Transporte de Los Generadores de Gas Rb211 y Avon Rolls Royce 3

8 - 1Page 1

Revision No. 001Operation, Maintenance and Parts Manual, July 2005

GENERAL

RB211-24GINDUSTRIAL APPLICATIONSOPERATION, MAINTENANCE AND PARTS MANUAL

rSection 1

GENERAL

SECTION CONTENTS

GAS GENERATOR STORAGE - INTRODUCTION 1

PROTECTION OF INSTALLED GAS GENERATORS 2

EXTERNAL PROTECTION 3

Aluminium Castings 3.1

RECOMMENDED PROTECTION PROCEDURES 4

DESPATCH PACKAGE ASSEMBLY 5

Bleed Valve Duct Removal Prior to Packing 5.1

Hydraulic (Volvo) Starter Motor Removal Prior to Packing 5.2

Air/Gas (Hilliard) Starter Motor Removal Prior to Packing 5.3

Refitting Starter Motors (Both Types) on Receipt of Gas Generator 5.4

Replacement of Nose Bullet Prior to Packing (if applicable) 5.5

RE-HUMIDITY PROOFING USING DESICCANT WHILE IN STORE 6

FITTING OF TRANSPORTATION BOLTS 7

PACKING THE GAS GENERATOR IN MVP BAG 8

SILICA GEL DESICCANT REGENERATION INFORMATION 9

SILICA GEL DESICCANT REGENERATION PROCEDURE 10

GAS GENERATOR INTO/OUT OF TRANSPORTATION STAND 11

Remove Gas Generator from Transportation Stand LW15085 11.1

Fit Gas Generator to Transportation Stand LW15085 11.2

TABLES

Table 1 Non-Installed Gas Generator Storage Requirements

Table 2 Installed Gas Generator Storage Requirements

RB211-24G

8 - 1Page 2

GENERAL


INDUSTRIAL APPLICATIONSOPERATION, MAINTENANCE AND PARTS MANUAL

r

INTENTIONALLY LEFT BLANK

8 - 1Page 3


GENERAL


rGENERAL

1 GAS GENERATOR STORAGE - INTRODUCTION

The storage life of a gas generator is a maximum of four years when stored in abagged and fully treated condition. Under these conditions an inspection, tocheck for the presence of moisture or a deterioration in the storage facilities,should be carried out at the specified time intervals. Gas generators which are tobe stored or transported require protection against the ingress of foreign materialand against corrosion.

2 PROTECTION OF INSTALLED GAS GENERATORS

The treatment of installed gas generators when they are not required to run for aminimum of one month or a maximum of six months is dependant upon theclimate and storage conditions. It is however, recommended that where possible,gas generators are stored in a bagged condition. If the gas generator is to bemaintained in a state of immediate readiness it should have a preservation runevery 30 days. The preservation run should consist of a five minute run at idlingspeed followed by one minute at the maximum operating rev/min or highestpracticable rev/min.

CAUTION REMOVE ALL COVERS, BLANKS AND VPI/CHC PAPERBEFORE STARTING THE GAS GENERATOR.

3 EXTERNAL PROTECTION

Prior to storage, the engine should be cleaned externally and any corrosionremoved by rubbing with fine abrasive cloth. The exposed metal should beprotected in the following manner.

3.1 Aluminium Castings

Apply one coat of primer and when the primer is dry apply one coat of theapproved colour of air drying enamel.

4 RECOMMENDED PROTECTION PROCEDURES

The protection procedure for a gas generator is dictated by the climatic andstorage conditions. Tables 1 and 2 give the minimum recommended proceduresfor installed and non-installed gas generator at each condition.

RB211-24G

8 - 1Page 4

GENERAL



r5 DESPATCH PACKAGE ASSEMBLY

CAUTION DO NOT LIFT THE COMPLETE STAND AND GASGENERATOR BY THE GAS GENERATOR LIFTING EYES.WHEN USING A SLING TO LIFT THE STAND AND GASGENERATOR THE ANGLE CONTAINED BY THE SLING MUSTNOT EXCEED 120 DEGREES.

The assembly consists of a gas generator mounted to a steel frame which issupported on a base by shock absorbers. Two spherical bearings bolted to theframe secure the trunnions, and a bracket which can be pivoted, is bolted to thebottom of the LP turbine casing rear flange at its circumference to provide thefinal support attachment. The gas generator is encased in a moisture and vapourproof bag containing silica gel and the gas generator and frame are supported onthe shock absorbers for protection against the shock loads of transit andhandling.

The intake assembly and nose fairing are further protected by a tubular steelframe, supported by two side members, which can be lowered for loading andunloading operations.

5.1 Bleed Valve Duct Removal Prior to Packing

(1) Applicable to gas generators fitted with three HP3 starting bleed valves.

(2) The bleed valve duct fitted around the starboard HP3 starting bleed valvemay be damaged whilst lifting the gas generator from its stand. Thestarboard duct on the horizontal centre line, (as viewed from the rear of thegas generator) protrudes slightly beyond the stand (due to the addition ofthe pipe unit adapter, HP3 air) and can be damaged by forklift trucks.

(3) Therefore in view of (2) preceding it is recommended that the duct togetherwith the starting bleed valve assembly and control pipe, should be removedfrom the gas generator prior to it being transported.

(4) Transportation blank, Part No. LK40910, is to be fitted to the exposedorifice. Suitable pipe blanks should be fitted to the pipe ends and interfaceconnection (refer to Chapter 5, Para 1.1).

(5) The duct, starting bleed valve assembly, control pipe and associated fittingsshould be suitably packaged and accompany the gas generator inside theMVP bag during transportation.

8 - 1Page 5


GENERAL


r5.2 Hydraulic (Volvo) Starter Motor Removal Prior to Packing

(1) Applicable to gas generators fitted with hydraulic (Volvo) starter motors.

WARNING UPON RELEASING THE STARTER MOTOR A SMALLQUANTITY OF RESIDUAL OIL IS RELEASED ANDACTION SHOULD BE TAKEN TO CONTAIN THIS OIL.

(2) Refer to Chapter 6, Para 3, the hydraulic (Volvo) starter motor should beremoved from the starter motor gearbox/gas generator and packed in itsown transportation container, Part No. ADT1419, before installing the gasgenerator in the transportation stand or canister LW15182.

5.3 Air/Gas (Hilliard) Starter Motor Removal Prior to Packing

(1) Applicable to gas generators fitted with air/gas Hilliard straight and helicallobed starter motors.

WARNING UPON RELEASING THE STARTER MOTOR A SMALLQUANTITY OF RESIDUAL OIL IS RELEASED ANDACTION SHOULD BE TAKEN TO CONTAIN THIS OIL.

(2) Refer to Chapter 6, Para 2, the air/gas (Hilliard) starter motor should beremoved from the gas generator and packed in its own transportationcontainer before installing the gas generator in the transportation stand orcanister LW15182.

NOTE The transportation container is supplied by Hilliard with thestarter motor on receipt of the gas generator and should remainwith the starter motor.

5.4 Refitting Starter Motors (Both Types) on Receipt of Gas Generator

(1) Refer to Chapter 6, Para 3 for details of refitting starter motor (both types)on receipt of the gas generator.

5.5 Replacement of Nose Bullet Prior to Packing (if applicable)

(1) Certain contractual specifications may delete the nose bullet and replace itwith an air guide duct to suit the radial intake assembly type of intake.

(2) However the nose bullet is initially supplied with the gas generator and isremoved on site and carefully stored and only then replaced by the air guideduct.

(3) On packing the gas generator for storage or despatch, the air guide duct isto be removed and carefully stored. The nose bullet should then be replacedon the gas generator. Refer to Chapter 5, Para 9, Removal of the NoseBullet and Removal of the Air Guide Duct.

RB211-24G

8 - 1Page 6

GENERAL



r6 RE-HUMIDITY PROOFING USING DESICCANT WHILE IN STORE

If humidity proofing is necessary whilst in store, proceed as follows:

(1) Refer to the instruction card (in the humidity bag pocket) and open up thehumidity bag.

(2) Remove the desiccant bandoliers from the gas generator and the humidityindicator card from inside the humidity bag.

(3) Heat the bandoliers as described in Para 9 to restore the protectiveproperties together with the indicator card, sufficiently to restore it to the'safe' condition.

CAUTION SINCE THE DESICCANT LOSES ITS PROTECTIVEPROPERTIES WITHIN TEN MINUTES OF EXPOSURETO ATMOSPHERE, IT IS ESSENTIAL THAT THE NEXTTHREE OPERATIONS ARE CARRIED OUT AS RAPIDLYAS POSSIBLE.

(4) Remove the closure tool from the humidity bag pocket, refer to theinstruction cards and fit the tool to the rear end of the closure in readinessfor full closure.

(5) Wrap the heated bandoliers on the gas generator and insert the indicatorcard in the 'safe' condition in the bag window pocket.

CAUTION THE DESICCANT BAGS OF THE BANDOLIERS MUSTNOT MAKE METALLIC CONTACT WITH ANY PART OFTHE GAS GENERATOR.

(6) Refer to the instruction cards and fully close the humidity bag.

(7) Return the instruction cards and closure tool to the bag pockets and fit thepacking case cover.

(8) Record the date of humidity proofing for reference when carrying out thehumidity checks.

7 FITTING OF TRANSPORTATION BOLTS

CAUTION IF THE GAS GENERATOR IS TO BE TRANSPORTEDWITHOUT ITS BURNERS, FIT THE FOUR TRANSPORTATIONBOLTS.

(1) Refer to Chapter 10, Section 1, Fig 53, during transportation either to orfrom a site installation, without the burners fitted, it is possible for thecombustion liner to move (rotate) slightly within the outer casing. Anymovement of the combustion liner relative to the outer casing causesmisalignment of the burner holes.

8 - 1Page 7


GENERAL


r(2) In order to prevent the combustion liner from moving when a gas generator

or 04 module is being transported, four bolts (Part No. LOT26011) are to befitted at burner positions 3, 7, 12 and 16 (refer toChapter 10, Section 1, Fig 53) and tightened to the standard torque11.5Nm (100 lbf in.). Please note that these are transportation bolts ONLYand should not, under any circumstances, be used for securing the burners.

8 PACKING THE GAS GENERATOR IN MVP BAG

(Refer to Chapter 10, Section 1, Fig 60).

(1) Remove the pip pins that secure the front guard support to the mainassembly; lower the guard.

(2) Remove the four pip pins that secure the rear guard; remove the rear guard.

(3) Pivot the rear support rearwards in the stand.

(4) Remove the two bolts, plain washers, spring washers and nuts that secureeach bearing housing and remove the housings complete with trunnions.

(5) Remove the three countersunk screws and clamping plate from each sideof the main assembly.

(6) Secure the trunnions and bearings to the gas generator by eight bolts andspring washers.

(7) Place the open MVP bag into position so that the holes are in line with thecorresponding holes and studs on the main assembly.

(8) Secure the bag with the two clamp plates and six countersunk screws.

(9) Lower the gas generator carefully into position so that the trunnions arelocated in line with the securing bolt holes.

(10) Pivot the rear support to locate the IP turbine rear flange and secure withbolts, washers and nuts.

(11) Secure each trunnion with the two bolts, plain washers, spring washers andnuts.

CAUTION 1 SINCE THE DESICCANT LOSES ITS PROTECTIVEPROPERTIES WITHIN TEN MINUTES OF EXPOSURETO ATMOSPHERE THE CLOSING OPERATIONSSHOULD BE CARRIED OUT AS QUICKLY AS POSSIBLE.

CAUTION 2 THE DESICCANT BAGS OF BANDOLIERS MUST NOTMAKE ANY METALLIC CONTACT WITH ANY PART OFTHE GAS GENERATOR.

RB211-24G

8 - 1Page 8

GENERAL



r(12) Refer to Chapter 5, Table 2, pad any sharp projections on the gas

generator with cellulose wadding.

(13) Refer to Chapter 5, Table 2, place greaseproof paper on top of the gasgenerator and secure with adhesive tape.

(14) Refer to Chapter 5, Table 2, place 42 bags of silica gel desiccant in sixbandoliers and place them in appropriate positions over the greaseproofpaper.

(15) Refer to the instruction cards, fit the closure tool and fully close the bag.

(16) Replace the instruction cards and closure tools in the bag pockets.

NOTE The MVP bag should not be left in the open condition for anyundue period of time.

9 SILICA GEL DESICCANT REGENERATION INFORMATION

(1) The procedure to regenerate silica gel described in Para 10 is taken frominformation supplied by a leading silica gel manufacturer.

(2) Although the regeneration of silica gel is possible under mostcircumstances, it should be noted that the silica gel could break and crackunder regeneration and the fabric of the packaging may suffer stress andweaken. If a small hole occurs in the packaging or the adhesion betweenlayers deteriorates then there is a possible risk of the gel leaking, causingcontamination of the gas generator.

(3) Whilst the information contained herein is given in good faith, theregeneration of the silica gel is a process beyond the control of RR PowerEngineering plc or the silica gel manufacturer. Neither RR PowerEngineering plc nor the silica gel manufacturer accepts any liability for anyloss or damage caused directly or indirectly by the regeneration of silica gelor by the use of regenerated silica gel.

10 SILICA GEL DESICCANT REGENERATION PROCEDURE

(1) Desiccant silica gel is supplied in an activated, dry state and its typicalmoisture loss at 140°C (284°F) is 1.5%.

(2) In this state the silica gel desiccant will rapidly pick up water vapour from theatmosphere and will continue to absorb moisture over a time until it cannothold any more. At this point, the silica gel is referred to as being saturatedor de-activated. For information, Chapter 10, Section 1, Fig 54, shows thetypical rate at which silica gel will absorb moisture from the atmosphere atambient temperature and varying levels of relative humidity.

8 - 1Page 9


GENERAL


r(3) Once saturated, silica gel can no longer function as a desiccant. However,

it is possible to remove the stored water from the pores of the silica gel andthereby reactivate it. This process is known as regeneration.

(4) Refer to Chapter 10, Section 1, Fig 55, regeneration can be achieved byheating in a ventilated oven to a temperature of 150°C (302°F) for betweentwo and four hours. It is important that temperatures above 180°C (365°F)are not used since at such high levels the structure of the silica gel isadversely affected and its absorption properties can be irreversiblydestroyed. In the case of gel sachets, a temperature of 100°C (212°F)should not be exceeded to avoid damaging the sachet material.

(5) A microwave oven can also be used to regenerate the desiccant silica gel.However, care should be taken not to overheat since this may cause the gelto shatter. Optimum heating times and power settings will vary from oven tooven and should be determined by trial. In general, heating at mediumpower for a few minutes should be sufficient.

(6) If silica gel is regenerated in a domestic oven, it is recommended that theoven should be properly cleaned afterwards.

(7) Provided regeneration is carried out correctly, silica gel may be successfullyre-used many times, although its efficiency will tend to reduce onsuccessive regeneration cycles.

(8) This information, properly applied may be of benefit to operators wishing toprotect their gas generators with silica gel and is reproduced from datasupplied by a silica gel desiccant manufacturer.

(9) However the processes and results previously described are laboratoryderived and there is no certainty that results obtained in a laboratory arereproducible on a larger scale or that they may be freely used withoutinfringing patents, (including patents owned by Unilever or its subsidiaries).

(10) Operators or overhaul bases should rely upon their own judgement andexpertise in determining whether a particular product is suitable for the useintended. For further assistance regarding silica gel reactivation, includinghealth and safety procedures please contact Technical Support.

RB211-24G

8 - 1Page 10

GENERAL



rNON-INSTALLED GAS GENERATOR

Table 1 Non-Installed Gas Generator Storage Requirements

(1) FIT COVERS AND BLANKS

(2) INSERT VPI/CHC PAPER

(3) LANOLIN SPRAY GAS GENERATOR FORWARD OF THE COMBUSTIONCASING

(4) GREASE VIGV LINKAGE

(5) GAS GENERATOR STORED INSIDE BUILDING

(a) PACK GAS GENERATOR IN THE MVP BAG AND ADD DESICCANTAS SPECIFIED IN PARA 9.

(6) GAS GENERATOR STORED INSIDE OR OUTSIDE BUILDING

(a) PACK GAS GENERATOR IN THE MVP BAG AND ADD DESICCANTAS SPECIFIED IN PARA 9. INSTALL IN CONTAINER LOE1080 ANDADD FURTHER DESICCANT AS SPECIFIED IN SECTION 2

(b) INSTALL GAS GENERATOR IN CONTAINER LOE1080 ANDNITROGEN PURGE AS SPECIFIED IN SECTION 2 (MVP BAGOPENED).

CONDITIONANTICIPATED

PERIODS(1) (2) (3) (4) (5/6)

Heated building and dry tropical

Up to 7 days *

8 to 30 days * *

31 days to 6 months * * *

over 6 months * * * *

Unheated building, temperature

Up to 7 days *

8 to 14 days * *

15 days to 30 days * * * *

31 days to 6 months * * * *


Humid tropical (above 80% humidity

Up to 3 days *

4 to 8 days * *



8 - 1Page 11


GENERAL


rTable 2 Installed Gas Generator Storage Requirements

(1) FIT COVERS AND BLANKS

(2) INSERT VPI/CHC PAPER

(3) INHIBIT COMPRESSOR

(4) LANOLIN SPRAY GAS GENERATOR FORWARD OF THE COMBUSTIONCASING

(5) GREASE VIGV LINKAGE

(6) BAG GAS GENERATOR AND ADD DESICCANT AS SPECIFIED INPARA 9

CONDITIONANTICIPATED

PERIODS(1) (2) (3) (4) (5) (6)

Heated building and dry tropical

Up to 7 days *

8 to 30 days * *


over 6 months * * * * *

Unheated building, temperate

Up to 7 days *

8 to 14 days * *

15 days to 30 days * * *

31 days to 6 months * * * * *


Humid tropical(above 80% humidity)

Up to 3 days *

4 to 8 days * *

8 days to 3 months * * * * *


RB211-24G

8 - 1Page 12

GENERAL



r11 GAS GENERATOR INTO/OUT OF TRANSPORTATION STAND

11.1 Remove Gas Generator from Transportation Stand LW15085

(Refer to Chapter 10, Section 1, Fig 68)

(1) Remove the front and rear guard units.

(2) Attach the lifting beam LW14741 to the gas generator lifting brackets andadjust the lifting beam to balance.

(3) Take the weight of the gas generator and remove the bolts securing thetransportation stand rear support bracket. Swing the bracket rearwards.

(4) Remove the bolts securing the stand trunnions and bearing housingassemblies to the stand.

(5) Lift the gas generator clear of the transportation stand.

11.2 Fit Gas Generator to Transportation Stand LW15085

(Refer to Chapter 10, Section 1, Fig 68)

(1) Remove the bearing housing and trunnion assemblies from thetransportation stand and fit to the gas generator.

(2) Carefully lower the gas generator into the transportation stand and securethe bearing housing and trunnion assemblies with the tool washers, boltsand nuts.

(3) Swing the rear support bracket forward and secure to the gas generator rearflange with the tool washers, bolts and nuts.

(4) Remove the lifting beam LW14741.

Documents

Transporte de Los Generadores de Gas Rb211 y Avon Rolls Royce 3