VBR Turbine Partners...14-15 June 2017 LM2500 User Group Meeting, Brussels 21 DLE Mapping When initial baseline mapping requires more than 1 day or corrective mapping takes more than

14-15 June 2017

VBR Turbine Partners

Independent solutions for:

• Water Washing

• Bearing Failures

• DLE Mapping

LM2500 User Group Meeting, Brussels14-15 June 2017 2

Welcome & thank you …

❖ Welcome …

❖ Thank you for inviting us to

participate in this ETN LM2500

user meeting


Who are we?

Jan Slagter

Technical Director

John de Ruyter

Principal Consultant

Dirk Kusters

Product Manager

Sjirk van der Goot

Business Development


What are we invited for?

❖ At your specific request we

have prepared three topics for

this interactive presentation:

❖ Water Washing

❖ Bearing Failures

❖ DLE Mapping

❖ Additional instruction: provide

information on independent solutions

on these topics that go beyond the

scope of the OEM service portfolio …


Independent solutions for

❖ Water Washing


❖ DLE Mapping


Water Washing

❖ Water Washing is a measure to

stop performance degradation

due to compressor fouling and

to restore compressor efficiency

to the highest possible level

❖ Three well-known solutions:

❖ Prevent : improve air inlet filtration

❖ Prevent : apply compressor coating

❖ Correct : do compressor cleaning

❖ We will present a different

perspective on this topic …


A different perspective

❖ Which combination of the available

compressor fouling prevention

solutions and compressor cleaning

solutions will enable me to operate

my GT engine over a longer period

of time in the most effective way to

optimize the revenue generating

potential of my GT engine?


GT Predictive Health Monitoring

❖ PHM applications enable

optimization of the economic

performance of a GT operation

❖ Optimizing GT compressor

efficiency is part of that system

❖ PHM applications are designed

& developed to optimize

compressor performance in an

effective way


PHM applications

❖ PHM applications provide real

time information about both the

core mechanical health and the

operational parameters of a GT.

❖ As a result it can predict the

economically most effective

moment to perform water

washing (full load or part load,

SAC or DLE, with or without

detergent etc.)


PHM applications

❖ PHM applications enable

evidence based decision

making on applying fouling

prevention or compressor

cleaning solutions like air

filtration, compressor coating,

type of washing (online, offline),

type of cleaning detergent etc.

❖ The results of every action can

be measured and evaluated to

improve future decision making

in a sustainable way


Summary Water Washing & PHM

❖ Predictive Health Monitoring

applications can provide

evidence based decision

support to decide what will be

the most economical

combination of measures and

timing of these measures to

optimize the economic

performance of a GT engine



❖ Water Washing


❖ DLE Mapping


Bearing failures

❖ Who came by plane to this

conference in Brussels?

❖ Who operates a LM2500/+/+G4

with overhauled bearings?


Bearing Failures

❖ The LM2500/+ engine fleet has

seen a large amount of bearing

failures in the past years,

affecting mostly 4B, 5R & IGB

❖ At the request of the ETN

LM2500 users VBR has

conducted a research study to

compare the performance of

(non-)OEM overhauled

bearings vs. new OEM

bearings


Overhauled vs. new bearings

❖ Overhauled bearings are of the

same quality as new OEM

bearings

❖ The use of overhauled bearings

can help to reduce engine

overhaul/repair costs

❖ Bearing overhaul TAT:

Level 1 repair: 2-7 days

Level 4 repair: 10-25 days

❖ The use of rotable bearings can

shorten TAT


Overhauled vs. new bearings

1. Authorized by GE for the LM-

IGT (incl. the LM2500,+ and

+G4):

❖ SKF

1. Authorized by the FAA* and/or

EASA* for the aviation industry:

❖ SKF, (and its subsidiary MRC)

❖ FAG,

❖ AeroBearings,

❖ BII (Timken)

* FAA – Federal Aviation Administration

* EASA – European Aviation Safety Agency


Bearing overhaul levels

NASA approved bearing overhaul:

❖ Level 1: Cleaning, minor buffing,

dimensional and visual inspection of

bearings components

❖ Level 2: Level 1 plus – refinishing of

raceways, replacement of rolling

elements, bore plating as required, and

replating or replacement of cage as

required

❖ Level 3: Level 2 plus – regrinding of one

component

❖ Level 4: Level 3 plus – replacement of

one bearing race. Can also include

updating to the latest configuration with

new part number assigned


Summary bearing overhaul

1. The use of overhauled

bearings in flight engines is

common practice in the

aviation industry

2. There is no difference in

quality between new bearings

and overhauled bearings

3. The use of overhauled

bearings can provide a cost

saving compared to the use

of new bearings



❖ Water Washing


❖ DLE Mapping


DLE Mapping

❖ Manual mapping required after

GG replacement is a time

consuming process and results

in production loss

❖ In general: DLE mapping is

required for a good performing

LM2500/+ DLE engine

❖ Our experience:

❖ Baseline mapping: 1 working day

(to be performed onsite)

❖ Corrective mapping: 0,5 day

(can be performed remote)


DLE Mapping

❖ When initial baseline mapping

requires more than 1 day or

corrective mapping takes more

than 0,5 day most likely other

issues are playing a role:

❖ Hardware problems in the

engine that are “solved” by

adjusting the DLE mapping

❖ Baseline mapping not correct

❖ Mapping engineer has limited

expertise and/or experience


DLE Mapping

❖ Effective maintenance

strategies to reduce turnaround

time required for baseline DLE

mapping and corrective DLE

mapping:

❖ No grounding, shielding or earth

faults

❖ Correctly calibrated

instrumentation

❖ Pre-mixers in good condition

❖ All valves in good working order


DLE Mapping

❖ A peek into the near future …

closed loop controls based on

the performance, emissions

and acoustics criteria of a GT

❖ VBR has developed fully digital

LM2500/+ SAC & DLE engine

models for various purposes:

❖ Predictive health monitoring

❖ Control system commissioning

❖ Control system retrofits

❖ Condition based maintenance

❖ Education & training


DLE Mapping

❖ During the DLE engine model

developments we noticed that

the OEM DLE algorithms were

unnecessary complex …

❖ This unnecessary complexity

provides a serious challenge for

the development of automated

DLE mapping

❖ VBR has developed new DLE

algorithms from scratch that are

more simple & straightforward

than the original GE algorithms


DLE Mapping

❖ These in-house developed less

complex DLE algorithms

provide exactly the same

outcomes as the original OEM

DLE algorithms

❖ We are convinced that these

simplified DLE algorithms

provide a better basis for

developing a reliable

automated closed loop DLE

control system than the original

OEM DLE algorithms …


Questions?

❖ Questions?


Thank you!

❖ Thank you for your

participation!

Documents

VBR Turbine Partners...14-15 June 2017 LM2500 User Group Meeting, Brussels 21 DLE Mapping When initial baseline mapping requires more than 1 day or corrective mapping takes more than