7 fa vigv 2

GE Power Systemse

Revision Date: 02/10/2000Revision Date: 02/10/2000 Property of Power Systems University- Proprietary Information for Training Purposes Only!Property of Power Systems University- Proprietary Information for Training Purposes Only!

Variable Inlet Guide Vane System

GE Power Systemse


GE Power Systemse


GE Power Systemse


GE Power Systemse


VIGV Actuator

GE Power Systemse


GE Power Systemse


GE Power Systemse


VIGV Components

Inner Bushings

Rack & Ring

Pinion Gear Vane

GE Power Systemse


GE Power Systemse


GE Power Systemse


GE Power Systemse


GE Power Systemse


GE Power Systemse


GE Power Systemse


GE Power Systemse


GE Power Systemse


GE Power Systemse


GE Power Systemse


GE Power Systemse


GE Power Systemse


GE Power Systemse


GE Power Systemse


GE Power Systemse


GE Power Systemse


Dump Valve Assembly

GE Power Systemse


Dump Valve

GE Power Systemse


GE Power Systemse


GE Power Systemse


GE Power Systemse


GE Power Systemse


GE Power Systemse


Filter

GE Power Systemse


GE Power Systemse


GE Power Systemse


Simple Cycle

GE Power Systemse


VIGV General Maintenance

• Grease Ring & Actuator - #2 Grease – Annually• Actuator Maintenance and Calibration• Note Clearances: The VIGV’s need to be physically

disconnected and in the normal operating (open) position (shim at the mechanical stop) or at the full open (against the mechanical stop) position. – Vane Tips, – Gear Backlash, ( < 0.040” ) (1.06 mm)– Inner Bushings ( < 0.100” ) (2.54 mm)

• Inspection for mechanical damage and cracks (dye penetrant)

• Hand Clean Vanes when Off-Line WW Performed

GE Power Systemse


IGV Actuator Assembly Maintenance

GE Power Systemse


Bushing

RackGear

Vane

GE Power Systemse


1. Set vanes to the full open position.

2. Set up dial indicator to measure motion normal to the vane cord. Position the indicator to read as close to the vane inner button as possible.

3. Deflect vane in a tangential direction (perpendicular to the air flow direction) to both sides of the bushing clearance and record full dial indicator reading.

Dial IndicatorBushing

AirflowDirection

VIGV in fullyopen position

1

2

3VIGV

VIGV BUSHING INSPECTION

GE Power Systemse


Frame Size VIGV Type 1

Bushing 2

Clearance Limitsfor Bushing

Changeout (>= inches)Inspection Interval

(Hours)

MS5001, MS5002, MS6001**Pre Model FA

403 Stainless403 Stainless

GTD 450

158A7888P004/5/6315A9681 or 339A9913315A9681 or 339A9913

0.0500.0500.075

5,0008,000

16,000 3 8,000

4

MS6001FA GTD 450 339A9913 0.075 16,000 3

8,000 4

MS7001*, MS9001**Pre Model F

403 Stainless403 Stainless

GTD 450

158A7888315A9681 or 339A9913315A9681 or 339A9913

0.0700.0700.100

8,0008,000

16,000 3

8,000 4

MS7001F/FA/FA+ GTD 450 339A9913 0.100 16,000 3

8,000 4

MS9001F/FA GTD 450 328A7020 0.100 16,000 3

8,000 4

Note 1: For unit specific drawing number identification, refer to Model List Item 1301Note 2: For unit specific drawing number identification, refer to Model List Item 0811Note 3: Nominal Base Load IGV angle of 84º or LowerNote 4: Nominal Base Load IGV angle greater than 84º (i.e. 86º or 88º)

VIGV BUSHING INSPECTION SCHEDULE

GE Power Systemse


VIGV TILsTIL 1041-3A: SUMMATION OF TILS FOR "VARIABLE INLET GUIDE VANE INSPECTIONS" May 5, 1989 Applicable to: GAS TURBINES: MS5001 (MODEL N, P&R); MS5002 (B); MS6001; MS7001 & MS9001. PURPOSE The purpose of this TIL is to summarize the requirements and recommendations outlined in all the previous variable inlet guide vane (VIGV) TILs issued concerning corrosion pitting, cracks, gears and gear rack seizure, high cycle fatigue, bushing wear and the related inspections. Also to emphasize the need for attention to be directed at the requirements and recommendations set forth in these TILs. DISCUSSION Several incidents of VIGV failures and subsequent compressor damage have been reported recently that could have been avoided if the recommendations in the TILs listed in Table I & II had been adhered to and/or applied. Table III list the applicable drawings for the inner bushing, C450 VIGV's, stainless steel VIGV's and inner segment modification. RECOMMENDATION Each customer needs to determine which TIL(s) applies to their turbine(s) and then implement the recommendations defined in the TIL(s). Inspection procedures to determine VIGV bushing clearances and cracks and the inspection data sheet to record the inspection data are defined in Attachment A & B and Figures 1, 2 & 3 . Attachments For further info, comments, questions, on these Web pages send and E-Mail to The Power Answer Center Administrator COPYRIGHT 1995, GE

GE Power Systemse


VIGV TILsTIL 1041-3A: SUMMATION OF TILS FOR "VARIABLE INLET GUIDE VANE INSPECTIONS" ATTACHMENT TABLE I VIGV TIL SUMMARY 1: TIL 461C (2-12-80) : Inlet Plenum & IGV Modification. APPLICABLE TO: Select MS5001 (N&P) & MS5002(B). PURPOSE: Reduce IGV vibratory stresses on units with side inlets. Modification to add scroll to the inlet plenum. Inspect IGVs and replace with new high flow design IGV. 2.TIL 511C (8-3-84): Variable IGV Inspection. APPLICABLE TO: MS6001. PURPOSE: Inspect for IGV Corrosion/Pitting. Defines inspection intervals. 3.TIL 515A (8-24-84): Variable IGV Cracks. APPLICABLE TO: Select MS5001(P). PURPOSE: Inspect IGVs for cracks on turbines with 316SS high flow IGVs. If no cracks found, inspect every 4000 hours. 4.TIL 517CR1 (3-28-86): Variable IGV Seizing. APPLICABLE TO: MS5001 (N&P); MS5002 (B); MS6001; MS7001 & MS9001. PURPOSE: IGVs have seized and shanks have seized. Inspect VIGVs gears and gear rack for corrosion and gear backlash.. Lubricate VIGV control ring. 5.TIL 522B (2-19-85): Variable IGV Inspection. APPLICABLE TO: MS5001(P), shipped in 1978, 1979 & 1980. PURPOSE: Follow-up to TIL 515A. Requires IGV inspection every 4000 hours for bushing clearance and IGV cracks on turbines with high flow 316SS IGVs. Defines inspection requirements and procedures. 6.TIL 532CR2 (4-5-89): Variable IGV Inspection. APPLICABLE TO: Select MS6001. PURPOSE: Inspect IGVs for bushing wear and cracks every 5000 hours. After the installation of the new bushings, inspect every 8000 hours. 7.TIL 1004-3 (12-26-86) Compressor Blade Corrosion Limits. APPLICABLE TO: MS5001 (N, P&R) ; MS5002; MS6001; MS7001 & MS9001. PURPOSE: Inspect IGV and 1st stage rotor blading for corrosion pitting. 8.TIL1013-3CR2 (4-5-89): Variable IGV Inspection. APPLICABLE TO: MS5001 (N&P); MS5002(B); MS7001 & MS9001. PURPOSE: Inspect IGVs for bushing wear and cracks every 4000 hours. After the installation of the new bushings, inspect every 8000 hours.

GE Power Systemse


VIGV Crack InspectionTIL ?????? ATTACHMENT A INSPECTION PROCEDURE A. EQUIPMENT REQUIRED 1.Wire brush 2.Scraper/knife 3.Flashlight 4.Rags 5.Solvent (except gasoline or other highly flammable liquid) 6.Liquid penetrant, developer and cleaner (Zyglo preferred) 7.Wire gauges (0.050 to 0.15 inches in 0.005 inch increments) 8.Dial indicator with base/standCAUTION - Prior to starting the inspections, ensure that the VIGV controls are rendered inoperative to prevent inadvertent movement and injury to personnel B. INSPECTION PROCEDURE 1.Prior to beginning the IGV inspection, set the IGV vanes at 84º and record the wear measurement normal to the vane. (See Figure 1 ) 2.Inspect VIGV for movement prior to cleaning by grasping the IGV and attempting to move it within the bushing. (See Figure 2 ) Record the observations on the data sheet ( Attachment B ). 3.Clean all inlet guide vanes by removing all deposits using the scraper/knife, wire brush and non-corrosive solvent. WARNING - DO NOT USE GASOLINE OR ANY OTHER HIGHLY FLAMMABLE SOLVENT 4.VIGV Inner Bushing Clearance Inspection (See Figure 1 & 2 ). a) Load the inlet guide vane inner stem against the inner bushing by pushing first on the pressure surface (concave side) of the vane then on the suction surface (convex side). b) With the inlet guide vane loaded against the bushing in each of the positions described above in item a, measure the clearances (maximum of 2) with the wire gauges. Record the measured clearances on the data sheet. It may be necessary to use a dial indicator to measure the wear in the bushing if the wear is in the form of an undercut and the undercut lip would prevent the feeler gauge from accurately measuring the undercut wear. In this case the dial indicator would measure the movement of the IGV when it is pushed from side to side. If the measured bushing wear exceeds the limits defined in the referenced TILs, it is recommended that new bushings be installed. After the new bushings are installed, reinspection is recommended at intervals of 8000 operating hours. 5.VIGV Inspection for Cracks (See Figure 3 ). a) Apply liquid penetrant to the inlet guide vane in the fillet region under the thrust collar. Flex the vane to ensure that the penetrant seeps into all possible cracks. b) Inspect for cracks. Record on the data sheet the length and location of all cracks observed. Also, record the location and the severity of all pitting observed on the inlet guide vane blade. If cracks are detected during the above inspection, GE strongly recommends the turbine be immediately removed from service to accomplish rectification. Rectification may consist of: 1) Replacing only the cracked IGV's with used non-cracked IGV's of identical part number and installing new bushings at the same time as a temporary fix, in which case the IGV's SHOULD BE REINSPECTED EVERY 4000 FIRED HOURS until a new replacement set of IGV's is installed; or 2) Replace the entire set of IGV's and bushings with new parts if they are available. If cracks are detected in any IGV's and the turbine cannot be immediately removed from service, contact the local GE Field Service Representative immediately. If assistance is needed to perform the recommended inspection, the local Field Service Representative should be contacted

GE Power Systemse


TIL 517CR1 – VIGV Seizing TIL 517CR1: VARIABLE INLET GUIDE VANE SEIZING Applicable to: MS5001, Models N and P; MS5002, Model B; MS6001; MS7001; MS9001 TIL Category: FGHIJ* BACKGROUND/DISCUSSION Variable inlet guide vanes (VIGV) have seized and shanks have been sheared in several incidents over the past few years. The aerodynamic stimulus created by a frozen VIGV has, in one case, resulted in the fracture of a first-stage stator blade. Product improvements have been implemented to minimize VIGV seizing. These improvements are: 1.The material of all bushing spacers has been changed from carbon steel to stainless steel. 2.The VIGV thrust face, at the junction of the shaft and the airfoil, now includes a thrust washer and increased chamfer at the outer diameter to reduce the frictional forces between the VIGV thrust face and inlet casing. 3.The VIGV gears and gear rack are now cadmium plated. RECOMMENDATIONS General Electric Company recommends that the above product improvements be incorporated on all gas turbines experiencing any VIGV seizing. In addition, the following inspections are recommended: A. In conjunction with each combustion inspection: 1.Inspect the VIGV mechanism for proper operation, ensuring each VIGV is free to rotate on its own axis and no shaft has been sheared due to a seizing vane. Seized VIGV's should be corrected when found. If an emergency situation exists and the gas turbine must be operated, ensure that the seized VIGV remains in a full open position, as this reduces but does not eliminate the aerodynamic stimulus. Operation of the gas turbine in this mode should not exceed 100 fired hours. 2.Inspect the VIGV gears and gear rack for corrosion and gear backlash. Excessive gear backlash will allow increased vibratory motion of the VIGV which may lead to VIGV cracking. Gear backlash must not exceed 0.040" (1.00 mm) as measured by dial indicator as shown in Figure 1. If backlash is excessive, contact your local General Electric Company Field Service Representative. 3.Inspect and ensure that the VIGV gear cover drainage hole is free of obstructions. 4.Visually inspect (red dye) the VIGV's for cracks at the junction of the airfoil to the outer thrust face. Replace any VIGV's with crack indications. B. At least once a year, lubricate the VIGV control ring and actuating arm with Shell Alvania #2 or an equivalent grease. If the gas turbine is located in a salt air or industrial environment, and the VIGV gears are not cadmium plated, paint the gears and the control ring rack with grease. For modification requirements and specific part numbers regarding the above product improvement, and for assistance, as required, contact your local General Electric Company Field Service Representative.

GE Power Systemse


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