Avon UTC 1535c5

INDUSTRIAL AVON GAS GENERATOR
MAINTENANCE
CHAPTER 5
FAULT DIAGNOSIS
CONTENTS
Para
GENERAL INFORMATION 1
STARTING AND START SEQUENCE 2

Starter and Gas Generator - Do Not Rotate 2.1
Starter Rotates, Gas Generator Does Not Rotate 2.2
Gas Generator Rotates but Fails to Light Up - 2.3
Gas Fuel
Gas Generator Lights Up but Fails to Accelerate 2.4
to Idling Speed
Gas Generator Lights Up but Acceleration to 2.5
Idling Speed is Too Fast (Resulting in High
Exhaust Cone Trip Activating)
RUNNING 3
Gas Generator Accelerates from Idling Speed but 3.1
Fails to Reach Selected Rating
Fluctuating Gas Generator Speed 3.2
Gas Generator Compressor Stall 3.3
High Oil Consumption 3.4
ALARMS AND TRIPS 4

Avon Vibration Alarm or Trip 4.1
Lubrication Oil Low Pressure Trip - Phase I 4.2
Gas Generators
Lubrication Oil Low Pressure Trip - Phase II 4.3
Gas Generators
Cooling Air Vent High Temperature Trip 4.4
Exhaust Cone High Temperature Alarm or Trip 4.5
Exhaust Cone High Temperature Spread 4.6
Exhaust Gas High Temperature Alarm or Trip 4.7
(Close coupled gas generators)
Exhaust Gas High Temperature Spread 4.8
Anti-Icing Failure Trip 4.9
SHUTTING DOWN 5
Gas Generator Run Down Time Excessively Short 5.1
CONTENTS
1535-GAS 5
May/00 Prelim 1
MAINTENANCE
CHAPTER 5
FAULT DIAGNOSIS
1 GENERAL INFORMATION
(1) The fault diagnosis details given in this Chapter are

intended to assist experienced gas generator
personnel in the interpretation of incorrect running
conditions during operation of the gas generator.
These details are not exhaustive but provide guidance
through a step-by-step sequence of possible causes
and remedial action.
(2) Diagnosis of faults should be logical and systematic,

and include:-
(a) Interpretations of symptoms
(b) Elimination of obvious causes, for example,

defective indicating equipment.
(c) Elimination of unlikely causes and establishing

probable causes.
(d) Determining which component(s) could be

responsible.
(e) Complete simpler, quicker checks before engaging

in extensive investigatory work.
(f) Decision if fault can be rectified by adjustment

or component change.
(3) The remainder of this chapter comprises a series of

charts, each dealing with a specific symptom. Where
this information fails to resolve a problem, further
advice and assistance may be obtained from Customer
Support Department, Rolls-Royce Power Engineering plc,
Ansty, Coventry CV7 9JR, England
FAULT DIAGNOSIS
1535-GAS 5
May/00 Page 1
MAINTENANCE
2 STARTING AND START SEQUENCE
2.1 Starter and Gas Generator - Do Not Rotate
Check gas generator for

freedom of rotation
IF
NOT O.K. O.K.
Reject gas generator Check Plant Starting

Circuit. See Plant
Manufacturer's Manual
IF
NOT O.K. O.K.

Rectify Plant Starting Circuit. Remove and check gas
See Plant Manufacturer's Manual generator starter motor
IF
NOT O.K. O.K.

Fit new gas generator mounted Check starter drive
starter motor assembly. See NOTE
IF
NOT O.K. O.K.

Fit new starter drive Attempt another start
assembly
IF
NOT O.K. O.K.

Consult Rolls-Royce before Gas generator serviceable
rejecting gas generator
NOTE: Check the operation of the starter engaging mechanism by

turning the gas generator in the correct direction and
listening for the clicking sound from the ratchet pawls.
FAULT DIAGNOSIS
5 1535-GAS
Page 2 May/00
MAINTENANCE
2.2 Starter Rotates, Gas Generator Does Not Rotate

freedom of rotation
IF
NOT O.K. O.K.

Reject gas generator Check operation of
starter engaging
mechanism by turning the
gas generator in the
correct direction and
listening for the
clicking sound from the
ratchet pawls
IF
NOT O.K. O.K.

Change pawl carrier assembly Remove gas generator
mounted starter motor,
or remove starter drive
coupling (as applicable)
and check reduction
gears for damage
IF
NOT O.K. O.K.

Change the starter drive Check movement of pawls
housing or ratchet bearing in pawl carrier assembly
housing (as applicable)
IF
NOT O.K. O.K.

Change pawl carrier assembly Reassemble and attempt
another start
IF
NOT O.K. O.K.

Consult Rolls-Royce before Gas generator service-
rejecting gas generator able
FAULT DIAGNOSIS
1535-GAS 5
May/00 Page 3
MAINTENANCE
2.3 Gas Generator Rotates but Fails to Light Up - Gas Fuel
WARNING: BEFORE EACH ATTEMPTED START, THE GAS GENERATOR

MUST BE SUBJECTED TO A PURGE CYCLE, I.E. A START
WITH IGNITION AND FUEL SUPPLY OFF, TO CLEAR ANY
RESIDUAL GAS FUEL FROM THE GAS GENERATOR.
Check that all control system connections

to the gas generator are satisfactory
IF
NOT O.K. O.K.

Rectify unsatisfactory With the ignition and
connection(s) fuel supply OFF, start
the gas generator and
check that the cranking
speed is satisfactory.
See Plant Manufacturer's
Manual
IF
NOT O.K. O.K.

Check gas fuel pressure at With ignition OFF and
inlet to starter OR gas fuel supply ON start
electrical supply to starter the gas generator and
and reset as necessary. check that the gas fuel
See Plant Manufacturer's Manual manifold starting
pressure is satisfactory.
OR See Plant Manufacturer's
Manual
Rectify starter. See
Plant Manufacturer's Manual
IF
NOT O.K. O.K.

Reset starting gas fuel Check the ignition
pressure. See Plant system, NOTE 1
Continued
FAULT DIAGNOSIS
5 1535-GAS
Page 4 May/00
MAINTENANCE
IF
NOT O.K. O.K.

Rectify ignition system. Remove and inspect fuel
See Plant Manufacturer's Manual burners for cleanliness
IF
NOT O.K. O.K.

Clean the fuel burners Check gas fuel control
system. See Plant
IF
NOT O.K.
Rectify gas fuel control
system. See Plant
WARNING: HIGH TENSION ELECTRICITY CAN BE LETHAL. ALLOW AT LEAST

TEN MINUTES OF TIME TO ELAPSE AFTER THE IGNITERS HAVE
OPERATED BEFORE TOUCHING THE HT LEAD OR IGNITER PLUG.
NOTE 1: With the gas fuel supply OFF and the ignition ON, motor
the gas generator on the starter and listen for the
sharp irregular double cracking sound which indicates
that the ignition system is functioning normally.
If only one regular crack is heard, one plug is not

firing. Check the defective plug.
If no cracking is heard, check the plant ignition system

(see Plant Manufacturer's Manual).
FAULT DIAGNOSIS
1535-GAS 5
May/00 Page 5
MAINTENANCE
2.4 Gas Generator Lights Up but Fails to Accelerate to Idling

Speed
Check that all control system connections
to the gas generator are satisfactory
IF
NOT O.K. O.K.

Rectify unsatisfactory Check that gas pressure
connection(s) at inlet to gas
regulating valve is
adequate. (Refer to
Operating Limitations
supplied with gas
generator installation)
IF
NOT O.K. O.K.

Rectify gas supply fault. Check air intake for
See Plant Manufacturer's obstruction or damage
Manual
IF
NOT O.K. O.K.

Clear obstruction Check rotating assembly
for freedom of rotation
IF
NOT O.K. O.K.

Reject gas generator Check gas manifold
pressure then check
regulated gas pressure
at inlet to gas control
valve (See Plant
Manufacturer's Manual)
IF
NOT O.K. O.K.

Rectify as detailed in Accelerate to gas
Plant Manufacturer's Manual generator idle
FAULT DIAGNOSIS
5 1535-GAS
Page 6 May/00
MAINTENANCE
2.5 Gas Generator Lights Up but Acceleration to Idling Speed

is Too Fast (Resulting in High Exhaust Cone Trip
Activating)
Check light up gas

pressure
IF
NOT O.K. O.K.

Reset the minimum flow Check control system
valve (See Plant
FAULT DIAGNOSIS
1535-GAS 5
May/00 Page 7
MAINTENANCE
3 RUNNING
3.1 Gas Generator Accelerates from Idling Speed but Fails to

Reach Selected Rating - Gas Fuel
Check that rpm is correct

for prevailing air intake
temperature
IF
NOT O.K.
Check rpm indication

system for accuracy.
Manual
IF
NOT O.K. O.K.

Rectify rpm indication Check that intake guide
system. See Plant vanes are fully open
IF
NOT O.K. O.K.

Reset the intake guide Check that the exhaust
vane ram cone temperature is
lower than top
temperature control
setting
IF
NOT O.K. O.K.

Exhaust cone temperature Exhaust cone temperature
higher. Refer to Para 4.6 lower: isolate top
temperature control and
recheck
Continued
FAULT DIAGNOSIS
5 1535-GAS
Page 8 May/00
MAINTENANCE
IF
NOT O.K. O.K.

RPM rises: rectify the top RPM still low: check gas
temperature control system. generator control
See Plant Manufacturer's system. See the Plant
Manual Manufacturer's Manual
IF
NOT O.K. O.K.

Rectify control system. Check regulated gas
See Plant Manufacturer's pressure at inlet to gas
Manual control valve (See Plant
IF
NOT O.K. O.K.

Reset regulated gas pressure Check P2 transducer and
(See Plant Manufacturer's pipework
Manual)
IF
NOT O.K. O.K.

Clean pipework, change P2 Check compressor blading
transducer (See Plant for damage
IF
NOT O.K. O.K.

Reject gas generator Crank soak wash the
compressor
FAULT DIAGNOSIS
1535-GAS 5
May/00 Page 9
MAINTENANCE
3.2 Fluctuating Gas Generator Speed
Check fuel supply for stability.

(See Plant Manufacturer's Manual)
IF
NOT O.K. O.K.

Rectify fuel supply fault. Check instrumentation
Manual
IF
NOT O.K. O.K.

Rectify instrumentation. Check intake guide vane
See Plant Manufacturer's ram and bleed valve
Manual control unit setting
IF
NOT O.K. O.K.

Rectify as necessary Check fuel control
system. See Plant
IF
NOT O.K. O.K.

Rectify as necessary. Consult the Customer
See Plant Manufacturer's Support Department,
Manual RRPEplc
FAULT DIAGNOSIS
5 1535-GAS
Page 10 May/00
MAINTENANCE
3.3 Gas Generator Compressor Stall
Check intake guide vane ram

and bleed valve control unit
settings
IF
NOT O.K. O.K.

Rectify as necessary Consult the Customer
Support Department,
RRPEplc
FAULT DIAGNOSIS
1535-GAS 5
May/00 Page 11
MAINTENANCE
3.4 High Oil Consumption
See NOTE 1 before proceeding with the following fault

diagnosis
external oil leaks, NOTE 2
IF
NOT O.K. O.K.

Rectify oil leaks Check gas generator for
evidence of internal oil
leaks, NOTE 3
IF
NOT O.K. O.K.

Rectify if possible or Check external wheelcase
reject gas generator, centrifugal breather for
NOTE 4 blockage, NOTE 5
IF
NOT O.K. O.K.

Clean external wheelcase Continue running but
centrifugal breather check oil consumption
over next five hours
running time
IF
NOT O.K. O.K.

Reject gas generator Gas generator service-
able
NOTE 1: Whenever possible, confirm suspected high oil

consumption by checking under controlled conditions with
the oil at normal operating temperature.
NOTE 2: In addition to the possibility of external oil leakage
from the gas generator pipes and connections, leakage
may also occur at any of the following locations:
(1) External wheelcase and oil sump drive shaft shroud
tube oil seals.
FAULT DIAGNOSIS
5 1535-GAS
Page 12 May/00
MAINTENANCE
(2) Transfer seals between the oil sump and the

compressor outlet casing. Remove the external
wheelcase and oil sump assembly.
(3) The joint between the external wheelcase and the
oil sump. Check the torque load on the retaining
nuts; if satisfactory, fit a new external wheelcase
and oil sump assembly.
(4) The joint between the return filter housing and the
oil sump. Check the torque load on the retaining
nuts; if satisfactory, remove and refit the return
filter housing to the oil sump.
(5) Leaks at (1) and (2) usually result from worn
external wheelcase and oil sump mountings. Check
the upper and lower mountings for wear and, if
necessary, fit new mountings.
NOTE 3: Internal oil leakage is indicated by the presence of oil

at the following positions:
(1) 15th stage air vent
(2) Cooling air vent
(3) External wheelcase centrifugal breather
(4) Governor pump (if fitted) and fuel pump combined
drain.
NOTE 4: Oil leakage from the positions in NOTE 3(1) and (2)
necessitate the immediate rejection of the gas
generator.
Oil leakage from the position in NOTE 3(3) may be

rectified by removing the breather end cover and fitting
a new sealing ring to the breather rear bearing housing.
If during subsequent running, oil is still emitted from
the breather the gas generator must be rejected.
Oil leakage from the position in NOTE 3(4) indicates a

defective drive shaft oil seal on either the governor
pump (if fitted) or the fuel pump. Isolate the defective
pump by examining the transfer tube between the governor
pump and the fuel pump. If oil is present in this tube
the governor pump is defective. Fit a new governor pump
or fuel pump, whichever is required.
NOTE 5: Symptoms of high oil consumption can be produced as a

result of an increase in oil sump pressure due to
partial or total blockage of the external wheelcase
centrifugal breather. Examine the breather screen for
blockage and, if necessary, remove and clean the
breather assembly.
FAULT DIAGNOSIS
1535-GAS 5
May/00 Page 13
MAINTENANCE
4 ALARMS AND TRIPS
4.1 Avon Vibration Alarm or Trip
ALARM ONLY
(1) If during the operating life of the gas generator, an

alarm is registered, it may be progressively reset in
0.0005 in. or 4 mm/sec (front pick-up) and 0.001 in.
or 6 mm/sec (Mod.4372, centre pick-up) increments,
until the maximum limits of 0.0035 in. or 20 mm/sec
(front pick-up) and 0.007 in. or 40 mm/sec (Mod.4372,
centre pick-up) have been reached, provided the
following conditions are complied with:
(a) When an alarm is registered, it should be reset

0.0005 in. or 3 mm/sec (front pick-up) and
0.001 in. or 6 mm/sec (Mod.4372, centre pick-up)
above the previous setting and, provided the
alarm is now cancelled, the operations
continued.
(b) If after resetting, the alarm is not cancelled,

or if it again registers before a further
50 hours of gas generator running has elapsed,
then the installation must be checked as
instructed below.
(c) If after resetting, an alarm is registered after

a further 50 hours of gas generator running has
elapsed, then the alarm may again be set
0.0005 in. or 3 mm/sec (front pick-up) and
0.001 in. or 6 mm/sec (Mod.4372, centre pick-up)
above the previous setting. This procedure may
be repeated until the maximum allowable
vibration is reached, always provided that not
more than 50 hours of gas generator running time
elapses between each occasion.
(d) If at any time, the gas generator is shut-down

by the trip circuit, the installation must be
checked as instructed below and, if necessary,
the gas generator returned for repair.
FAULT DIAGNOSIS
5 1535-GAS
Page 14 May/00
MAINTENANCE
ALARM ONLY - See above
OTHERWISE
Check instrumentation
for accuracy
IF
NOT O.K. O.K.

Rectify instrumentation. Check gas generator
See Plant Manufacturer's mountings for security,
Manual NOTE 3
IF
NOT O.K. O.K.

Retighten gas generator Check external wheelcase
mountings and sump upper and lower
mountings for wear
IF
NOT O.K. O.K.

Rectify external wheelcase Check compressor for
mountings cleanliness
IF
NOT O.K. O.K.

Clean the compressor Examine intake guide
vanes and visible
compressor blades for
ingestion damage
IF
NOT O.K. O.K.

Proceed as detailed in Check rotating assembly
NOTE 1 for freedom of rotation
FAULT DIAGNOSIS
1535-GAS 5
May/00 Page 15
MAINTENANCE
IF
NOT O.K. O.K.

Reject gas generator Examine turbine assembly
for blade damage
IF
NOT O.K. O.K.

Reject gas generator Check plant connections
to gas generator, NOTE 2
IF
NOT O.K. O.K.

Rectify plant connections. Remove and inspect gas
See Plant Manufacturer's generator magnetic chip
Manual detectors and oil
filter and plant oil
filters. See Plant
IF
NOT O.K. O.K.

Reject gas generator Check airflow control
system
IF
NOT O.K. O.K.

Reset airflow control Reject gas generator
system
FAULT DIAGNOSIS
5 1535-GAS
Page 16 May/00
MAINTENANCE
NOTE 1: Remove the compressor top half casing and inspect the
damaged blades.
Rectify all stage 00 and stage 0 repairable blades.

Where irreparable damage is present reject the gas
generator.
Where irreparable damage has been sustained by the

intake guide vanes, fit a new front bearing housing
assembly. Reject the gas generator if irreparable damage
is apparent on blades in stages other than those
detailed above.
NOTE 2: Check, for security, all the components of the plant

system directly associated with the gas generator
including pipe retaining clips, bleed valve ducting,
intake flare mounting, support struts and gearboxes.
NOTE 3: If no defect is apparent which would activate the

vibration alarm or trip, a vibration survey should be
carried out on the gas generator by a representative of
the Plant Manufacturer or Rolls-Royce before the gas
generator is removed from the installation.
FAULT DIAGNOSIS
1535-GAS 5
May/00 Page 17
MAINTENANCE
4.2 Lubrication Oil Low Pressure Trip - Phase I Gas Generators
Check for internal and external

oil leakage
IF
NOT O.K. O.K.

Rectify, and replenish Check oil level in
auxiliary oil tank auxiliary tank
IF
NOT O.K. O.K.

Replenish auxiliary tank Check that oil level in
sump corresponds to that
in storage tank
IF
NOT O.K. O.K.

Turn on stop cock Check rotating assembly
for freedom of rotation
OR
Clear obstruction from
oil supply pipe
OR
Clear obstruction from

oil balance pipe and
check that connections
are tight and that the
auxiliary oil tank is
airtight
IF
NOT O.K. O.K.

Reject gas generator Remove and inspect gas
generator high pressure
oil filter
Continued
FAULT DIAGNOSIS
5 1535-GAS
Page 18 May/00
MAINTENANCE
IF
NOT O.K. O.K.

Reject gas generator Check gas generator oil
consumption over
previous four week
period
IF
NOT O.K. O.K.

Reject gas generator Run gas generator on
internal oil system,
NOTE 1
IF
NOT O.K. O.K.

Rectify as in NOTE 2 Check plant oil supply
system. See Plant
IF
NOT O.K. O.K.

Rectify plant oil supply Check accuracy of
system. See Plant instrumentation. See
Manufacturer's Manual Plant Manufacturer's
Manual
IF
NOT O.K. O.K.

Rectify instrumentation. Check electrical supply.
See Plant Manufacturer's See Plant Manufacturer's
Manual Manual
Continued
FAULT DIAGNOSIS
1535-GAS 5
May/00 Page 19
MAINTENANCE
IF
NOT O.K. O.K.

Rectify electrical supply. Fit new low pressure oil
See Plant Manufacturer's warning switch. See
Manual Plant Manufacturer's
Manual
NOTE 1: Disconnect the oil supply pipe from the connection on

the gas generator oil sump, the pressure balance pipe
from the connection on the external wheelcase and, if
fitted, the remote oil cooler relief pipe from the
connection on the oil sump. Fill the oil sump to the
correct level, if required, then blank off the exposed
oil sump and external wheelcase connections.
Fit an appropriate pressure gauge to the oil pressure

tapping on the oil sump.
Start the gas generator and monitor the oil pressure

when the gas generator is running at 6000 rpm maximum.
Refer to Operating Limitations supplied with gas
generator installation.
When the oil pressure has been monitored and the gas
generator stopped, reconnect the oil supply pipe, the
pressure balance pipe and, if required, the external oil
cooler relief pipe to the gas generator.
NOTE 2: If the oil pressure is still low investigate as follows:
(1) Inspect the oil pressure relief valve; rectify as

necessary.
(2) Remove and examine the high pressure oil feed

filter and the scavenge filters. If the
contamination exceeds the limits specified, reject
the gas generator.
(3) Check oil cooler (if fitted) for blockage and

rectify as necessary.
(4) Remove and examine high pressure oil filter. If

contamination is suspected, reject the gas
generator.
(5) Fit a new external wheelcase and oil sump assembly.
Run the gas generator as detailed in NOTE 1; if the oil

pressure is still low, reject the gas generator.
FAULT DIAGNOSIS
5 1535-GAS
Page 20 May/00
MAINTENANCE
4.3 Lubrication Oil Low Pressure Trip - Phase II Gas

Generators
Check oil level in storage tank.

See Plant Manufacturer's Manual
IF
NOT O.K. O.K.

Replenish storage tank Check plant oil system
and connecting pipes to
gas generator. See Plant
IF
NOT O.K. O.K.

Rectify plant oil system Check accuracy of
and connecting pipes. instrumentation. See
See Plant Manufacturer's Plant Manufacturer's
Manual Manual
IF
NOT O.K. O.K.

Rectify instrumentation. Remove and inspect gas
See Plant Manufacturer's generator magnetic chip
Manual detectors and oil filter
and plant oil filters.
Manual
IF
NOT O.K. O.K.

Reject gas generator Inspect gas generator
for internal and
external oil leaks
Continued
FAULT DIAGNOSIS
1535-GAS 5
May/00 Page 21
MAINTENANCE
IF
NOT O.K. O.K.

Rectify Run gas generator and
monitor oil pressure
IF
NOT O.K. O.K.

Reject gas generator Gas generator
satisfactory
FAULT DIAGNOSIS
5 1535-GAS
Page 22 May/00
MAINTENANCE
4.4 Cooling Air Vent High Temperature Trip

CAUTION: THE FAULT FINDING PROCEDURE DETAILED BELOW MUST
BE CARRIED OUT BEFORE A FURTHER START IS
ATTEMPTED.
Check instrumentation for accuracy.
IF
NOT O.K. O.K.

Rectify instrumentation. Check gas generator for
See Plant Manufacturer's freedom of rotation
Manual
IF
NOT O.K. O.K.

Reject gas generator Check gas generator oil
consumption over
previous four week
period
IF
NOT O.K. O.K.

Refer to Para 3.4 Remove burners and check
for damage
IF
O.K.
Borescope inspect flame
tubes and turbines
IF
NOT O.K. O.K.

Reject gas generator Attempt further start
and monitor cooling air
vent temperature, NOTE 1
NOTE 1: Attach a suitable temperature measuring device to the
cooling air vent pipe as close as possible to the gas
generator cooling air manifold. Run the gas generator
and monitor the cooling air vent temperature. Reject the
gas generator if the temperature exceeds the maximum
limit specified in the Operating Limitations supplied
with gas generator installation.
FAULT DIAGNOSIS
1535-GAS 5
May/00 Page 23
MAINTENANCE
4.5 Exhaust Cone High Temperature Alarm or Trip
IF
NOT O.K. O.K.

Correct fault or recalibrate Check thermocouple
instruments harness
IF
NOT O.K. O.K.

Change thermocouple harness Borescope inspect flame
tubes and turbines
IF
NOT O.K. O.K.

Reject gas generator Run gas generator at
same corrected speed and
check if exhaust cone
temperature has
recovered to the normal
level
IF
NOT O.K.
Alarm only; clean the Trip or recurring alarm;

compressor. Run the gas check exhaust cone
generator and check temperature indicating
exhaust cone temperature system. See Plant
Continued
FAULT DIAGNOSIS
5 1535-GAS
Page 24 May/00
MAINTENANCE
IF
NOT O.K. O.K.

Rectify exhaust cone Check inlet guide vanes
temperature system. See and visible compressor
Plant Manufacturer's Manual blades for damage
IF
NOT O.K. O.K.

Proceed as in NOTE 1 Check operation of
compressor bleed valves
IF
NOT O.K. O.K.

intake guide vane ram
IF
NOT O.K. O.K.

Proceed as in NOTE 3 Reject gas generator
damaged blades.

generator.
Where irreparable damage has been sustained by the inlet

guide vanes, fit a new front bearing housing assembly.
Reject the gas generator if irreparable damage is
apparent on blades in stages other than those detailed
above.
NOTE 2: Adjust bleed valves. If still unsatisfactory, fit a new

bleed valve assembly.
NOTE 3: Adjust intake guide vane ram. If still unsatisfactory,

change the intake guide vane ram.
FAULT DIAGNOSIS
1535-GAS 5
May/00 Page 25
MAINTENANCE
4.6 Exhaust Cone High Temperature Spread
IF
NOT O.K. O.K.

Correct fault and recalibrate Check thermocouple
instruments harness
IF
NOT O.K. O.K.

Change thermocouple harness Remove and inspect fuel
burners for damage
IF
NOT O.K. O.K.

Borescope inspect flame tubes Inspect fuel burners for
and turbines then consult cleanliness/carboning
Customer Support Department,
RRPEplc
IF
NOT O.K. O.K.

Clean or change the fuel Reject gas generator
burners
WARNING: WHEN MIXING CAUSTIC SOLUTIONS THE POWDER MUST BE ADDED
TO THE LIQUID TO AVOID A REACTION THAT WILL CAUSE
SPLASHING. NEVER ADD THE LIQUID TO THE POWDER. REFER TO
THE CHEMICAL MANUFACTURER'S SAFETY DATA SHEETS.
NOTE: Burners with stainless steel feed arms should be cleaned
in accordance with Service Bulletin No.65, using a nylon
or hard bristle brush (not a wire brush), followed by
soaking in a cleaning solution of 1 to 2 lbs (0,45 to
0,91 kg) of Turco 4228 cleaning powder in 1 Imperial
gallon (4,55 litres) of water heated to 80 deg C
(176 deg F). Turco is a caustic solution and a face shield
(visor), suitable gloves and protective clothing must be
worn. Soak the burners for a minimum of two hours, wash in
cold water and allow to drain, then immerse the burner
nozzles in methyl alcohol or methylated spirit and allow
to dry in air.
FAULT DIAGNOSIS
5 1535-GAS
Page 26 May/00
MAINTENANCE
4.7 Exhaust Gas High Temperature Alarm or Trip

IF
NOT O.K. O.K.

instruments harness
IF
NOT O.K. O.K.

Change thermocouple harness Borescope inspect flame
tubes and turbines
IF
NOT O.K. O.K.

Reject gas generator Run gas generator at
same corrected speed
and check if exhaust gas
temperature has recovered
to the normal level
IF
NOT O.K.
Alarm only; clean the Trip or recurring alarm;

compressor. Run the gas check exhaust gas
generator and check exhaust temperature indicating
gas temperature system. See Plant
Continued
FAULT DIAGNOSIS
1535-GAS 5
May/00 Page 27
MAINTENANCE
IF
NOT O.K. O.K.

Rectify exhaust gas Check inlet guide vanes
temperature system. See and visible compressor
Plant Manufacturer's blades for damage
Manual
IF
NOT O.K. O.K.

compressor bleed valves
IF
NOT O.K. O.K.

intake guide vane ram
IF
NOT O.K. O.K.

Proceed as in NOTE 3 Reject gas generator
damaged blades.

generator.
Where irreparable damage has been sustained by the inlet

guide vanes, fit a new front bearing housing assembly.
Reject the gas generator if irreparable damage is
apparent on blades in stages other than those detailed
above.
NOTE 2: Adjust bleed valves. If still unsatisfactory, fit a new

bleed valve assembly.
NOTE 3: Adjust intake guide vane ram. If still unsatisfactory,

change the intake vane ram.
FAULT DIAGNOSIS
5 1535-GAS
Page 28 May/00
MAINTENANCE
4.8 Exhaust Gas High Temperature Spread

IF
NOT O.K. O.K.

instruments harness. See Plant
IF
NOT O.K. O.K.

Change thermocouple harness. Remove and inspect fuel
See Plant Manufacturer's Manual burners for damage
IF
NOT O.K. O.K.

Borescope inspect flame tubes and Inspect fuel burners for
turbines then consult Customer cleanliness/carboning
Support Department, RRPEplc
IF
NOT O.K. O.K.

Clean or change the fuel Start gas generator and
burners. See NOTE recheck exhaust gas
temperature spread
IF
NOT O.K.
Reject gas generator
WARNING: WHEN MIXING CAUSTIC SOLUTIONS THE POWDER MUST BE ADDED
TO THE LIQUID TO AVOID A REACTION THAT WILL CAUSE
SPLASHING. NEVER ADD THE LIQUID TO THE POWDER. REFER TO
THE CHEMICAL MANUFACTURER'S SAFETY DATA SHEETS.
NOTE: Burners with stainless steel feed arms should be cleaned
in accordance with Service Bulletin No.65, using a nylon
or hard bristle brush (not a wire brush), followed by
soaking in a cleaning solution of 1 to 2 lbs (0,45 to
0,91 kg) of Turco 4228 cleaning powder in 1 Imperial
gallon (4,55 litres) of water heated to 80 deg C
(176 deg F). Turco is a caustic solution and a face shield
(visor), suitable gloves and protective clothing must be
worn. Soak the burners for a minimum of two hours, wash in
cold water and allow to drain, then immerse the burner
nozzles in methyl alcohol or methylated spirit and allow
to dry in air.
FAULT DIAGNOSIS
1535-GAS 5
May/00 Page 29
MAINTENANCE
4.9 Anti-Icing Failure Trip
Check anti-icing indicator switch.

IF
NOT O.K. O.K.

Fit new switch. See Plant Check operation of ice
Manufacturer's Manual detector unit. See Plant
IF
NOT O.K. O.K.

Fit new unit. See Plant Check that 110 volt
Manufacturer's Manual supply is available at
appropriate two pins in
plant input socket. See
Plant Manufacturer's
Manual
IF
NOT O.K. O.K.

Rectify plant supply system Check low tension
See Plant Manufacturer's Manual electrical harness
IF
O.K.
Check hot air valve
solenoid. See Plant
IF
NOT O.K. O.K.

Change solenoid. See Plant Change hot air valve
NOTE: On gas generators fitted with Mod.3677 hot air valves the
manual override may be used if continued running is
essential.
FAULT DIAGNOSIS
5 1535-GAS
Page 30 May/00
MAINTENANCE
5 SHUTTING DOWN
5.1 Gas Generator Run Down Time Excessively Short
Check for other indications that

could suggest damage to bearings,
compressor or turbine, starter
pawl and drive mechanism
IF
NOT O.K. O.K.

Complete borescope
examination
IF
NOT O.K. O.K.
Seek advice from Customer Support Department

Rolls-Royce Power Engineering plc
FAULT DIAGNOSIS
1535-GAS 5
May/00 Page 31/32

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INDUSTRIAL AVON GAS GENERATOR

STARTING AND START SEQUENCE 2

ALARMS AND TRIPS 4

(1) The fault diagnosis details given in this Chapter are

(2) Diagnosis of faults should be logical and systematic,

(a) Interpretations of symptoms

(b) Elimination of obvious causes, for example,

(c) Elimination of unlikely causes and establishing

(d) Determining which component(s) could be

(e) Complete simpler, quicker checks before engaging

(f) Decision if fault can be rectified by adjustment

(3) The remainder of this chapter comprises a series of

2 STARTING AND START SEQUENCE

2.1 Starter and Gas Generator - Do Not Rotate

Check gas generator for

NOT O.K. O.K.

Reject gas generator Check Plant Starting

NOT O.K. O.K.

NOT O.K. O.K.

NOT O.K. O.K.

NOT O.K. O.K.

NOTE: Check the operation of the starter engaging mechanism by

2.2 Starter Rotates, Gas Generator Does Not Rotate

Check gas generator for

NOT O.K. O.K.

NOT O.K. O.K.

NOT O.K. O.K.

NOT O.K. O.K.

NOT O.K. O.K.

2.3 Gas Generator Rotates but Fails to Light Up - Gas Fuel

WARNING: BEFORE EACH ATTEMPTED START, THE GAS GENERATOR

Check that all control system connections

NOT O.K. O.K.

NOT O.K. O.K.

NOT O.K. O.K.

NOT O.K. O.K.

NOT O.K. O.K.

WARNING: HIGH TENSION ELECTRICITY CAN BE LETHAL. ALLOW AT LEAST

If only one regular crack is heard, one plug is not

If no cracking is heard, check the plant ignition system

2.4 Gas Generator Lights Up but Fails to Accelerate to Idling

NOT O.K. O.K.

NOT O.K. O.K.

NOT O.K. O.K.

NOT O.K. O.K.

NOT O.K. O.K.

2.5 Gas Generator Lights Up but Acceleration to Idling Speed

Check light up gas

NOT O.K. O.K.

3.1 Gas Generator Accelerates from Idling Speed but Fails to

Check that rpm is correct

Check rpm indication

NOT O.K. O.K.

NOT O.K. O.K.

NOT O.K. O.K.

NOT O.K. O.K.

NOT O.K. O.K.

NOT O.K. O.K.

NOT O.K. O.K.