r TRENT 60 & RB211

INDUSTRIAL APPLICATIONS
OPERATION AND MAINTENANCE MANUAL

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GENERAL INSTRUCTIONS

These operating procedures are authorised for use by a competent person only.

In the event of the system exceeding its designed operating limitations, the
system is to be made safe and supervisory staff informed.

Any irregularities or discrepancies found in these procedures are to be brought

to the attention of the supervisory staff.

All WARNINGS and CAUTIONS contained in this volume are to be strictly

adhered to.

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WARNING AND CAUTIONS

WARNING 1 IGNITION SYSTEM

BEFORE YOU EXAMINE THE GAS GENERATOR IGNITION

SYSTEM, MAKE SURE THAT THE LOW TENSION LEAD IS
FIRST DISCONNECTED FROM THE SUPPLY TO THE HIGH
ENERGY IGNITION UNIT, AS THE HIGH VOLTAGE RELATED
TO THE IGNITION PLUGS CAN KILL YOU. MAKE SURE THAT
THE TIME BETWEEN DISCONNECTION AND THE
CHECKING OF A COMPONENT IS A MINIMUM OF TWO
MINUTES.

SYSTEM SAFETY

MAKE SURE THAT ELECTRICAL CIRCUITS, FUEL,

LUBRICATING OIL, HYDRAULIC OIL AND FIRE
EXTINGUISHING SYSTEMS ARE ISOLATED AND SAFE AS
SPECIFIED IN LOCAL ORDERS AND MAINTENANCE
MANUAL INSTRUCTIONS BEFORE YOU START WORK ON
THE EQUIPMENT. FUNCTION TESTING WITH EQUIPMENT
ENERGIZED MUST ONLY BE DONE BY APPROVED
PERSONNEL.

IGNITER/HIGH ENERGY IGNITION UNIT FUNCTION

TESTING

ALWAYS OPERATE A DRY MONITORING CYCLE

IMMEDIATELY BEFORE YOU DO A FUNCTION TEST OF
IGNITERS, HIGH ENERGY IGNITION UNITS OR THEIR
RELATED CIRCUITS.

WARNING 2 VITON SEALS EXPOSED TO HIGH TEMPERATURES

WHEN YOU DISASSEMBLE COMPONENTS WHICH

CONTAIN PARTS MADE FROM VITON THAT HAVE BEEN
USED IN TEMPERATURES OF APPROXIMATELY 400 DEG.C
(750 DEG.F) OR HIGHER, THE VITON BREAKS DOWN
CHEMICALLY. ONE OF THE RESULTS IS HYDROFLUORIC
ACID WHICH CAUSES CORROSION AND CANNOT
USUALLY BE REMOVED ONCE IT HAS CONTAMINATED
THE SKIN.

THE FOLLOWING PRECAUTIONS MUST BE OBEYED:

1. IF IT IS NECESSARY TO INSPECT AND/OR REPLACE

AN OVERHEATED COMPONENT MADE FROM VITON
DO NOT GET THE MATERIAL ON YOUR BARE SKIN.

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2. IF AN ACID CONTAMINATION HAS OCCURRED, THE

AFFECTED AREA MAKE SURE THAT THERE IS NO
CONTAMINATION BEFORE WORK STARTS.

3. IF SKIN CONTAMINATION OCCURS GET MEDICAL AID

IMMEDIATELY FOR TREATMENT WITH
HYDROFLOURIC ACID BURN JELLY.

WARNING 3 PX24 (ARDROX 3691) INHIBITING FLUID VAPOR HAZARD

BECAUSE OF A POSSIBLE DANGER TO HEALTH, TAKE

CARE NOT TO INHALE PX24 INHIBITING FLUID VAPOR, OR
EQUIVALENT, WHEN INHIBITING GAS GENERATORS. THIS
CAN OCCUR WHEN A GAS GENERATOR IS AT REST OR ON
BARRING BUT IS VERY IMPORTANT WHEN USING
AEROSOLS IN A CLOSED SPACE. WHEN INHIBITING WITH
WD40 IN THESE CONDITIONS A DRY GAUZE FACE AND
NOSE MASK SHOULD BE WORN AS A PRECAUTION. A FINE
MIST OF PX24 OR EQUIVALENT, IN THE ATMOSPHERE CAN
BE EASILY IGNITED (FLASH POINT 41 DEG.C (110 DEG.F)
(MINIMUM) OPEN CUP), THUS ALL SOURCES OF IGNITION
IN THE AREA MUST BE EXTINGUISHED BEFORE
INHIBITING IS DONE.

WARNING 4 SYNTHETIC LUBRICATING OIL HAZARD

THE SYNTHETIC LUBRICATING OIL USED IN THIS GAS

GENERATOR CONTAINS ADDITIVES WHICH, AFTER
PROLONGED SKIN CONTACT, CAN BE TOXIC THROUGH
ABSORPTION. PERSONAL PROTECTIVE EQUIPMENT IS TO
BE USED TO MINIMISE CONTACT. ANY OIL SPILT SHOULD
BE CONTAINED/WIPED AND DISPOSED OF IN AN
APPROPRIATE MANNER.

WARNING 5 LUBRICATING OIL - TEMPERATURE AND PRESSURE

WHEN THE GAS GENERATOR IS IN OPERATION, THE OIL

REACHES HIGH TEMPERATURE AND PRESSURE. THUS
THE LUBRICATION AND HYDRAULIC SYSTEM MUST BE
STOPPED AND NO WORK DONE ON THE SYSTEM UNTIL
THE PRESSURE AND TEMPERATURE HAVE DECREASED
TO A SAFE LEVEL.

DURING OPERATION, THE OIL PRESSURE IS CONTAINED

IN THE SYSTEM. BUT A LEAK CAN RELEASE HOT OIL AT
HIGH PRESSURE.

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THUS PERSONNEL MUST STAY A SAFE DISTANCE FROM

THE GAS GENERATOR AND LUBRICATION SYSTEM WHILE
THEY ARE IN OPERATION.

PERSONNEL MUST NOT STAND OR APPLY A HEAVY LOAD

TO THE OIL SYSTEM PIPEWORK DURING MAINTENANCE
AS THIS CAN CAUSE LEAKAGE.

WARNING 6 SAFE LIFTING OF COMPONENTS

APPROVED LIFTING EQUIPMENT MUST BE USED FOR ALL

HEAVY ITEMS.

WARNING 7 SITE REGULATIONS

BEFORE YOU START WORK ON A PART OF THE

GENERATING SET, YOU MUST OBEY ALL APPLICABLE
SITE REGULATIONS. YOU MUST ALSO GET APPROVAL
FROM THE ENGINEER IN CHARGE BEFORE YOU ENTER
AN EQUIPMENT ENCLOSURE.

WARNING 8 ELECTRICAL SYSTEM ISOLATION

BEFORE YOU DO ELECTRICAL MAINTENANCE

(E.G. CHANGE LIGHT BULBS) IN THE GAS GENERATOR
PACKAGE, YOU MUST REMOVE THE APPLICABLE FUSES
OR ISOLATE THE APPROPRIATE SYSTEM AT THE
CONTROL PANEL.

WARNING 9 PERSONNEL ENTRY INTO GAS GENERATOR ENCLOSURE/

TURBINE HALL

OPERATORS ARE REMINDED THAT PERSONNEL MUST

NOT ENTER THE ENCLOSURE CONTAINING THE GAS
TURBINE DURING OPERATION OR WHEN STARTER
MOTOR IS BEING OPERATED, UNLESS THE FOLLOWING
CRITERIA ARE SATISFIED:

1. LOCAL LEGISLATION IS NOT CONTRAVENED.

2. THE GAS TURBINE IS AT STABLE IDLE.

IT IS ADDITIONALLY RECOMMENDED THAT PERSONNEL

DO NOT ENTER AN ENCLOSURE CONTAINING AN
OPERATING GAS TURBINE IF ANY OF THE FOLLOWING
CONDITIONS EXIST:

1. ALARMS/TRIPS HAVE OPERATED OR

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2. THE INTEGRITY OF THE GAS TURBINE IS IMPAIRED

OR SUSPECT.

ENTRY INTO AN ENCLOSURE WITH AN OPERATING GAS

TURBINE SHOULD ONLY BE AUTHORIZED IF A SUITABLE
RISK ASSESSMENT BY A RESPONSIBLE PERSON HAS
BEEN COMPLETED AND AUTHORIZED BY THE SITE
OPERATIONAL AUTHORITY.

WARNING 10 OVER-RIDING OF SAFETY SYSTEMS

ENCLOSURE DOORS MUST REMAIN CLOSED DURING

OPERATION AS SPECIFIED IN PERSONNEL AND
MACHINERY SAFETY REGULATIONS.

ENCLOSURE DOORS WHICH ARE LEFT OPEN CAN HAVE

DANGEROUS EFFECT ON VENTILATION, GAS AND FIRE
DETECTION, PROTECTION SYSTEMS, SAFETY
INTERLOCKS AND ALARMS.

OPERATORS MUST ALSO BE AWARE THAT DELIBERATE

OVER-RIDING OF SAFETY OR PROTECTION SYSTEMS
COULD JEOPARDIZE THEIR ‘CONDITIONS OF INSURANCE’
IN THE EVENT OF AN ACCIDENT OR FAILURE.

WARNING 11 PERSONNEL ENTRY INTO AIR INTAKE PLENUM

PERSONNEL ARE NOT TO ENTER THE AIR INTAKE
PLENUM AREA WHILE THE GAS GENERATOR IS IN
OPERATION.

WARNING 12 PERSONNEL ENTRY INTO GAS GENERATOR ENCLOSURE

DURING STARTER MOTOR OPERATION

NO PERSONNEL ARE TO BE ALLOWED INTO THE GAS

GENERATOR ENCLOSURE DURING STARTER MOTOR
OPERATION.

WARNING 13 REMOVING MCDs WHILE RUNNING

DO NOT REMOVE MAGNETIC CHIP DETECTORS (MCDs)

WITH THE GAS GENERATOR IN OPERATION.

MCDs MUST ONLY BE REMOVED WITH THE GAS

GENERATOR STOPPED AND PERSONNEL WEARING
APPLICABLE PROTECTIVE CLOTHING.

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WARNING 14 TIME EXPIRED COMPONENTS

COMPONENTS WHICH ARE LIFE EXPIRED OR MADE

WITHOUT ROLLS-ROYCE POWER ENGINEERING PLC
APPROVAL ARE NOT TO BE USED. RRPE PLC QUALITY
ASSURANCE CONTROLS MAKE SURE THAT ALL
COMPONENTS SOLD TO THE CUSTOMER MEET THE RRPE
PLC SPECIFICATION. THE ORIGINAL DESIGN OF THE
COMPONENT WILL HAVE BEEN BASED ON YEARS OF
OPERATING EXPERIENCE OF THE GAS GENERATORS,
THE USE OF APPLICABLE MATERIALS AND THE NEED FOR
SAFE OPERATION.

COMPONENTS MADE WITHOUT RRPE PLC APPROVAL

CAN BE INFERIOR IN QUALITY TO THAT OF THE ORIGINAL.
EXTERNAL APPEARANCE COULD BE THE SAME BUT
METALLURGICAL PROPERTIES, AND CONSEQUENT LIFE,
CAN BE BELOW RRPE PLC DESIGN SPECIFICATION. IT IS
NOT POSSIBLE TO ESTIMATE LIVES FOR THESE
COMPONENTS BUT IT CAN BE A LARGE REDUCTION
COMPARED TO GENUINE PARTS.

THE USE OF THESE COMPONENTS CAN CAUSE VERY

HIGH REPAIR COSTS AFTER FAILURE, OR THE DANGER
OF SERIOUS INJURY OR DEATH OF OPERATING
PERSONNEL.

THE REUSE OF LIFE EXPIRED COMPONENTS SUCH AS

TURBINE AND COMPRESSOR BLADES AND DISCS. HAS
THE SAME DANGERS AS THOSE OF UNSATISFACTORY
BUILD QUALITY. RRPE PLC APPROVED REPAIR FACILITIES
HAVE PROCEDURES IN PLACE TO COVER LIFE EXPIRED
COMPONENTS. SOME NON APPROVED REPAIRERS, HAVE
SUBMITTED THESE COMPONENTS, VISUALLY
REFURBISHED FOR RESALE.

RRPE PLC ACCEPTS NO RESPONSIBILITY FOR FAILURE

OR DAMAGE CAUSED BY THE USE OF LIFE EXPIRED
COMPONENTS OR COMPONENTS SUPPLIED BY A
NON-RRPE PLC APPROVED SOURCE.

TO PROTECT AGAINST THE POSSIBLE USE OF LIFE

EXPIRED OR NON-RRPE PLC APPROVED COMPONENTS,
THE OPERATOR MUST:

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1. MAKE SURE THAT ALL GAS GENERATORS AND

POWER TURBINES ARE SERVICED, REPAIRED AND
OVERHAULED BY RRPE PLC APPROVED PERSONNEL
AND REPAIR FACILITIES.

2. MAKE SURE THAT WHERE NEW OR REPLACEMENT

COMPONENTS ARE INSTALLED, THEY ARE
APPROVED RRPE PLC PARTS AND THAT THEY ALL
HAVE RRPE PLC PART NUMBERS AS APPROVED BY
RRPE PLC (INFORMATION ON THIS WILL BE
SUPPLIED TO RECOGNIZED OWNER/OPERATORS).

3. INSTRUCT THE OVERHAUL BASE TO DAMAGE LIFE

EXPIRED COMPONENTS IN SUCH A WAY AS TO MAKE
UNAPPROVED REFURBISHMENT IMPOSSIBLE, E.G. A
NOTCH CUT OR GROUND INTO THE LEADING EDGE
OF A BLADE AEROFOIL.

WARNING 15 SMOKING/FLAME EXCLUSION

DO NOT SMOKE OR CAUSE A FLAME TO COME NEAR THE

EQUIPMENT. FLAME, OIL AND GAS ARE A VERY
DANGEROUS MIXTURE WHICH CAN CAUSE A FIRE OR
EXPLOSION.

WARNING 16 FIRE RETENTION DAMPERS ISOLATION

THE FIRE RETENTION DAMPERS ARE AN AUTOMATED
SYSTEM. WHEN WORKING ON THE DAMPERS, ALWAYS
MAKE SURE THAT THEY ARE ISOLATED FROM ALL
ACTUATION SOURCES. THE OPERATOR MUST:

1. ISOLATE DAMPERS FROM ELECTRICAL POWER.

2. ISOLATE PNEUMATIC SUPPLY.

3. ISOLATE CO2 SUPPLY.

4. INSERT A PHYSICAL STOP IN THE LOUVER

BLADES.

WARNING 17 ARC FLASH AND SHOCK HAZARD

ALL ARC FLASH AND SHOCK HAZARD WARNING SIGNS

MUST BE ADHERED TO. PRIOR TO ANY WORK IN THESE
AREAS AN ARC FLASH AND SHOCK HAZARD ASSESMENT
MUST BE CARIED OUT. ONLY APPROPRIATE PPE AND

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TOOLS MUST BE USED WHEN WORKING IN THESE

AREAS.ENSURE ALL ARC FLASH AND SHOCK HAZARD
SAFETY PRECAUTIONS HAVE BEEN PUT INTO PLACE
PRIOR TO ANY WORK IN THESE AREAS.

CAUTION 1 THE OIL SPECIFIED FOR USE IN ALL OIL CONSOLES CAN
CAUSE DAMAGE TO PAINTWORK AND SOME TYPES OF
RUBBER AND MUST NOT BE PERMITTED TO
CONTAMINATE THOSE PARTS NOT NORMALLY IN
CONTACT WITH IT. ALL OIL SPILLED MUST BE
IMMEDIATELY REMOVED.

CAUTION 2 CONTAMINATION BY SMALL AMOUNTS OF SOME

ALKALINE CLEANING FLUIDS CAN CAUSE COMPLETE
BREAKDOWN OF SYNTHETIC OIL. USE COMPLETELY
CLEAN CONTAINERS AND EQUIPMENT.

CAUTION 3 DO NOT WALK OR CLIMB ON THE EQUIPMENT. THE

WEIGHT OF A PERSON CAN DAMAGE ELECTRICAL
EQUIPMENT CONDUIT AND PIPE FLANGES.

CAUTION 4 WEAR PROTECTIVE GLOVES AND EQUIPMENT TO

PROTECT FROM VERY HOT COMPONENTS, IF POSSIBLE
LET ITEMS COOL TO AMBIENT TEMPERATURE.

CAUTION 5 KEEP WORK AREA CLEAN.

WARNING AND CAUTIONS

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