Whittaker C173285-3 Manual

T.M. C173285-3
TECHNICAL MANUAL
OPERATION AND
MAINTENANCE INSTRUCTIONS
ELECTRIC GAS
FUEL METERING SYSTEM
PART NUMBER C173285-3
AND ASSOCIATED
MOTOR CONTROLLERS
PROPRIETARY INFORMATION NOTICE: – T HE INFORMATION CONTAINED
HEREIN IS THE PROPERTY OF
W HITTAKER C ONTROLS , A U NIT OF W HITTAKER
C ORPORATION , AND DISCLOSURE OF THE CONTENTS TO OTHERS IS GIVEN IN CON -
FIDENCE . T HIS MATERIAL MUST NOT BE REPRODUCED OR COPIED , OR OTHERWISE
DISCLOSED IN WHOLE OR IN PART WITHOUT THE APPROVAL OF
W HITTAKER C ON -
TROLS , N ORTH H OLLYWOOD , C ALIFORNIA , U.S.A.
1 DECEMBER 1997

T.M. C173285-3
1 DECEMBER 1997
A
Reproduction of the information or illustrations contained in this publication is not permitted, without written
permissionfromthepublisher:WhittakerControls,12838 SaticoyStreet,NorthHollywood,California90605,
U.S.A.
LIST OF EFFECTIVE PAGES
Insert latest changed pages; dispose of superseded pages.
NOTE: On a changed page, the portion of text affected by the change is indicated by a vertical line or other
change symbol in the outer margin of the page. Changes to illustrations are indicated by miniature pointing
hands. Changes to wiring diagrams are indicated by shaded areas.
Dates of issue for original and changed pages are as follows:
Original 1 . . . . . . . . . . . . 1 December 1997
Total number of pages in this manual is 74 consisting of the following:
Page #Change
No. No. Page #Change No. No. Page #Change No. No. Page #Change No. No.
Title ............. 0
A............... 0
i – iv ............ 0
1-1 – 1-3 ..........0
2-1 – 2-13 .........0
3-1 – 3-2 ..........0
4-1 – 4-10 ........ 0
5-1 – 5-7 ......... 06-1 – 6-3 ......... 0 7-1 – 7-30 ........ 0
#Zero in this column indicates an original page.

T.M. C173285-3
1 DECEMBER 1997
i
TABLE OF CONTENTS
Section Paragraph/Title Page Section Paragraph/Title Page
SAFETY SUMMARY ................. iii
IINTRODUCTION ...................1-1
1-1. Purpose of Manual .............1-1
1-4. Scope of Manual ..............1-1
1-7. Symbols and Abbreviations ......1-1
II SYSTEM DESCRIPTION AND
OPERATION ......................2-1
2-1. General .....................2-1
2-3. Fuel Metering Skid ............2-1
2-5. Motor Controllers .............2-1
2-7. Operation ....................2-5
2-9. DLE Engine Skid Settings ......2-5
2-11. SAC Engine Skid Settings ......2-5
2-13. System Operation .............2-5
2-17. Gas Isolation Shutoff Valves
(SOV1 and SOV2) ...........2-5
2-20. Inter-Shutoff Vent Valve
(GVV) .....................2-7
2-22. Gas Supply Temperature
Transmitter (TT1/TT2) ........2-7
2-23. SAC/DLE Manual Selector
Valve (SOV4) ...............2-9
2-27. Fuel Metering Valves (FMVB
FMVP, FMVO and FMVI) .....2-9
2-30. DLE Absolute Pressure
Transducer (GP1/GP2) ......2-11
2-32. SAC Absolute Pressure
Transducer (GP1B) .........2-12
2-34. Motor Controllers (MCB, MCI,
MCO and MCP) ............2-12
III INSTALLATION ....................3-1
3-1. General .....................3-1
3-3. Mechanical Interfaces ..........3-1
3-5. Gas Inlet Supply Flange .......3-1
3-7. DLE Engine Outlet Flanges ....3-1
3-9. SAC Engine Outlet Flange .....3-1
3-11. Seal Vent Interface Flange .....3-1
III 3-13. Electrical Interfaces ............3-1
3-14. PE Grounding Connection ......3-1
3-16. Main Junction Box
Connectors ..................3-1
IV FAULT ISOLATION ................. 4-1
4-1. General .....................4-1
4-2. Fault Isolation –Gas Isolation
Shutoff Valve (SOV1 or SOV2) ..4-1
4-3. Position Indication ...........4-1
4-4. Position Indicator Moves
Normally –Possible Position
Indicating Switch Fault ........4-1
4-5. Position Indicator Will Not
Move –Possible Solenoid
Fault ......................4-1
4-6. Gas Supply Temperature
Transmitter (TT1/TT2) .........4-2
4-8. SAC Gas Supply Absolute
Pressure Transducer (GP1B) ...4-2
4-10. DLE Gas Supply Absolute
Pressure Transducers
(GP1/GP2) ..................4-2
4-12. SAC/DLE Manual Selector
Valve (SOV4) ................4-3
4-13. Position Indication ...........4-3
4-14. Inter-Shutoff Vent Valve (GVV) ..4-3
4-15. Valve Will Not Operate .......4-3
4-16. Motor Controllers (MCB, MCI,
MCO and MCP) ..............4-3
4-19. Motor Controller Enable .......4-3
4-21. Error Code Fault Isolation ......4-7
4-22. Fuel Metering Valves (FMVB,
FMVI, FMVO and FMVP) ......4-7
4-23. Valve Position ..............4-7
4-24. LVDT Position Indication ......4-7
4-25. Actuator Motor Control or
Position Problems ...........4-9
4-27. Fuel Metering Valve Motor
Controller Enable ...........4-10

T.M. C173285-3
1 DECEMBER 1997
ii
Section Paragraph/Title Page Section Paragraph/Title Page
VMAINTENANCE ....................5-1
5-1. General .....................5-1
5-4. Repair Tasks ................5-1
5-5. Gas Isolation Valve (SOV1 or
SOV2) ....................5-1
5-6. Closed Position Indicating
Switch Replacement .........5-1
5-7. Gas Isolation Valve
Replacement .............5-2
5-8. Fuel Metering Valve (FMVB,
FMVI, FMVO or FMVP) .......5-2
5-9. LVDT Replacement .........5-2
5-10. Fuel Metering Valve
Replacement ..............5-3
5-11. SAC Gas Supply Absolute
Pressure Transducer (GP1B) ...5-4
5-13. Pressure Transducer
Replacement ..............5-4
5-14. Gas Supply Temperature
Transmitter (TT1/TT2) ........5-4
5-16. Temperature Transmitter
Replacement ..............5-5
5-17. Inter-Shutoff Vent Valve
(GVV) .....................5-5
5-19. Vent Valve Replacement .....5-5
5-20. SAC/DLE Manual Selector
Valve (SOV4) ...............5-5
V5-21. Switch Enclosure
Replacement ..............5-5
5-22. Selector Valve Replacement ..5-6
5-23. Motor Controller (MCB, MCI,
MCO or MCP) ...............5-6
5-25. DLE Gas Supply Absolute
Pressure Transducer
(GP1/GP2) .................5-6
5-26. Pressure Transducer
Replacement ..............5-6
5-27. Circuit Board Replacement ...5-7
VI MAINTENANCE PARTS LIST .........6-1
6-1. General .....................6-1
6-3. Maintenance parts ............6-1
VII ELECTRICAL WIRING INFORMATION
AND INTERCONNECTION
DIAGRAMS .......................7-1
7-1. General .....................7-1
7-3. Installation Recommendations ...7-1
7-4. Shielding ...................7-1
7-6. Cable Entries ...............7-1
7-8. Cable Wire Sizing ............7-1
7-10. Cable Lengths ..............7-1
7-12. Special Cable Capacitance
Requirements ...............7-1
LIST OF ILLUSTRATIONS
Figure Title Page Figure Title Page
2-1. Fuel Metering Skid Major Compo-
nent Locations ...................2-2
2-2. Gas Isolation Shutoff Valve (SOV
and SOV2) ......................2-5
2-3. Fuel Metering System Flow Diagram ..2-6
2-4. Inter-Shutoff Vent Valve (GVV) .......2-8
2-5. Gas Supply Temperature Transmitter
(TT1/TT2) ......................2-8
2-6. Fuel Metering Valve (FMVB, FMVI,
FMVO and FMVP) ...............2-11
2-7. DLE Gas Supply Absolute Pressure
Transducer (GP1/GP2) Junction
Box ...........................2-12
2-8. SAC Absolute Pressure Transducer
(GP1B) ........................2-13
2-9. Motor Controller (FMVB, FMVI,
FMVO and FMVP) ...............2-10
3-1. Electrical Interface Panel Diagram ....3-2
4-1. Motor Controller/Fuel Metering Valve
Test Setup ......................4-5

T.M. C173285-3
1 DECEMBER 1997
iii
Figure Title Page Figure Title Page
7-1. DLE Gas Supply Absolute Pressure
Transducer (Outer GP1/GP2) .......7-2
7-2. DLE Gas Supply Absolute Pressure
Transducer (Inner GP1/GP2) .......7-3
7-3. DLE Gas Supply Absolute Pressure
Transducer (Pilot GP1/GP2) ........7-4
7-4. Fuel Metering Valve (FMVB, FMVI
FMVO and FMVP) ................7-8
7-5. Motor Controller (MCB, MCI, MCO
and MCP) .....................7-17
7-6. Inter-Shutoff Vent Valve (GVV) ......7-26
7-7. Gas Supply Temperature Transmitter
(TT1/TT2) .....................7-27
7-8. Gas Isolation Shutoff Valve (SOV
and SOV2) .....................7-28
7-9. SAC/DLE Manual Selector Valve
(SOV4) ........................7-29
7-10. SAC Gas Supply Absolute Pressure
Transducer (GP1B) ..............7-30
LIST OF TABLES
Table Title Page Table Title Page
1-1. Fuel Metering System Specifications/
Specifications/Major Components ...1-2
2-1. Gas Isolation Valve (SOV1 and
SOV2) Specifications/
Characteristics ...................2-7
2-2. Inter-Shutoff Vent Valve (GVV)
Specifications/Characteristics .......2-8
2-3. Gas Supply Temperature Transmitter
(TT1/TT2) Specifications/
Characteristics ...................2-8
2-4. SAC/DLE Manual Selector Valve
(SOV4) Specifications/
Characteristics ...................2-9
2-5 Fuel Metering Valve (FMVB, FMVI,
FMVO and FMVP) Specifications/
Characteristics ..................2-10
2-6. DLE Gas Supply Absolute Pressure
Transducer (GP1/GP2) Specifica-
tions/ Characteristics .............2-11
2-7. SAC Absolute Pressure Transducer
(GP1B) Specifications/
Characteristics ..................2-13
2-8. Motor Controller (FMVB, FMVI,
FMVO and FMVP) Specifications/
Characteristics ..................2-13
3-1. Main Junction Box Interface
Connectors .....................3-2
4-1. Motor Controller Enable Test
Parameters .....................4-6
6-1. Recommended Spare Parts .........6-1

T.M. C173285-3
1 DECEMBER 1997
iv
SAFETY SUMMARY
GENERAL
The following are general safety precautions that
are not related to specific procedures and therefore
do not appear elsewhere in this publication. These
are recommended precautions that personnel must
understand and apply during many phases of main-
tenance.
WEAR PROTECTIVE CLOTHING
Wear protective clothing (gloves, apron, etc.) ap-
proved for the materials and tools being used.
USE APPROVED SAFETY EQUIPMENT
When cleaners and primers are being applied,
approved explosion-proof lights, blowers, and other
equipment shall be used. Make sure that fire fight-
ing equipment is readily available and in working
order.
GIVE CLEANERS SPECIAL CARE
Keep cleaners in special polyethylene bottles or
in safety cans and in minimum quantities. Discard
soiled cleaning rags into safety cans.
ELECTRICAL SYSTEM PRECAUTIONS
Theequipmentcontainsahighvoltage115(±25)
VDC electrical system. Prior to performing electrical
system repairs after testing, make sure that the 115
VDC power source is disconnected prior to
attempting removal or disassembly of any electrical
components. This will protect personnel from
possible electric shock as well as protecting the
equipment from possible damage.

T.M. C173285-3
1 DECEMBER 1997
1-1
SECTION I
INTRODUCTION
1-1. PURPOSE OF MANUAL.
1-2. This technical manual contains instructionsfor
operation and maintenance of Electric Gas Fuel
Metering System and the associated Motor Con-
trollers, hereinafter referred to as the fuel metering
system.
1-3. The fuel metering system operates in con-
junctionwiththeGeneralElectricMarkVLM Engine
Control System to controlthe deliveryof natural gas
to the individual combustor manifolds of the SAC
(Single Annular Combustor) and DLE (Dry Low
Emissions) Gas Turbine Engines. Refer to Table 1-
1 for specifications/characteristics, component
designations/tag numbers and hazardous area
ratings.
1-4. SCOPE OF MANUAL.
1-5. This manual is intended to provide information
in sufficient detail to permit proper startup, oper-
ation, and shutdown of the equipment and, to
prescribe proper daily and periodic inspection and
procedures.
1-6. The technical manual is divided into seven
sections:
Section I –Introduction –Describes the purpose
and scope of this manual.
Section II –System Description and Principles
of Operation –Contains a physical descrip-
tion of the equipment together with explana-
tions of its operating modes and component
functions and characteristics.
Section III –Installation –Provides information for
installing, connecting, and preparing the
equipment for use.
Section IV –Fault Isolation –Contains proce-
dures for finding the cause of a malfunction.
Section V –Maintenance –Provides instructions
for adjustment of system components and re-
placement of defective components.
Section VI –Maintenance Parts List –Contains a
list of spare parts recommended for on-site
support of the equipment.
Section VII –Diagrams –Contains the necessary
wiring and flow schematic diagrams.
1-7. SYMBOLS AND ABBREVIATIONS.
1-8. Symbols and abbreviations used in this
technical manual are as follows:
AWG American Wire Gage
CCentigrade (Celsius)
DC Direct current
DLE Dry Low Emissions
FFahrenheit
Hz Hertz
kg Kilogram
kg/s Kilograms/second
kPa KiloPascal
LVDT Linear variable differential transformer
mm Millimeter
NPT National Pipe Thread
P/N Part Number
PE Primary Earth (electrical ground)

T.M. C173285-3
1 DECEMBER 1997
1-2
psi Pounds per square inch
psia Pounds per square inch, absolute
psid Pounds per square inch, differential
psig Pounds per square inch, gage
SAC Single Annular Combustor
SPDT Single-pole, double-throw
VDC Volts direct current
Table 1-1. Fuel Metering System Specifications/Specifications/Major Components
Applications ...........................................General Electric LM1600, LM2500, LM2500+
and LM6000 Gas Turbine Engines
Service Fluid ....................................................Natural Gas (per MID-TD-0000-1)
Electrical Power ............................................................... 115 (±25) VDC
Temperatures
Normal Ambient ................................................. –54 to 104°C (–65 to 220°F)
High Ambient (one hour) ..................................................... 177°C (350°F)
Natural Gas ....................................................... 0 to 149°C (32 to 300°F)
Weight (approximate) ...................................................... 615 kg (1350 pounds)
MAJOR COMPONENTS
DESCRIPTION WHITTAKER PART NUMBER WHITTAKER DESIGNATION HAZARDOUS AREA RATING
Gas Isolation Shutoff Valve 1 C329305 SOV1 EEx d IIB T4 Ta 120°C, Demko Cer-
tification 95D119.660
Gas Isolation Shutoff Valve 2 SOV2
SAC/DLE Manual Selector Valve C326961 SOV4 Explosion Proof Class 1, Divisions 1
and 2, Groups C and D, FM/CSA
DLE Engine Inner “C”Fuel Metering
Valve C329635-D5 FMVI Actuator: EEx d IIB T4 Ta 105°C, LCIE Certification 97D6070
LVDT: EEx d IIB T4 Ta 120°C,
Demko Certification 97D112.635
DLE Engine Pilot “B”Fuel Metering
Valve FMVP
DLE Engine Outer “A”Fuel Metering
Valve FMVO
SAC Engine Fuel Metering Valve C329635-D3 FMVB
Inter-Shutoff Vent Valve C327048 GVV EEx d IIB T4, PTB Certification Ex
88.B.1049

T.M. C173285-3
1 DECEMBER 1997
1-3
Table 1-1. Fuel Metering System Specifications/Specifications/Major Components (continued)
DESCRIPTION WHITTAKER PART NUMBER WHITTAKER DESIGNATION HAZARDOUS AREA RATING
Gas Supply Temperature Trans-
mitter C173265 TT1 EEx d IIB T4 Ta 120°C, Demko Cer- tification 95D119.657
TT2
DLE Gas Supply Absolute Pressure
Transducer C173255-1 Inner GP1A EEx d IIB T4 Ta 120°C, Demko Cer- tification 95D119.658
Inner GP1B
Pilot GP1A
Pilot GP1B
Outer GP1A
Outer GP1B
Inner GP2A
Inner GP2B
Pilot GP2A
Pilot GP2B
Outer GP2A
Outer GP2B
SAC Gas Supply Absolute Pressure
Transducer C327049 GP1B Ex ds IIC T5, BASEEFA Certification Ex 81252X
DLE Engine Inner Motor Controller C173455 MCI –
DLE Engine Pilot Motor Controller MCP
DLE Engine Outer Motor Controller MCO
SAC Engine Motor Controller MCB

T.M. C173285-3
1 DECEMBER 1997
2-1
SECTION II
SYSTEM DESCRIPTION AND
OPERATION
2-1. GENERAL.
2-2. The fuel metering system (see Figure 2-1)
consists of two major components, the Electric Gas
Fuel Metering Skid (P/N C173285-3), and the four
individual Motor Controllers (P/N C173455).
2-3. FUEL METERING SKID.
2-4. The Fuel Metering Skid is comprised the fol-
lowing components and the associated piping net-
work, all of which are mounted on a steel chassis
with casters which allows easy movement of the
system. The fuel metering skid is designed specifi-
cally for test cell usage, and customer connections
have been optimized for easy installation and re-
moval via the use of quick-connectstyleconnectors
for all electrical interfaces.
C
Gas Isolation Shutoff Valves (SOV1 and
SOV2)
C
Inter-Shutoff Vent Valve (GVV)
C
Gas Supply Temperature Transmitter
(TT1/TT2)
C
SAC/DLE Manual Selector Valve (SOV4)
C
SAC Engine Fuel Metering Valve (FMVB)
C
DLE Engine Fuel Metering Valves (Inner
“C”, Pilot “B”and Outer “C”) (FMVI, FMVO
and FMVP)
C
Absolute Pressure Transducers (GP1 and
GP2) (each consisting of four absolute
transducers with their associated electrical
interface cards)
C
SAC Gas Supply Absolute Pressure Trans-
ducer (GP1B)
2-5. MOTOR CONTROLLERS.
2-6. The four Motor Controllers (MCP,MCO,MCI,
MCB) are installed remotely from the Fuel Metering
Skid, but must be located within 200 feet wire run
length from the Fuel Metering Skid. Each motor
controller consists of a servo amplifier, an inlet and
outlet signal noise filter and a capacitor/resistor ar-
rangement, all of which are packaged in a compact
assembly with readily accessible customer wiring
terminations.
NOTE
If the motor controllers must be instal-
led in a hazardous area, Part Number
C173465 Motor Controllers should be
used. These function the same as Part
Number C173455, but the explosion
proof enclosure provides an extra
degree of protection for the electronic
components.