LM2500+G4 SAC GEK 112859

GE Industrial AeroDerivative Gas Turbines Volume II

WP 432 00

WORK PACKAGE

TECHNICAL PROCEDURES
INDIVIDUAL FUEL NOZZLE FLOW TEST
USING 9400M86 TEST STAND

(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM2500+G4 SAC - MODELS HA, HG, RA and RC

LIST OF EFFECTIVE WP PAGES

Total Number of Pages in this WP is 12
Page Change Page Change Page Change
No. No. No. No. No. No.

1 - 11 . . . . . . . . . . . 10
12 Blank . . . . . . . . 10

Alphabetical Index

Subject Page
Fuel Nozzle Flow Test Analysis........................................................................................................... 10
Fuel Nozzle Fuel Flow Test.................................................................................................................. 8
Initial Setup of Test Stand (9400M86). ................................................................................................ 3

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Volume II GE Industrial AeroDerivative Gas Turbines
WP 432 00

1. Introduction.

This work package contains instructions for individually flow testing the fuel nozzles while installed on the
engine. The fuel nozzles can be tested either installed on the engine, or off-engine if securely mounted on a
bench or in a suitable fixture.

A calibrated sonic nozzle is used to establish a reference flow value from a new or recently repaired fuel
nozzle, or for comparison across the entire set of nozzles currently on the engine. The test stand does not pro-
vide specific serviceable criteria, but rather a relative comparison between fuel nozzles. If one or more
nozzles flow either higher or lower than the reference fuel nozzle, or higher or lower than the other fuel
nozzles currently on the engine, then replacement of the fuel nozzle(s) should be considered.

The tool contains nine different sonic nozzles to provide test capability for all SAC and DLE, LM or LMS
model fuel nozzles. The tool can be used with 110-240 volt (50-60 Hz) input power.

2. Reference Material.

Title Number
Operation and Maintenance Manual GEK 112859
Natural Gas Fuel Nozzle Replacement SWP 101 01
Dual Fuel Nozzle Replacement SWP 101 02
Coke Oven Gas Fuel Nozzle Replacement SWP 101 05

3. Support Equipment.

NOTE

 Part 9400M96G01 contains all sonic nozzles and nozzle adapters necessary to per-
form this flow test on any General Electric marine/industrial gas generator or gas
turbine.

 Sonic nozzles and adapters are available individually from tooling vendor as neces-
sary. User does not need to purchase entire collection of nozzles and adapters con-
tained in 9400M96G01.

 Refer to Table 1 for listing of specific sonic nozzles and nozzle adapters necessary
to perform this flow test.

Nomenclature Part No.

Test Stand, Flow - Fuel Nozzle 9400M86G01
Adapters, Test Stand - Flow Fuel Nozzle 9400M96G01
International Business Machine (IBM) Power Cord Local Purchase

4. Consumable Material.

Dry Shop Air or Nitrogen.

5. Expendable Material.

None required.

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GE Industrial AeroDerivative Gas Turbines Volume II
WP 432 00
6. Initial Setup of Test Stand (9400M86).

A. Install sonic nozzle on control panel as follows:

(1) Identify the part number of the fuel nozzle to be tested.

(2) Identify the circuit on the fuel nozzle to be tested (Figure 1).

NOTE

Each circuit on the fuel nozzle may require a different sonic nozzle.

(3) Obtain the appropriate sonic nozzle to be used (refer to Table 1)

(4) Obtain the appropriate fuel nozzle adapter to be used (refer to Table 1).

(5) Insert the sonic nozzle assembly (9400M96) into position on the control panel using the three
quick-disconnects (Figure 2).

(6) Clamp the sonic nozzle into position using the two toggle clamps.

WARNING

Ensure pressure regulator valve is turned to the minimum pressure, to prevent high
pressure air damage to equipment or personnel.

B. Turn the Position Control Valve (Figure 2) on the control panel to the CLOSED position.

C. Turn Pressure Regulator valve knob fully counterclockwise to minimum pressure.

D. Install inlet coupler and inlet hose onto the control panel inlet connection.

NOTE
If shop air is not available, nitrogen (in tank with maximum pressure of 3,000 psi
[20,684 kPa]) can be used but requires the use of a regulator, provided in the 9400M86
tool storage case. Attach regulator to nitrogen tank and set output pressure to 100 psi
(689 kPa). Otherwise, use of tool is the same as when shop air is used.

E. Install supply coupler (with regulator, if required) to shop air or nitrogen. Maximum inlet pressure is
limited to 110 psi (758 kPa).

F. Install the outlet coupler and outlet hose onto the control panel outlet connection.

G. Verify power supply switch is in the OFF position.

WARNING

Electrical power shall be off before connecting or disconnecting electrical connec-

tors. Electricity causes shock, burns and death.

H. Connect power cable with compatible customer-supplied IBM cord to 110 or 220 volt power supply.

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Volume II GE Industrial AeroDerivative Gas Turbines
WP 432 00

Figure 1. Fuel Nozzle Circuits

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GE Industrial AeroDerivative Gas Turbines Volume II
WP 432 00

Figure 2. Test Stand, 9400M86, Setup for Nozzle Flow Test

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Volume II GE Industrial AeroDerivative Gas Turbines
WP 432 00

Table 1. Fuel Nozzle Adapter and Sonic Nozzle Selection

Fuel Nozzle Circuit Sonic Nozzle Fuel Nozzle

Part Number Part Number Adapter
L31809P08 Gas 9400M96P14 9400M96P08
9400M96P22
Water 9400M96P11 9400M96P02
L31809P12-P13 Gas 9400M96P14 9400M96P08
9400M96P22
Primary 9400M96P12 9400M96P04
9400M96P05
Secondary 9400M96P13 9400M96P02
L31810G06 Gas 9400M96P14 9400M96P08
9400M96P22
L31810G07 Gas 9400M96P17 9400M96P08
9400M96P22
L38631P01 Gas 9400M96P14 9400M96P08
9400M96P22
Primary 9400M96P12 9400M96P04
9400M96P05
Secondary 9400M96P13 9400M96P02
L638784P02 Gas TBD 9400M96P08
9400M96P22
Water 9400M96P13 9400M96P02
L61065P01 Gas 9400M96P17 9400M96P08
9400M96P22
Primary 9400M96P12 9400M96P04
9400M96P05
Secondary 9400M96P10 9400M96P02
L61766P01-P05 Gas 9400M96P17 9400M96P08
9400M96P22
Primary 9400M96P12 9400M96P04
9400M96P05
Secondary 9400M96P10 9400M96P02

I. If fuel nozzles are installed on engine, disconnect fuel hoses from fuel nozzle to be flow tested per
SWP 101 01, SWP 101 02, or SWP 101 05. If fuel nozzles are removed from engine, securely mount
nozzles on a bench or in a suitable fixture.

J. Install the fuel nozzle adapter (obtained in step 6.A.(4)) to the fuel nozzle circuit (Figure 1) to be tested.

K. Connect the control panel outlet hose quick-disconnect to the fuel nozzle adapter (Figure 3).

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GE Industrial AeroDerivative Gas Turbines Volume II
WP 432 00

Figure 3. Test Stand Setup for Fuel Nozzle Flow Test

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Volume II GE Industrial AeroDerivative Gas Turbines
WP 432 00

7. Fuel Nozzle Fuel Flow Test.

A. Turn the control panel power switch to the ON position.

B. Set manometer to channel 2 to read SYSTEM PRESSURE. Depress HOLD button when channel 2 is
being displayed.

C. Turn Position Control valve (Figure 2) to the OPEN position. Slowly increase pressure by adjusting
pressure regulator valve on control panel until system pressure is 18.5-19.5 psi (127.5-134.4 kPa).
Record as CALIBRATION PRESSURE. Refer to attached Excel spreadsheet:

Fuel_Nozzle_Flow_Test_20161202.xlsx

D. Press the SCAN button to change to channel 1 on the manometer and then press HOLD button to hold
channel. Wait 30 seconds or until pressure reading is stabilized. Record as TESTED FN PRESSURE on
attached Excel spreadsheet. Refer to Table 2 for sample chart from spreadsheet.

WARNING

Pressure of 100 psig (689.5 kPa) exists in the supply lines. Relieve pressure to prevent
injury when disconnecting fittings.

E. Repeat step 6.G through step 7.D for all fuel nozzles and circuits to be evaluated.

F. When all fuel nozzle circuits have been tested, turn Position Control Valve to CLOSED position and
close pressure regulator valve.

WARNING

Electrical power shall be off before connecting or disconnecting electrical connec-

tors. Electricity causes shock, burns, and death.

G. Turn ON/OFF power switch to OFF position and disconnect power cable and all the hoses.

H. Store all loose items in storage container.

I. Reinstall nozzles and/or fuel hoses as necessary per SWP 101 01, SWP 101 02, or SWP 101 05.

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GE Industrial AeroDerivative Gas Turbines Volume II
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Table 2. Sample Form from Excel Spreadsheet for Fuel Nozzle Flow Test Calibration and Test Data Recording

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Volume II GE Industrial AeroDerivative Gas Turbines
WP 432 00

8. Fuel Nozzle Flow Test Analysis.

A. Record TESTED FN PRESSURE results (Table 2) for each circuit in each fuel nozzle on attached Excel
spreadsheet.

B. Refer to appropriate 1x, 2x, or 3x chart on attached Excel spreadsheet. Chart will calculate and display
+/- 2 percent flow rate for each nozzle tested. See Figure 4 for example chart.

C. Fuel nozzles should be considered for replacement as follows:

(1) Any fuel nozzle with flow higher or lower than the reference fuel nozzle, or higher or lower than
the nozzles currently used on the engine, by more than 2 percent, should be considered for replace-
ment.

(2) Recommend replacing any fuel nozzle having a supply pressure that falls outside +/- 5 percent of
the average pressure for all 30 nozzles.

D. Replace fuel nozzle(s) as necessary per SWP 101 01, SWP 101 02, or SWP 101 05.

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GE Industrial AeroDerivative Gas Turbines Volume II
WP 432 00

Figure 4. Sample Fuel Nozzle Flow Test Plot

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