GE Power Product Service

PSIB 20240307A Torque Converter : Generalities, Publish Date: 07 MARCH 2024

maintenance and related issues

KB0031875 Information
Bulletin
Overview
The torque converter is a system used on both 7E and 9E frame gas turbines. It is a part of the starting mean arrangement. One
of its roles is to convert the full speed (3000 or 3600 Rotations Per Minute) of the starting motor into a torque able to start the gas
turbine rotor from roll-out to about 50% of shaft nominal speed in approximately six minutes.

That speed-to-torque conversion is done using the “fluid coupling principle,” with lube oil as the media (See Figure 1). The high-
speed rotation of the driving coupling (starting motor) induces rotational energy (movement) to the oil that is then transferred to
the driven coupling (turbine rotor).

Torque converter
7E frame starting means system
principle

Figure 1

The torque converter is also used (when drained from oil) to decouple the gas turbine shaft from the starting motor shaft when
the turbine is operating. In this condition, the side of the torque converter connected to the gas turbine rotor is rotating
permanently at the turbine speed whereas the side of the torque converter connected to the starting motor side is not rotating.

Therefore, the gas turbine side of the torque converter is subject to more wear and tear, in particular, normal time-related bearing
aging. User can notice the presence of several bearings (roller or other types) and the important number of rotating parts (See
Figure 2).

Copyright © 2024 General Electric Company. This information is proprietary and is the property of GE Power. The content of this
document is provided for general information and awareness. Always refer to your unit's O&M manuals for detailed information relevant to
the operation and maintenance of your equipment. This document shall not be reproduced in whole or in part nor shall its contents be
disclosed to any third party without the written approval of GE.

Date Printed: 07 MARCH 2024

 1- Input shaft (starting motor‘s side)
2 - Pump impeller (rotating with
starting motor)
3 - Turbine wheel 1 (fastened to
turbine wheel 2)
4 - Turbine wheel 2 (fastened to
output shaft)
5 - Guide wheel adjustable
6 - Output shaft (connected to gas
turbine)
7 - Adjustment mechanism (orients the
adjustable wheel)
8 - Guide wheel fixed
9 – Filling and drain valve

Figure 2: Torque converter (EL10ZFG) major components

Application
All the 7E, 9E frames with electric or diesel starting motor.

The purpose of this document is to raise the awareness of potential risks associated with improper maintenance of the torque
converter system (MLI 0605) and to communicate best practices to reduce the occurrence of equipment out of service.

Background
GE Vernova has observed several events where the torque converter sustained cracks, component damage, or separation,
during turbine operation. In some cases, this has led to oil leaks and fires, as well as projectiles, in a short time span.

Investigation revealed that the realization of correct maintenance, inspection, and monitoring would help mitigate this risk. This
document serves as a reminder that maintenance shall be done, as per the operation and maintenance manual (OMM). Also,
access to the compartment shall comply with the recommendations presented in GEK111309.

Advisory

1 Safety and maintenance recommendations

1.1 Entry to the accessories compartment for maintenance

It is reiterated that personnel entering compartments/enclosures must be aware of potential risk and take the proper safety
precautions to prevent the risk of injury.

Copyright © 2024 General Electric Company. This information is proprietary and is the property of GE Power. The content of this
document is provided for general information and awareness. Always refer to your unit's O&M manuals for detailed information relevant to
the operation and maintenance of your equipment. This document shall not be reproduced in whole or in part nor shall its contents be
disclosed to any third party without the written approval of GE.

Date Printed: 07 MARCH 2024

Routine checks (such as instrument reading, noise and vibration measurements) recommended in the torque converter OMM
shall be done in accordance with GEK111309. At no time shall compartment door opening or entry be permitted during operation
to troubleshoot alarms or abnormal conditions. It shall not be permissible to be in the compartment during transient conditions
such as starts, fuel transfers, or significant load changes.
If the routine inspection or any element is preceded by an abnormal situation (such as smoke inside the compartment, abnormal
noise, specific smell, visible vibration, sparking, or fire), the operator shall exit from the compartment and not attempt to reenter.

1.2 General recommendation about the torque converter maintenance interval

The unit OMM shall be used as the main point of reference. According to typical OMM documentation the torque converter has
an expected lifetime that could reach 30 years, considering 350 starts per year if well maintained.
The typically stated maintenance interval recommendation is as follows:
Visual and vibration check every few months.
Alignment checks and visual inspection every 2,500 hours of passive operation (Starting motor stand still, torque
converter is turned by the driven machine, oil drained, equivalent to fired hours) or 800 starts (at least at the Annual BI
outage)
Overhaul including bearings changes every five years of operating time (24,000 turbine operating hours - fired hours /
1200 starts).

As the bearing on the turbine side is subject to continuous rotation and strain from gas turbine, the adherence to the minimal
maintenance recommendations is therefore of high importance for damage and failure mitigation.
It must be noted that the unit torque converter’s OMM recommendations shall supersede the above generic recommendation
figures if they are more restrictive.

1.3 Monitoring the torque converter vibrations

It is reiterated that per OMM, like any rotating system, vibrations should be regularly checked (approximately every 500 hours). It
may be carried out by the operator on a routine maintenance schedule using a portable vibration system, if required, to be
compared to the criteria herein defined as limits for unit in passive operation: starting motor at stand still, while torque converter is
rotated by the driven machine, and the oil drained from it casing.

These values are the limits for EL10ZFG and EL10ZFT. However, values provided in the OMM documentation will take
precedent.

Copyright © 2024 General Electric Company. This information is proprietary and is the property of GE Power. The content of this
document is provided for general information and awareness. Always refer to your unit's O&M manuals for detailed information relevant to
the operation and maintenance of your equipment. This document shall not be reproduced in whole or in part nor shall its contents be
disclosed to any third party without the written approval of GE.

Date Printed: 07 MARCH 2024

The location of vibration measurement is on output side on bearing location and casing using velocity probe:

Close view of torque converter, turbine side

1.4 Monitor the starting motor rotation speed when the unit is in operation.
During all the periods where the torque converter is empty of oil, air is present in the cavity. Some drag can be created due to
windage. This drag may cause the input shaft (starting motor side) to the torque converter to rotate at a low RPM. If such
behavior is identified on the unit, it is recommended to monitor this slow rotation during the machine lifetime and to report any
evolution or question/comment to your GE Vernova service contact.

1.5 Extend the maintenance to related equipment.

The torque converter is integrated in the starting mean system that includes, oil, drain valves, motors, bearings, coupling, etc.,
which should be maintained as per them respective operation and maintenance instructions.

2 Further references.

For a detailed description of the starting system operation, refer to:

The starting system description or related GEK available in the MLI 0421 folder of the site Operation and Maintenance
Manual
Torque converter supplier Operation and Maintenance Manual
GEK 111309: GE Product Safety Recommended Best Practices - Safe Site Work Practices
Please contact your local GE representative for additional information or assistance.

Copyright © 2024 General Electric Company. This information is proprietary and is the property of GE Power. The content of this
document is provided for general information and awareness. Always refer to your unit's O&M manuals for detailed information relevant to
the operation and maintenance of your equipment. This document shall not be reproduced in whole or in part nor shall its contents be
disclosed to any third party without the written approval of GE.

Date Printed: 07 MARCH 2024