 39.8

PSL-6074 GLO DC Pump Press Low 20 PSIG DEC 17.3 20.2

PSL-6050 Jacking Oil Pump Inlet Press Low 10 PSIG DEC 10.1 10.1

PSL-6051 Jacking Oil Pump Inlet Press Low Low 5 PSIG DEC 5.1 5.1

PDSH-6015 GLO Filter Hi Difference 20 PSIG INC 19.5 19.5

PT-6026 GEN. Lube Oil Pressure 0-100 PSG - -0.1 ,100 -0.1,100

TURBINE LUBE OIL SYSTEM

Tag

Name Description Setpoint

Low As Found

High As Found

Low As Left

Low As Left

PT-6122 TURBINE LUBE OIL SCAVENGE PRESSURE

0 -200 PSIG

0.11 199.95 0.11 199.95

PT-6121 TURBINE LUBE OIL SUPPLY PRESSURE

0 -100 PSIG

0.13 100.1 0.13 100.1



Tag Name Description SP Unit INC

DEC

NO/

NC Found Left

PDSH-6120 TURB L/O SUPPLY FILTER HI DP 20 PSID INC NC 20.1 20.1

PDSHH-6144 TURB L/O SUPPLY FILTER HI HI DP 25 PSID INC NC 25.4 25.4

PDSH-6118 TURB SCAVENGE FILTER HI DP 20 PSID INC NC 19.95 19.95

PDSHH-6119 TURB SCAVENGE FILTER HI HI DP 25 PSID INC NC 25.2 25.2

PSLL-6115 TURBINE LUBE LO LO PRESS 15 PSIG DEC NO 13.5 15.0

PSLL-6116 TURBINE LUBE LO LO PRESS 6 PSIG DEC NO 6.1 6.1

PSH-6117 TURB SCAV OIL PUMP PRESS HI 100 PSIG INC NC 99.5 99.5

PSLL-1605 HYD STARTER SKID PRESSURE LO LO 250 PSIG DEC NO 249 249

PDSH-6146 TURBINE VG LUBE OIL FILTER DP 20 PSIG INC NC 21.1 21.1

Pressure switches were calibrated within +- 1 PSIG of set-point.

FIRE PROTECTION SYSTEM



Tag Name

Description

Setpoint

Unit

Found

( ma )

Left

%0 LEL

( ma )

Left

%50

LEL

( ma )

AE-6304A TURBINE GAS

DETECTOR 50% LEL 4.0 4.0 12.0

AE-6304B TURBINE GAS

DETECTOR 50% LEL 5.1 4.0 12.0

AE-6304C TURBINE GAS

DETECTOR 50% LEL 3.8 4.0 12.0

AE-6304D TURBINE GAS

DETECTOR 50% LEL 4.2 4.0 12.0

AE-6304E TURBINE GAS

DETECTOR 50% LEL 3.5 4.0 12.0

AE-6313 GENERATOR GAS

DETECTOR 50% LEL 4.0 4.0 12.0

CHIP DETECTORS

Tag Name Resistance As Found Test Results As Left

MCD 6865 Open Circ. 161 Ohms 2 Ohms 161 Ohms



BATTERY SYSTEMS

24 VDC CONTROL SYSTEM BATTERY VOLTAGES

POSITIVE TO NEGATIVE +27.35 VDC

POSITIVE TO GROUND +27.05 VDC

NEGATIVE TO GROUND -0.30 VDC

BATTERY WATER LEVELS NORMAL

24 VDC FIRE SYSTEM BATTERY VOLTAGES




BATTERY WATER LEVELS NORMAL

125 VDC SYSTEM BATTERY VOLTAGES




BATTERY WATER LEVELS -



Ambient Pressure Replaced Combustible Gas Sensor

Replaced T48 Thermocouples Replaced Chip Detector

Replaced Igniter Replaced RTD 6 Channel Linknet



Replaced Hydraulic System SOV1619 Replaced Fire Protection System Strobe

Fire Protection System Function Checks DC Battery System



HMI SCREENS


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