TROUBLESHOOTING EQUIPMENT The tools and test equipment needed to properly adjust, align, calibrate, and troubleshoot the ECSS equipment are listed in volume 1, chapter 6, of all the S9234-series technical manuals. This is a list of all test gear, tools, and consumables needed. However, it does not necessarily mean that all of them have to be used on each piece of equipment. Equivalent tools and test gear with superior measuring capabilities may be substituted for the items shown by a double asterisk (**) before the name.
THE ALLISON 501-K17 GTE Maintenance and troubleshooting procedures for the Allison 501-K17 GTE are similar to the procedures used for the LM2500 engine. In all cases, you must use the proper EOSS, PMS, and technical manuals when conducting any maintenance or troubleshooting.
Volume 2 of the Model 104/ Model 139 Gas Turbine Generator Set technical manual is divided into two parts. Part 1 contains all the necessary information, procedures, and diagrams for locating a malfunction. Part 2 contains the corrective maintenance procedures for adjustment and alignment, repair, and removal/ replacement of components.
When entering and working within the engine enclosure, follow the proper EOSS procedures and all standard safety precautions at all times.
COMPONENT CHANGEOUT Gas turbine-powered ships are outfitted with all the equipment necessary to remove and replace engine components. As a senior petty officer, you will be supervising component changeouts. As with any job, you must plan and organize before starting the project. Since most GTE problems occur while the ship is underway, corrective maintenance must be performed immediately. If you insist upon strictly following step-by-step procedures as set forth in the technical manual, you will save time by preventing errors. Do not rely upon your memory for component changeouts.
PREPARATIONS Before changing components on a GTE, be sure that the replacement parts and tools needed to do the job are available. Inspect all measuring devices (such as torque wrenches, meters, and micrometers) to ensure they are in calibration. Also be sure that you and your team have read the proper technical manual procedures.
One method that helps ensure proper use of the technical manual procedures is to provide team members with a copy of the procedures. Have them check off each step as it is completed
ESTIMATED TIME OF REPAIR When making an estimated time of repair (ETR), you must be as accurate as possible. Your ETR could ultimately affect the operational schedule of the ship. Take into account all the factors that may affect an ETR, such as capabilities of your personnel, availability of materials, test procedures, preparations, and time for unexpected delays.
REPLACEMENT As a supervisor, your primary concern is for the safety of your personnel and equipment. As a responsible petty officer, you set the example. Short cuts that go around safety precautions do not save time. You can prevent accidents and save time by explicitly following safety precautions and actively using safety programs such as tag-out and electrical safety.
During component changeout, keep track of tools going into and out of the GTE enclosure. Be sure your personnel use care when removing lockwires, cannon plugs, and so forth. Tag and bag all bolts, nuts, washers, and interferences that are removed for reinstallation. Capping fluid lines will prevent contamination of open systems. Use care when replacing GTE components. Most problems that arise after component replacement are easily avoided. Just remember to work carefully and always follow the procedures listed in the technical manuals.
COMPLETION OF REPAIRS After GTE repairs are complete, ensure that the proper entries are made in the MGTESR. and Engineering Log. If the replaced component is from selected equipment, make sure you follow procedures outlined in NSTM, chapter 234, "Marine Gas Turbine Equipment Log Books and Service Records," section 8.
When preparing turn-in components for shipment, plug or cap all openings. Do not take the components apart to look inside. You may damage the component and distort the findings of the testing facilities. The repair activity must make a determination of cause of failure. Other activities collect and use information on failed components to create design improvements.
LM2500 ENGINE CHANGEOUT At some point in your career, you may have the opportunity to supervise an engine changeout. This section discusses this topic from a supervisory standpoint. For more information on procedures for engine changeout and post changeout adjustments, you should consult the Propulsion Gas Turbine Module LM2500, volume 2, part 3; the Gas Turbine Generator Set, volume 2; and the Team Leader Guide for FFG-7 Class Ships or the Team Leader Guide for DD-963 Class Ships, as applicable.
PREPARATION Planning a full-scale evolution such as a GTE changeout takes effort, coordination, and drive. Careful planning is an essential ingredient to your effective supervision of a GTE changeout. You can reduce delays and confusion by anticipating the needs of escorts and clearances for intermediate maintenance activities (IMAs), civilians, and other personnel involved.
An organizational meeting of all personnel, including those involved with ancillary tasks (crane operators, hook tenders, riggers, and so forth), is necessary to plan the evolution. At the meeting you should inform each individual of his or her responsibility to the overall team effort. Explain how each job affects the effort and completion schedule. You should distribute monitoring guides and inventory lists to the parties concerned with an explanation of how and when to use them. During the meeting, you should clarify the time frame established for each task completion. Having given personnel clear directions, you can expect them to perform the procedures on schedule. They should not be surprised when you arrive for a checkpoint verification. The most important topic to emphasize is safety. It is your responsibility as team leader to ensure that all safety precautions are strictly followed.
Assign a safety observer to your changeout team. His/ her sole responsibility is to ensure the safety of personnel working inside the GTE module and uptakes. The safety observer should ensure ancillary personnel and technicians are qualified for tasks assigned and all safety equipment is on station before starting changeout.
COORDINATION You can reduce or eliminate wasted of time by properly coordinating several tasks throughout the changeout. Simple things such as the proper placement of the special support equipment (SSE) containers can eliminate extra walking and moving of components. The SSE containers should be placed within the reach of the crane to avoid unnecessary movement of equipment into the lift area. Crane service must be controlled and used exclusively for the changeout. The engine containers should be brought to the site as soon as possible so they can be opened and ready for installation when scheduled.
Team members must coordinate amongst themselves for certain functions, such as the removal and installation of components and the constant passing of fixtures down and into the module. Communication between team members during the changeout process is very important. One way you can enhance both teamwork and communications is by the use of portable radio equipment.
POST CHANGEOUT REQUIREMENTS With the completion of an engine changeout, you must return the SSE and container to the cognizant repair (support) facility. The damaged engine is packaged in a container and is then shipped to the appropriate NADEP for repairs. The paper work involved in the changeout is lengthy, but necessary for proper documentation. careful preparation of SSE containers and engine containers will ensure they will reach their final destination with no shipping damage.
Returning Containers Returning the replaced gas generator, power turbine," and containers requires that the major components plus the T5.4 and Pt5.4 harnesses and the speed sensors of that engine be packed within the containers. The completed log book is also returned with the container. After everything is secured within the containers and the desiccant bags have been dried out/ changed, the cover is bolted down and pressurized with nitrogen for shipment. The ship's supply department is responsible for shipping the engine containers to the designated NADEP.
When the SSE containers have been completely inventoried, restacked, and secured, the supply system is responsible for returning the empty containers to their place of origin. The 05X32 office of NAVSEA is notified of the condition of the containers by the team leader via the chain of command.