# =~ Description 6. LO FLUSHING - GENERAL NOTES vesssssesssssseeeseeees 13 ANNE 2» FLUSMNG CERCA ee : T|1.1. Definition of flushing: lubricating oil (LO) system(s} cleanliness is a mandatory requirement to ensure the reliable operation of all rotating equipment. The scope of LO system flushing is the removal from LO piping of foreign matters entered during fabrication and installation (dust debris, gross material, organic material, welding waste, incrustation, rust, lamination scale etc... 12. The LO system is always shipped in several components, to be interconnected with piping assembled / manufactured at site. While these components (console, skids, etc) could be already clean within acceptability limits, depending on the fabrication, preservation and shipping processes, in the factory and at site, its virtually impossible to hove, at site conditions, an interconnecting piping fabrication process “dirt free", and therefore a cleaning procedure must be applied. The cleaning of the LO system is achieved through the LO flushing, that means executing a forced circulation of oil inside of the piping to be cleaned, in a.closed loop configuration that mandotorily shall include a fitering system dedicated to stop the dirt and remove it from the oil. The circulation is executed for an extended period of time, Periodically checking the cleanliness of the oil, and will terminate once the required Cleanliness condition is achieved. 13. Considering the very wide range of technical solutions and possible configurations of LO systems, it's not possible to define a “standard” flushing procedure, covering all options in a step by step format. It is instead possible to define the main guidelines and the solutions to the most common problems that are likely 1o be encountered during flushing execution. 2. LO SYSTEM GENERAL DESCRIPTION 2.1, The LO system is composed of several components, physically arranged in different way depending on different design practices, typical for each type of machine. The different. ‘arrangements will imply different approaches of the LO flushing. 22. There are two main categories of LO systems, depending on the type of oil used to lubricate the machine bearings: Mineral LO system, used on every type of Heavy Duty machines, and Synthetic LO, used on AD GT's. 23. Most of the LO main components are grouped together in an Auxiliary Skid (HD gas turbines) or in a LO Console. 24, The Auxiliary Skid includes also other auxiliary systems, such as starting devices, fuel gas valves, liquid fuel control system, atomizing air, etc. It may be common with the GT Skid (single skid machines, such os MS5001, GE10-1 and GE10-2), or may be separated (double skid machines, such as MS$5002, MS6001, MS7001 and MS9001. On some pipeline turbocompressor, using a PGT25 aeroderivative GT os driver, the mineral LO system is ‘arranged on the Centrifugal Compressor ski. 25. The main components of the LO system ore: 25.1. Lube oil tank, usually equipped with one or more electric heaters 25.2. At least two redundant lube oil pumps, driven by electric motor (AC or DCI, steam turbine, etc, or driven, through an auxiliory gearbox, by the machine itself. The pumps may have differentiated drivers, 253. Lube oil cooling system, based on a number of oil-to-air or oil-to-water heat exchanger(s) and a thermostatic valve for temperature control. 25.4 Filtering system, usually made of o duplex filter (on-line and stand-by), capable to be swapped while in operation through a manual 3-way valve, 2.5.5, Instruments and electrical components, pressure control and relief valves, etc. 2.5.6. Piping system, connecting all components together, sending oil to the machine bearings (LO header and bearings feed lines) and collecting the oil discharged by the ne aGeur ys, SEHUIIY 1 UULR WU UIE LTR (LU UII). HF SUITE CUBED, UIE UR igs 1eeU ne nd the drain lines-may be coaxial, with the oil feed line(s) running inside of the drain line / channel. 25.7. Oil vapor separator 2.58. Other optional components, such as rundown tank, hydraulic accumulators), LO Purifier, etc. 26. In mony cases, depending on the application, the LO system incorporates also other auxiliory sub-system, such os: 26.1. Hydraulic Gil, used on HD Gas Turbines and Steam turbines 2.6.2. Control Gil, used on HD Gas Turbines 263. Starting Gil, used on AD Gas Turbines 2.64, Seal Gil, used on some type of Centrifugal Compressors 3. ITS: Document type Code Reference for Oil Contamination Class ISO 4406 / API 614 Disegno disposizione tubazioni olio di | Job Documentation machina. il piping isometries Job Documentation Line Specification Job Documentation ‘Schematic piping diagram (P&ID) Job Documentation ‘Cleanliness Requirements for Power Plant GEK 110483b Installation, Commissioning, and Maintenance 1SO V632 Oil Specification 0502110 1SO V646 Oil Specification. sosozi11 ‘general guidelines for the verification of the | RIC8952207 correct installation and precommissioning of Iv motors at site installation & commissioning procedure for _ | RICB952213 de panels, installation & commissioning procedure for | RICB952215 low voltage motor control centre ‘general procedure for installation of mark vi_| RICB952216 Uucp pane! General notes for gos piping installation RICB952143 ‘on compressor interconnecting piping system - general RIC8952048 guidelines for execution at site ‘general guidelines for construction of RICB952283 primary lines (tubing) at site ‘general guidelines for blind flanges RICB990002 management at site GENERAL NOTES FOR OIL SYSTEM SICQOO45 FLUSHING FOR RECIPROCATING COMPRESSOR <1> THe DOCURENT CODE @ 6£i16.os | SENERAL NOTES FoR LUBE OL SYSTEM FLUSANG sicoo00s RsON if REVSION OESCRPTION PAGE RARER rev NA SECURTY cone N RRA 108 we 0804970 4 THNGUASE A SETRey FLAG REVIEW ‘According to RFR process, the LO flushing is part of the checks and verifications of the 1% milestone. Flushing 1+ Milestone shall be requested at least from 20 to 10 days before Oil Flushing Start. This milestone may include also some of the checks belonging to the 2" Milestone if some Electrical and Control System power up is required for flushing execution. The Red Flag Review is an Oil & Gas internal mandatory process that has the purpose to prevent issues during installation & commissioning activities at site. Its implementation will be taking place for all new units under installation where a Service Job is opened, involving Site Team (site Manager, Mechanical Engineer, Control Specialist, etc.) and HQ Teams (RFR team, Tech. Expert and Installation Manager). Critical issues related to First Fire are discussed and resolved “online’, if possible, and receipt of all required documentation ii. site Audit, Commissioning Procedures, etc. is verified and documented. The Red Flag Review also initiates communication between the site and the Product service Installation Engineer who will “own" the site from factory shipment to COD. Customers may Participate to the process, however this is owned by GE Oil & Gas. oe ee Eateal ; BR perin i :Ube UL 31d 1er CLEANLINESS: 51. Classification of cleanliness levels: The LO that arrives to the machine bearings, supplied by the LO systemis}, must be clean within acceptable limits defined by GE Oil & Gas per each type of machinery. These cleanliness levels ‘re defined according to international standards such as ISO4406 or NAS1638. Comparison lst International stondarde wo moeah wromy] wasise | se] ac | ons crvor mr 70H win aoe | sen) | comms | tae lds i907 ams m0 . seo 113 10 . 1 ssa » 3 awn “ 0 sw s oo eee 0 o Ba leise 52. Lubricating oll acceptability standard criteria for GE Oil & Gas machines: The following table defines the LO acceptobilty criteria for each type of GE Oil & Gas machines, in terms of cleanliness and chemical/physical characteristics. At the end of all flushing activities, including system restoring, the LO shall be in compliance with the following values, Mineral LO systems for Heavy Duty machinery, such as: 1504406 (17 15/12 Gas Turbines, Centrifugal Compressors, Electrical Generators, Electric or NAS1638 6 Motors, Steam Turbines. Chemical & physical characteristics compliant with new oil specification for SO G32 see $0S02110), Synthetic LO system for Aeroderivative Gas Turbines 1504406 (18/) 16/13 or NAS1638 7 Chemical & physical characteristics compliant with new oil specification (See ANNEX 1) Rec ect aa So 1504406 (17/) 15/12 or NAS1638 6 according to SICO0045 Closed loop hydraulic starting system for AE GT 1504403 (16/) 14/11 or NAS1638 5 NOTE 150 4406 may use two or three digits (see paragraph 154) 53. Acceptability verification method: The flushing successful completion will be verified and certified using porticles count method, executed on an oil sample taken downstream of the LO fiers, from a point close to the last THE TENT CE FETS @ GEO6os | ENERAL NOTES FoR LUBE 0. SYSTEM FLUSHING Sico0006 1 ESN ESTRPTON PAS aR SORT TOE mv Wh N TRGRAL 08] Sue | aR 0804970 4 A a ea etc [STeur Yeu mie, A second cil sample shall be:token from the LO tank, as reference of the general quality of the lube oil. This sample, in order to be representative of the entire volume of oil, shall be taken while the lube oil is circulating, avoiding separation of impurities and, particularly, water. NOTE: chemical & physical characteristics degradation may require corrective actions to be evaluated case by case. Typically, excessive water may be eliminated using centrifugal treatment systems, while other contaminants may require oil replacement. NOTE: ifthe oil is replaced after flushing completion, new samples have to be token to assess its acceptobilty. See olso paragraph 67 Any deviation from the above criteria must_be notified to GE Oil & Gas HQ prior to certify flushing completion, 5.4, Example of ISO 4406 cleanliness class: The following example explains the meaning of the SO 4406 class 15/12 541 Class 15/12 means that the particles present in the oil sample, having dimensions equal or larger than 5 microns, shall be no more than 320 per mililitre (scale number 15 or less), and particles having dimensions equal or larger than 15 microns shall be no more than 40 per mililitre (scale number 12 or less) Recent versions of the ISO standards indicate a three digits reference, specifying the cleanliness grade referred to three ranges of particles size, instead of two: © >4microns 1 digit, © >6microns 2° digit i © > 14microns 3 digit + 25microns 1+ digit + 215microns — 2~ digit In the three digits reference system, |SO 4406 17/15/12, equivalent to 15/12, shall be red in this, way: 542 Class 17/15/12 means that the particles present in the oil sample, having dimensions larger than 4 microns shall be no more than 1300 per mililitre (scale number 17 or less), and particles having dimensions larger than 6 microns shall be no more than 320 per mililtre (scale number 15 or less), and particles having dimensions larger than 14 microns shall be no more than 40 per mililitre (scale number 12 or less. The following description of IS04406 specification is abstracted from API614 4 specification, April 1999 edition, chapter 1, para. E2.5.2 SB THe TOCURENT CODE RevSON GEIS Gos | SENERAL NOTES FOR LUBE OL SYSTEM FLUSHING Sicoo006 1 REVISION DESCAPTION PAGE RARER ‘SEAT COE NO REVISON 1S INTRODUCED IN THS PAGE WA N TRIGRAL 108 ‘Ste | UoNGuae 0804970 ‘ A aS ae ae | LT2521 Tie Heralic Fad Pover—Fuds—Code for Table 2180-4006 Defining the Level of Contamination of Slt Pacis bie re s2s22 ee ‘nero Paris peri anh atl Pane eee Mar Tin UpToaedncng’_ Soe Number {eid The codes composi of two sae mumbo rade ‘ama Tasos ‘asd on the numero pars greater thn geal yn 100000 0.00000 ‘and 1Synper ilies uid. In recent years many groups a ‘have expanded o he standard system to cover dd ange ae an a for pate coons of 2 wm or rz Particle counts re made ee pees a 2 microscope or by mean of somatic parce come 300000 ‘m000 » ‘Theresa ate reponed as two or tee grade mums ee 2son00 ‘sone » “Table E- fr pari ist of grade umber). Each nomber 100.0 2 Separated by sash“? The mur for the smallest sine ae F 3 = 00 1300 ” ee 200 ‘1000 i ven s2n00 5 00 1000 5 00 000 3 2000 on 2 10m 2000 0 so 1000 © 250 00 ° 250 . ose 130 1 ox ost ‘ os 032 s 005 cas ‘ oo 08 3 om oot 2 ot az 1 5:5. Recommendations for oil sampling and oil analysis; The oil sample shall be taken while the oil is circulating, from a downstream point of the system, upstream of the test screen. * General criteria according to 1S03722 * Use only sealed bottles, furnished by an analysis laboratory; Open the bottles only when they have to be filed; * In order to get homogeneity for the contamination class in the bottle and the oil one, follow the next steps in the order os they are presented Open the sampling valve and let the oil flow away for a quantity of about 10 times the volume of the drain line, that is at least 5 liters; ‘Fill the bottles for approximately a half of their volumes; ‘Close the bottles and shake them vigorously for at least 30 seconds; then empty them, draining the ol to the tank: ‘* Repeat this step twice again {totally three cleaning cycles}; ‘Now actually fil the bottles and bring them to the laboratory. 5.6. Test mesh screens: ‘very common and well known verification method is based on the visual inspection of test mesh screens installed at the end of each portion of piping under flushing, These test screens are able to capture all particles having a dimension larger than the mesh openings (typical: 100 mesh screen, openings ~ 0.15 mm). The acceptability, according to this method, requires the absence of particles exceeding certain conditions, in terms of dimensions, quantity and distribution on the mesh screen. Moreover, the particles left on the mesh screen shall not be metalic. In Gil & Gas industry, these conditions are standardized by API 614, para 4337.1. (see the abstract below) a =o 5 Fee ses ir ; apes571. 4.3.3.7.1 After | hour of oil circulation at the design flow rate and a temperature of 66°C to 71°C (150°F to 160°F) or lower, as component design dictates, screens placed at all dis- charge terminations from the console or the packages and at other strategic points mutually agreed on by the purchaser and the vendor shall be within the particle count limits listed in Table E-6, Appendix E, Chapter 1, The screen mesh shall be No. 100 plain-weave, stainless stee! wire with a diameter of 0.1 mm (0,004 in.) and a 0.15-mm (0.006 in.) opening. The panicles’ greatest dimension shall not exceed 0.25 mm (0.010 in,), and the particles shall be randomly disuibuted on the sereen. Piping. coolers, and vaives shall be hammered fre quently di uring the tes! Note; Typically, screens are mounted such the screen in a vertical downward direction to prevent debris from escaping the screen al the flow is entering This method have pro’s and con's. On the pro's side, these test screens are reasonably easy to procure and install, and can be managed quickly for frequent inspections during flushing execution. On the con’s side, the cleanliness verification is based on experience more than on solid data, and it's virtually impossible to leave and transmit evidences of the results. For these reasons, GE Oil & Gas, also in accordance with GE Energy standards, does not apply ‘any more the test screens method for final flushing approval, The test screen remains valid for flushing intermediate control, meaning that flushing steps can be terminated when the test screens are free of debris, but the final, formal verification shall be done using particles count method. ss levels in different subsections of the lubricating system sm - Feed lin drain lin. ‘The main purpose of flushing of LO system is to prevent that the dirt arriving with the oil to the machine's bearings may damage the bearings themselves and, particularly, the shafts bearings collars. For this reason, the real flushing effort is concentrated on cleaning the feed ling m_of rin Instead, talking of flushing of the bearings droins is inappropriate, because these are composed of large (or very large) channels / pipes, imy le to clean jing the same it nd_meth¢ for the lines (forced circulation, turbulent fl During flushing, most of the dirt present in the drain system will be, in any case, washed away and carried to the tank. The limited quantity of dirt that, after every effort, might remain in the irain m_at the end of the flushing, h¢ In the reliabl ration of the jipment wil be, in any cose, blocked by the high efficiency LO fiter Having said that, it is always necessary to ensure that, at least, any movable foreian object, such as rags, paper sheets, etc, is removed from the drains, becouse it could cloa pumps suctions. This can be done also by air blowing the drain lines and headers, to be visual or boroscopic inspected before and after flushing 5.7.2. Mineral LO system - Oil tank: The mineral LO tank shall always be manually cleaned prior to the first filling, using lint free rags. WARNING: this is a confined space activity, to be done following all applicable EHS THE SORE RE aE @ 6€016.e | GENERAL WOTES FoR LBE OL SYSTEM FLUSINS SIco0006 1 av OTT PASE SRT so REVS sD WTS PAE Wh N aaa BSE | 0804970 ‘ A57. Wines WHE HUSH 19 EACLULEY UoIHY U SepUIULEU LUIBUIE, UypuDsIy Ure JUU LU LurIR, however, at the end of flushing the LO tank will be again contaminated by a large amount of dirt, coming from the flushed piping. While it's very likely that, during oil circulation, the smaller and lighter particles will be carried by the oil to the fiters and definitely removed from the system, some of the bigger and heavier particles will drop down on the LO tank bottom. The removal of this accumulated dirt con be done emptying the tank and performing a manual cleaning. At the end, the LO tank shall be refilled with the same oil used for flushing, as explained at paragraph 6.7. NOTE: this post-flushing tank cleaning requires that the LO is moved to a temporary storage tank applying a strict cleanliness control, and must be considered carefully against the risk of reintroducing again dirt, water and other contaminants. Therefore, it_is_a_mandotory prerequisite for this operation that the equipment used for tank emptying and refiling is inspected ond formally certified os clean. Its olso required that the LO tonk is refiled through 2.100 mesh screen. NOTE: the borrels used for transportation of the new oil are not to be considered a clean storage system, because they cannot be properly inspected and cleaned. If certified clean equipment cannot be provided, leaving the oil in the tank at the end of flushing is an option to be serious! nsider¢ is with, il HQ, case by case. . Synthetic Oil system ~ Oil tank The Synthetic Oil tank shall always be manually cleaned prior to the first filing, using lint free rags. During flushing, in normal conditions the oil tank remains not contaminated because the cil passes through the scavenge filters before returning to the tank. For this reason, it is not recommended to empty the tank for cleaning at the end of flushing. It is instead required to nalyse the oil and compare it with the expected characteristics of the new oil for Aero GT (refer to ANNEX 1. REVISION DESCRPTON evi a es er 5; ooo Le | HET6A 62 63. ku revsniny ~ uemenaL nuies ll parameters during flushing: FLOW. The most important parameter during flushing is the flow. As a matter of fact, the oil flow is responsible for the actual removal of ditt from the system, while, for instance, lube oll pressure has no impact on the flushing effectiveness. Therefore, the flushing strategies shall aim ot moximizing the oil flow. In ony cose, for each section of piping, the flushing shall be executed reaching ot least the higher flow thot could be reached also in normal running conditions. Turbulent FLOW During flushing, the value of the oil ow in each section of piping must be at least higher than the value necessary to achieve “turbulent flow This is because oil turbulence will help the dirt to get free from the piping and move downstream to the fiter. The value for “turbulent flow” condition depends on oil viscosity, and therefore from oil temperature. The following formula is taken from GE Energy procedure GEK 110483b Flow (gpm) = 1.268 * ((4)*d) (4)- Kinematic viscosity (in centistokes) of flush fluid at 170°F - Pipe diameter measured in inches The following table defines the minimum flow vs diameter of pipe, for the typical Mineral Oil Iso VG32, colculated through the above formula Oil Temperature Degt 40°C 70°C pipe dametre | Oil Flow ‘il Flow inches [mm [W/min ‘gpm USA |V/min [gpm USA 6 1524 [865 228 284 75 4 1016 _|577 152 189 50 3 762 [433 14 a2 37 2 508 1288 76 95, 25 15 [381 [216 57 71 19 1 254 [144 38 a7 12 * Injection of air or nitrogen can help achieving turbulent flow even at lower temperature. The injection shall be done downstream of the filters in order to prevent damaging the cartridges. + Piping hammering or vibrating; there may be other methods helping the detachment of Piping incrustation, such as hammering manually on the piping, at frequent intervals, or installing pneumatic vibrators. Oil parameters during flushing: TEMPERATT The above table gives a clear indication: per each pipe diameter, the required minimum oil flow is three times lower at 70 DeaC than at 40 DeaC, Therefore, increasing LO temperature during flushing can be highly beneficial, helping to reduce the duration of flushing. On the other hand, the complexities of achieving LO temperature above 40-50 DegC often SIC00006 1 TE OCFENT CODE RESON GEOG Gos | SENERAL NOTES FOR LUBE OL SYSTEM FLUSHING REVISION DESCRPTION PAGE HARKER SECURITY CoOE No REVISION IS INTRODUCED W THE PAGE WA N RIGRAT 108 SHE | UmGunGe 0804970 4 A So a oe ocean ea mei > ET64, 65. 66. 67. WSLUUIUYED UE CHUN, PUIILUIUY HWE HUSH PUNTIPIS) CUpULiLy 19, HUWEvE!, EHUUY!T LU reach turbulent flow even-at-lower temperature, Therefore, for GE Oil & Gas, there is no mandatory requirement to perform flushing at a specific temperature. It is instead recommended to keep oil temperature during flushing as high as possible, within the Fange 50-70 DegC. It is also recommended to cycle the temperature within this range, Oil parameters during flushing: PRESSURE. The LO pressure inside of the piping, during flushing, is not considered to have any effect on the effectiveness of the flushing, Of course, every limitation of the system remains applicable even if its configuration may be very different from the normal running conditions, This means that the oil pressure shall never be higher than the rated value of the system. Sometime there could be situations when this can be at risk, for instance when using volumetric pumps and in presence of foreign objects, such as rags, that clogging the lines may lead the pressure to reach dangerous values. For this reoson, it is mandatory that the pressure limitation devices (Relief Valves) present in the system shall not be removed 1.0. pumpls} discharge pressure Limitations during flushing. in normal conditions, the pressure reached during flushing is very low, because of the many bypasses installed in many points of the system, reducing the pressure losses, Sometime, this may take the LO pump out ofits operating range, ond couse damages to the pump or to the electric motor (overload For this reason itis necessary to monitor the pump discharge pressure and the motor current during all flushing. Depending on the type of pump used it may be necessary to introduce ‘additional pressure losses, for instance adjusting some manual valve lin some case already present in the job system, or sometime to be installed for the purpose) or inserting temporary orifice on the pump discharge line * On centrifugal pumps, the discharge pressure must be within the operating range of the pump, preferably set at the rated value as written in the PID or in the pump datasheet, * On volumetric pumps, the discharge pressure shall be higher than 3-3,5 Bara, in order to ensure proper pumps bearings lubrication, Flushing oil type: Within the extent of the present document, the oil used for flushing is the same lube oil used in normal running conditions, NOTE: the effects of unknown chemical products on some LO system components (2.4 LO tank internal painting, O-Rings, gaskets, etc.) cannot be predicted and therefore the use of different oil type and/or not approved cil additives is not all Flushing oil to be re-used for normal operation: must be noted that, most of the time, the new oil available on the morket hos a cleanliness level that is usually worse than what is required, The transportation of this oll is normally done through commercial barrels of limited capacity, whose handling (in quantity that, for mineral cil, can be close to on hundred) makes very difficult to prevent contamination. For this reason it’s to be understood that + The oil circulation through the filters, during flushing, will couse not only the system to be cleaned, but also the lube oil itself to be cleaned * Therefore_at_the end of flushing, the some oil should be reused, provided that ‘chemical/physical_choracteristics, woter content, etc. are _in_compliance with the So | ea. ores rox neo sath ub @ «osc Sicoo006 i RESIN DESCRPTON PAGE HARKER SELURTY TOE revi WA N RENAL 208 SHE | UNGUAGE 0804970 4 A ec ta eTSeUuUUE UE LEW UU ‘oFor Mineral Oil, refer to $0S02110 / 4 or $0S02111 /4 ‘For Synthetic OIL, refer to ANNEX 2. 6.8. Flushing using an external flushing console or the job LO system: The oil Grculation may be done using an external fushing console or using the job LO system. 68.1 The job Mineral LO Console kid, and its tank, pumplsi, filters, etc. can be effectively used, and in most cases this is the easiest and less expensive solution. The rest of this document is based on the assumption that this the selected choice. 68.2. The external Mineral il flushing console is normally composed, at least, by the following elements: ‘© Oil tank equipped with electrical heaters . Flushing pump © Oilfiterts) ‘+ __ Temporary piping & fexible hose NOTE: the flushing console shall be equipped with LO filters having at least the some filtration dearee of the job fters This option may be very effective, particulary if tis possible to provide a flushing console having increased flow, heating and filtration capability. The main advantages of this solution are: * The flushing oil returns to the external tank instead than to the job tank, therefore the dirt removed during the flushing is accumulated in the flushing tank, leaving the job tank clean + The entire job piping system is flushed with filtered oil. Instead, using the job console, the piping upstream of the fter is flushed with unfiltered cil Normally these consoles can be rented together with the service of specialized contractors, able to prepare, perform and certify the entire flushing of the system. Within the scope of this document this option is not explored in details, because the detailed procedure shall be developed by the flushing contractor, that will be responsible to define a procedure able to meet the acceptance criteria defined by GE Oil & Gas. Such procedure, however, shall be in conformance with the guidelines defined by this document for everything thot is concerning the machines and skids configuration (blinds and by-pass positions). The procedure, including a marked up P&ID defining the flushing configuration, how and where the external console is connected to the job LO system, etc, shall be submitted to GE Oil & Gas HQ for approval Note: sometime, when using an external flushing console, flushing contractors propose to remove the job LO filters cartridges (for a number of reasons, including the opportunity of having new cartridges available for first startup). However, it must be considered that, in case of failure of the external fers, a severe contamination of the job LO system may occur. The impact of such event may be very severe, particulary ifthe flushing circuit includes some not bypassed bearing (as it is common in most HDGT). For this reason, GE Oil & Gas cannot take ny responsibility if the job LO fiters are removed, NOTE: the limitations of the LO system components, in terms of pressure, temperature and flow, must be considered when choosing the external flushing console, Some of the LO system ‘components might not stand a flow much higher than the system nominal value, gs itis the case for instance, of the LO filters, or the Air/Oil coolers, a ee a ;69, Synthetic oil/Hydraulic Starting flushing pump: The synthetic oil is always flushed using an external centrifugal pump, having the following characteristics: 691 Rated flow 200 Ipm 692 Discharge pressure 4 BarG 693, Impeller material: steel, bronze, aluminium. No plastic It is recommended that the pump is also equipped with an additional filter having the following characteristics: 694. Filter element: B5{c) 2 1000 (PALL code:HZ8300FKP39YZ755) ‘The same pump / filter can also be used for flushing of closed loop Hydraulic Starting System. Apart from the flushing pump, any other component (such as oil tank, heaters, filters, etc) will be part of the job system components. 610, Electr ‘ontrol systems - Grounding - Flushing operations control The execution of LO flushing requires having the availability of a safe and reliable power distribution system, able to feed, control and protect ony electrical device involved during flushing, such as pumps), heaters, etc. Moreover, this system shall be used to control flushing ‘operations, starting and stopping the pumpls) when needed. The best option should be to have the job Motor Control Centre (MCC) and the Unit Control Panel (UCP) already powered up and commissioned, at least for the functions involved in the LO system control. In case the job systems are not yet available, flushing can be anticipated using provisional electrical power, controlled through a provisional switchboard installed locally. The system shall have at least the capability for automatic overload protection of each connected device, and must be in compliance with all regulations in place for safety and certifications. The earthing system and any other protection device shall be fully operational rior to power up any system, ‘While some automatic control feature may be desirable (such as LO heater temperature control, LO tank low level alarm/pump stop, etcl, the flushing control shall be performed in manual under continuous monitoring of some operators in charae, whose attendance shall be ensured at all time while the pumps are running, in order to check for leakages and any other inconveni at me n during the initial LO circulation, WARNING: a safety plan must be prepared and applied prior to stort the activities. THe DOCURENT CODE mavSON {GE Oi16 Gos | GENERAL NOTES FOR LUBE OL SYSTEM FLUSHING sico0006 1 REVISION DESCRIPTION. PAGE WARE SECURTY (OO No REVISON I INTRODUCED NTH PAGE WA N ‘ORGNAL 08 Se | NURSE 0804970, 4 Aah 72, Depending on the type of flushing, the oil circulation will include the entire LO system, or part of it The normal oil circulation path, most of the time, needs to be temporarily modified, in order to exclude sections not to be flushed (eg: becouse already clean and not be contaminated), or in order to connect the job components to external flushing equipment {flushing pump or console, etc). This may be achieved by plugging/biinding/spading piping connections, preventing the oil to flow to that leg, or installing by-passes, allowing the oil flowing from upstream to downstream of the bypassed portion of the system. The position of the plugs, binds, spading and by-passes is peculiar per each project, ond defines the strategy of the flushing, The TP (Technical Package for installation) always includes a marked up PID, showing the flushing configuration customized per job. Machines internals, n¢ hed at site: In normal conditions, machines internals, particularly the bearings, are to be considered clean from the factory, and shall not be contaminated by potentially dirty oil during flushing, This shall be done either by-passing the bearings or plugging their feed lines. In case it is possible to confirm the cleanliness of the oil arriving to the bearings, it is not ne isconnect the beorinas fe nthe ft it_could introduce contamination or leakages due to improper piping handling, damaged gaskets, etc, The oil coming from the job LO filters, or equivalent external fitering system, and flowing through oiready clean/flushed piping, is to be considered clean, In general, GE Oil & Gas connection points are protected, for transportation, with colour coded plugs, covers, bind flanges, etc: ‘© Red colour identifies systems already cleari/lushed, This is usually imited to machines body connections. * Yellow colour identifies systems whose cleanliness cannot be guaranteed. Typically, this is applicable to most on skid piping limits of supply In case there is any doubt that the machines internals have been contaminated due to poor shipping, or preservation, or housekeeping (flanges left open and unattended, etc) a specific inspection plan and corrective action shall be agreed involving GE Oil & Gas HO. The definition of "machine internals" may change, and the limit between what is already clean ‘and what is not may change depending on the type of equipment, the manufacturing process, etc. The following paragraphs will define o few typical examples. Disconnecting bearings feed lines: When the on skid piping is already flushed and clean, as itis the case for all the gas turbines listed ‘ot paragraph 7.4 and 7.6, disconnecting feed lines to the machines bearings is usually not necessary and, considering the dangerousn ion, it's stronaly di Typically, the bearing's feed lines of these gas turbines are contained inside of the drain pipes, and ‘are connected to the bearings internal piping with pipe unions, or with flexible hoses. For flushing, these unions/hoses should be opened and left disconnected inside of the drain, allowing the oil to flow without reaching the bearings. Unfortunately, once the drain is closed, from the outside it's not possible to see that the feed line inside is disconnected; sometime it's not even easy to see the Piping at all, due to its position under the turbine (as for MS5002, #2 & #3 bearings). As a matter of fact, it's pretty easy to forget to re-connect the bearing feed lines after several weeks of flushing {0s proven by several catastrophic failures happened in the past There are, however, cases that require the bearings feed line to be disconnected in order to flush the interconnecting piping. These cases, limited to a number of typical arrangement where the by-pass can be installed in a clearly visible and accessible position, will be detailed at the next paragraph 75. g Tie OCUENT CODE FESR GEOI6 Gos | BENERAL NOTES FOR LUBE OL SYSTEM FLUSHING sicooo0s 1 EVSION GESCRPTON PAGE HARKER ‘SET COE NO REVISION 1S INTRODUCED IN THS PASE WA N RIGNAL 108 HE | Onan 0804970 4 A SE nn ST7.3. On skid piping relevant to machines tested in factory WITHOUT their job skid: Most of the GE Oil & Gas machines are installed on a skid, that always includes the LO piping (bearings header, feeds and drains). In some cases, typical for the models listed below, the machines are assembled on the skid after the mechanicol test, without a factory flushing of the skid. In this case the job skid piping must be flushed ot site, disconnecting the oil feed lines to the beorinas as close as possible to the machine's flanges, re-routing the feed lines to any drain using temporary bypasses, normally done with flexible hoses, The position of the by-passes identifies the position of the test mesh screen. Examples given: + All models of Centrifugal Compressors All models of Reciprocating Compressors All models of Steam Turbines PGT25 and HSPT gas turbines Load Gearboxes manufactured by any sub-suppliers Electric generators manufactured by any sub-suppliers 7.4. On skid piping relevant to machines tested in factory WITH their job skid: The machines belonging to this family (double skid gas turbines) are tested on their job skid, ‘and this requires that the on skid piping is flushed in the factory prior to the test. In this case, the on skid piping, included between the oil inlet and oil drain flanges, shall be considered clean_and does not need to be re-flushed at site, Examples given ‘+ All models of MS5002 gas turbine (GT skid) ‘+ All models of MS6001 gas turbine (GT skid) ‘+ All models of MS7001 gas turbine (GT skid) ‘+ All models of MS9001 gas turbine (GT skid) Considering the criticality of the cleanliness of the system, it’s suagested to perform a visual or boroscopic inspection of the accessible part of the on skid piping, from the skid Terminal Points, removing the yellow transportation covers/blinds, before connecting the interconnection piping, in case any contamination is found, a specific inspection plan and corrective action shall be agreed involving GE Oil & Gas HQ. 7.5. interconnecting piping between GT Auxiliary skid and GT The gas turbines listed at paragraph 7.4 are always coupled with an ouxiliary skid that is including all, or most, of LO system components. The auxiliary skid delivers the lube oil to the ‘gas turbine skid through a set of interconnecting piping that, being installed and sometime manufactured at site, shall be flushed at site, To do that, it wll be necessary to disconnect the pipes at the downstream flanges and install temporary bypasses, normally done with flexible hoses connected to any convenient drain, The position of the by-posses identifies the position Of the test mesh screen, ing from has been said ot paragraph 7,2, in a few cases, the installation of the mn onk sconnecting the bearings feed lines: + Beoring # 1 for all double skids GT's in the list at porograph 7.4, Ths is becouse the inter- skid pipe, coming from the auxiliary skid, is connected directly to the machine's bearing LO inlet flange, without on skid- piping, + Beoring #2 for MS6001. This is because the last connection of the LO line, inside of the external oil channel, consists of a very short flexible hose that cannot be diverted or rotated, and makes much more convenient to disconnect one of the two available breaking points in the bearing on-skid pipe. ee erated ea ; cum [| a76. 77. 78. 79. 7.10. Single skid Gos Turbines, tested in factory: ‘These GT's are installed on a single skid that includes also all, or most, of the components of the LO System, without interconnecting piping to the turbine. They are tested in the factory in this configuration, therefore the entire skid shall be considered clean and does not need to be re-flushed at site Examples given: * All models of M5001 gas turbine (single skid, auxiliaries & GT) + All models of GE10-1 (single skid, auxiliaries & GT) The same prescriptions about the dangerousness of disconnecting bearings feed lin ain ragraph 7.2 oF Auxiliary skids and Mineral LO Consoles: The auxiliary skids and the LO consoles are always flushed in the factory, therefore re-flushing at site is not required. The main oil path downstream of the filters, however, is always re- flushed together with the interconnecting piping, and the verification of the cleanliness at the downstream end of the system, of course, is to be extended to all the upstream sections, including the aux skid/console internal piping. Having considered the skid/console already flushed at the factory, itis not required to do any special preparation for flushing of the on skid components, such as removing valves, orifices ‘and instruments, blinding or spading oil feeds to any auxiliary (such as auxiliary gearbox, torque converter, etc), particularly for whatever is part of the system downstream of the LO filters. Considering the criticality of the cleanliness of the system, it’s suggested to perform a visual or bboroscopic inspection of the accessible part of the on skid piping, In case any contamination is found, a specific inspection plan and corrective action shall be agreed involving GE Oil & Gas HQ. Flushing done in different steps/phases: The flushing of the LO system may be done in different steps, “cutting” the system in sub- sections, either in parallel or in serial, and completing one step prior to proceed to the next one. This strategy may be selected, for instance, if the oil flow available from the pumpls) is not sufficient to give turbulent flow to all parallel legs of the piping system. ‘Another example may be when an upstream portion of the LO system is known to be dirtier than the other ones, downstream of it. In this case, the most upstream should be flushed first, ‘and once it's clean it can be used to feed oil to the more downstream ones. Flushin liminary acceptance criteria: The completion of each flushing step can be verified through visual inspection of test mesh ‘screens, as explained at paragraph 5.6, The acceptability is defined according to API 614, para 4.3.37.1, except for the requirement of the oil temperature that can be any value within the ‘Suggested range (see 63) Flushing with / without test mesh screens: Usually, there are two different approaches when planning the installation of the mesh screens: 7.10.1. installing them since the beginning, and flushing with them in place all the time 7.10.2. flushing without mesh screens, to be installed only at the end, for cleanliness check The first case gives to the mesh screens the function of "secondary filters", and has the ‘advantage that the larger particles can be blocked by the meshes, limiting drains and tank contamination. The second case, instead, maximizes the efficiency of the oil circulation, QB cco rer nme eae ; Faesnatee-rsen 2 fVOU UHUE LHe FESULUUHS GUE LY CIUYYEU HEDIS Huy HNL UIE Un HUW Int SUTKE UF Ue parallel legs of the circuit ttolso prevents the need of frequent inspections of the meshes that if not equipped with manual isolation valves, would require stopping the pump, causing cil cool-down, etc. Considering that the easily movable dirt, such as rags and paper sheets (that unfortunately tare sometimes found in the piping as a consequence of poor fabrication and assembly processes! is removed within the first minutes/hours of flushing, GE Oil & Gas suagests the following scheme, that is « combination of the above ones ‘© install the meshes ond flush for 1-2 hours, ‘© inspect ond lean the meshes, then restart ond flush for 4-6 hours ‘© repeat 2-3 times, then remove meshes ond continue flushing Bs [ee wrens son cae 5; ome i m wan [a | a©, MINERAL LUBE IL rLUsmINY INS RULLUNS 8.1. Preparation for flushing The LO system shall be prepared for flushing, setting up its configuration according to the ‘applicable typical marked up PID, referenced in paragraph 3, or according to the job Specific PSID present in the job TPL, This P&ID is showing the position of the by-passes, the test mesh screens, etc. for each of the flushing steps. In general, the following checks should also be performed: * Verify that all pressure transmitters and pressure switches inserted in the oil circuit to be flushed (or any other device that may be sensitive to dirt} have the root valves in SHUT position. At the end of flushing, prior to set the instruments in service, itis suggested to open for a short period the drain valve, to let the oil flow ‘and removing in this way any particles present in the tubing. * Verify that all temperature probes inserted in the oil circuit to be flushed are properly installed, otherwise close the installation hole with an appropriate plug. + Oil Filters Differential Manometer shut-off valves in OPEN position. * Oil ters drainage valves in SHUT position. * Gil fiters equalisation valves in SHUT position. * Oil fiters differential test volves in SHUT position. © Other checks prior to tank filing: = Cleanliness check of piping from oil console to pump suction; pump suction mesh verification. = Oil coolers internal cleanliness check (on skid coolers) - Filters cartridges bodies internal cleanliness check. Cartridges integrity & correct installation check = Check of the differential pressure gauges used for indicate the filters cartridges status. - Checks cleanliness and absence of any non-conformity of all tanks and reservoirs present in the system, as explained in paragraphs 183, 184, 185, 186. ‘+ Itis not recommended to remove any component of the auxiliary skid/con: explained at paragraph 7.7 NOTE: All tubing/piping temporarily disconnected shall be protected to prevent any dirt ‘& foreign object ingress. Installation of blind flanges and spading shall be executed following the relevant standard procedure RIC8990002_- GENERAL GUIDELINES FOR BLIND FLANGES MANAGEMENT AT SITE 82. Suggested materials (not in std GE Oil & Gas scope of supply) 82.1. Temporary bypasses The main requisites for flushing temporary bypasses are: * Material: to be compatible with the flushing oil (mineral/synthetic] at the rated temperature (at least 70 DegC). This can be achieved using certified suitable flex hose (up to 4-6'), stainless steel piping, or a combination of the two. The pressure rating is usually not a concern, due to the very low pressures at which the flushing is executed. * NOTE: use of carbon steel piping is forbidden. Qc fren ens sense a ; Sion tim mea i "viumever. € nun Yor ue introduce excessive-pressure loss Length: usually its possible to purchase the flex hoses in various length rolls, to be cut os needed. However, the lenght should be limited os much as possible, for the same reason as above. The bypasses shall be preventively blown and cleaned, in order to limit the quantity of dirt sent to the LO tonk. The bypasses shall be properly supported to ovoid vibrations during flushing operation. Connection to drains or tank manhole shall be done safely, preventing that the oil jet may force the bypass to slp off, cousing injuries and/or domages. Connections: the bypasses shall be equipped, at the incoming end, with the same type of flange or fitting at which the bypass shall be attached. On LO systems, this is most of the time an ASME B16.5, series 150 RF. In case of rigid pipe bypass, the flange can be a slip on flange (reference ITN83000-ITN83001). In case of fiexible hose bypass, usually equipped with NPT threaded fitting, the reference for the mating flange is should be the bypass is ITN83007. All flanged connections shall be equipped with suitable gaskets (spirometall, to be replaced with new ones at system restoring, Job tie rods can be reused, if visually inspected don't show any damage. HLTH pipe weLor sueUL , 1 UIUEL HULL 8.2.2. Test mesh screens: They can be prepared as shown in figure 1. On larger piping, however, itis advisable to use cone filters (see ITN 84018-84046), using the same double layer structure (20 mesh + 100 mesh). NOTE: the temporary screen is not a filter, that can be used to clean the oil during flushing. It is only a device to be used to check the system cleanliness. ee. — — tea] = aes figure 1 They shall be positioned at the end of each leg of circuit to be flushed, installed on the last avoilable flange. The mesh screen sets the limit between the clean side (upstream) and the dirty side (downstream, Whenever possible, the mesh screen should be installed on a vertical position, in such a way that the upstream side is upward. This prevents that the oil, flowing backward when the flushing results. is stopped, washes away the particles left on the screen, giving false positive test Q 2 [oe mera ere ae ; ea almsinstall mesh screens always-upstream of the temporary by-passes, using a configuration as shown in the sketch reported below ffigure 2). Mesh screen x SN Tooil drain Manual vaives Figure 2 The function of the optional manual valves installed upstream and downstream of mesh screen is: ‘+ To cut off from circuit every single mesh screen, that can be inspected without stopping the flushing activity * To adjust the flow rate in the various lines of the flushing circuit, chocking the flow on larger pipes, if necessary, to bolance the oil speed on branches with different internal diometer. * To shut off a line whose mesh screen has already shown that the preliminary acceptance criteria is met, and let fushing activities continue on other branches. NOTE: the upstream manual valve is required to isolate the mesh screen for inspection, while the downstream manual valve prevents oil vapours, potentially dangerous, to escape. 8.2.4. Servovalves by-pass blocks: These are required to replace servovalves when performing hydraulic oil flushing (see paragraph 821). For each servavalve it's necessary to provide a bypass valve (ref GE Oil & Gas code RVO07006, see figure 3) and an adapter block, to be selected between the ones listed below (typical figure 4) depending on the type of servovaive to be replaced. ‘* SMPB316093 (inlet Guide Vane for MS5001-5002-6001-7001-9001) © SM 78542 (NGV for MS5002) «SM 22185 (SRV & GCV for MS5001-5002-6001-7001-9001) AS) Fayre an it Raf] bee. 1 ” er Figure 3 Figure 4 THE ToCIRENT CoE RS (GEOIE Gos | GENERAL NOTES FOR LUBE OL. SYSTEM FLUSH SIC00006 1 REWION DESCRPTION PAGE RARER SECURTY COOE No REMISON I MTRODUCED IN THS PASE on N TERA 08 ae | mene 0804970 4 A8.4, 85. 86. 87. Before first filing with oi, itis.« recommended best practice to inspect and clean the mineral LO tank, using lint free rags. This is also required to remove preservation products (oil and/or vpci emittin nges) that are lly inserted in the tank for shipping protection. Particularly, itis necessary to verify the following points: ‘Internal tank and piping painting: highlight on possible unpainted spots after welding repairs. ‘= Internal piping supporting: completeness and correct tightening ‘* Flanged connections: correct gaskets installed; correct tightening ‘* Tubing: correct connections and routing, as per P&ID * Check valves: correct installation in the right direction, as per PID Regulating valves: correct installation * Orifices: correct dimension, as per PSID * Cleaning WARNING: LO tonk cleaning is a “Confined Space" activity, to be executed under strict observation of all EHS prescriptions Cleaning of run down tank: Even if the run down tank is always cleaned in the factory, its position downstream of the filter makes mandatory a cleaning at site. This con be done manually, if an inspection flange / manhole is present, alternatively it must be inspected through the oil piping flanges to assess the internal cleanliness ond decide an action plan, ifnecessary, case by case. The run down tank is always by-passed during run down tank piping flushing, Cleaning of seal oil overhead tank: Seal oil systems are nowadays obsolete, however in case such systern must be commissioned the same consideration as for the run down tank applies: it must be manually cleaned if an inspection flange / manhole is present, alternatively it must be inspected through the cil Piping flanges to assess the internal cleanliness and decide an action plan, if necessary, case by case. The seal oil overhead tank is always by-passed during seal oil piping flushing. Cleaning of any other oil reservoir: For any other reservoir that might be present in the system, a manual cleaning is always required, This may apply to: '* Drain boxes of the Oil Mist eliminator + Degassing tank of Seal Oil system '* Oil channel (MS6001-MS7001-MS9001 gas turbines) stems preliminary commissioning (MCé rs and pumps| Prior to proceed to motor/pumps energization it is necessary to perform all pre- commissioning and commissioning activities on the system components. If the job control systems are used (see poragraph 6.10) at least the following operations are required: ‘+ UCP power up os per applicable procedure (for MK6 see RICB952216) and job SOCL MCC setting and commissioning as per RICB952215 ‘+ DCP setting and commissioning as per RICB952213, If temporary local panel is used, its commissioning needs at least to consider setting of motor protection devices to be aligned with motor tag data, Next steps: SIC00006 1 THe THREAT TE FETS @ 51 Gos | SNERAL NOTES FoR LURE 0 SYSTEM FLUSANG REVSON DESTRPTION PASE ARE SECURITY TOE No REVISION IS NTRCOUCED MTHS PAGE WA N RGN 108 Se | UNRSE 0804970, 4 A |= mois: precormmissioniy \UNYHIENE CHEK, UMELUUTE UF TOLUULTE LHELK, 1 uncoupled run, etc:)as per RIC8952207. 8.8. LO tank first filling; first starting of pump(s); oil level check The LO tank shall be filled through a fitration system {for instance, a simple mesh screen), that is necessary to prevent that the impurities, typically present at the bottom of the oil transportation borrels, go inside the tank. The amount of oil to be loaded, in. normal running conditions, is usually indicated in the P&I, both in terms of volume of oil and in terms of cil level to be reached in the tank. In flushing conditions, however, the quantity of oil needed might be slightly different becouse the piping volume is not the same as in running conditions, The best and practical way to proceed at the fist filing is as follows: * Mark high, normal and low levels on the tank level indicator + Fill the oil tank up to the high level + Start the pumpls) for short periods of time, monitoring the oil level through the indicator. If available, it may be advisable to use the emergency DC pump that, having a lower flow, will help detecting and limiting any possible leakages. * _ Inthis phase, the level will decrease while the oil fills the empty piping. Also monitor motor current and vibrations, particularly ifthe oils cold theaters should be on) ‘© Ifthe oil level approaches the low limit the pump(s) shall be stopped and the tank shall be filed with more oil, up to normal level, This will prevent the pump suction and the heaters working above the oil level, causing pump cavitation and heater's damages. ‘+ NOTE: the ol level, ofter pumpis) stop, wil ncrease again due to the oil flowing back from the piping. This may happen more or less quickly depending on the system configuration (height of the coolers, type and position of check valves, etc). This effect shall be considered before filing the tank ‘+ After stabilization, it will be possible to run the pumps) for extended periods. ‘+ At the first opportunity, stop the oil ond check that the oil level never exceeds high level ft may take several hours before the new steady level is reached). 8.9. Oil cooler flushing (only for off-skid coolers): The oil cooler is a standard component of the LO system, always positioned between the pumps) discharge and the LO filters. Sometime this is a part of the Auxliary Skid/Console, ready c to the rest of the skid LO system, and it's cleanliness hos been ensured the factory flushing, This solution is always done with a woter-to-oil type of cooler. The cooler may also be a stand-alone component, installed out and for from the aux skid/console, connected to it through interconnecting piping manufactured at site. In this case the cooler can be either water-to-oil or air-to-oil type. In cose the oil cooler is off-skid, regardless of the type, itis always necessary to perform the flushing of the interconnecting piping to and from the cooler. itis a known fact that this section of piping is, most of the time, the most complex to flush, because of the large quantity of debris that is found in it. This is because it is normally the largest ond longest line of the entire LO system, completely fabricated at site starting from commercial bars, needing a large number of cutting, welding, etc. Dedicating special effort to the cleaning of this portion of the system may be very effective on reducing the overall duration of flushing For this reason, itis a suggested best practice to flush the cooler lines separately from the rest of the system. (as shown in figure 5], disconnecting the cooler oil return line upstream of the filter, and discharging the oil into the tank through a temporary pipe/hose, connected at one ‘end to a large basket, composed of an external gross net (20 mesh or less) ond an internal +100 mesh (see Figure 6, 7 AND 8 FOR REFERENCE], This flushing step shall be provided before 101 @ Te DOCRENT CODE Fev CGE Oi16 Gos | GENERAL NOTES FOR LUBE OL SYSTEM FLUSKINS sicoo006 1 REVSEN GESCRPTON PAGE MARKER “SERTY COE No REVISION IS WTRODUCED THES PAGE WA N ‘IGRAT 108 Sa | canna 0804970 4 A Se a