-
GRD
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A4
07/12/2012 11/02/2013
403A5502
CAINERO CHRISTOPHE RIVIERE BERTRAND
RIVIERE BERTRANDCAINERO CHRISTOPHE
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FLUSHING GUIDELINE B&E CLASS GAS TURBINE
FLUSHING GUIDELINE B&E CLASS GAS TURBINE
A
11-F
eb-2
013-
16:5
3
DT-7C
GE Of
ficial
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Commissioning Guideline GPO / GFO / M&I 403A5502 Revision: A
Unit: B & E GT Page : 1 / 32
Flushing Guideline B & E-Class Gas Turbine
Observations :
This document, sole property of our company, is strictly
confidential. It must not be
communicated, copied or reproduced without our written
consent.
Ce document, proprit exclusive de notre Socit, est strictement
confidentiel. Il ne peut
tre communiqu, copi ou reproduit sans notre autorisation
crite.
Este documento, proprietad exclusiva de nuestra Compania, es
estricamente confidential. No puede
ser communicado, copiado o reproducido sin su autorizacion
escrita.
1 GENERAL INFORMATION:
1.1 Purpose of the document: The purpose of this document is to
guide trained, qualified and authorized GE-commissioning engineers
or GE-technical advisors (TA) or GE-supervisors to perform the
various flushing required during the start-up of a power plant. It
has to be adapted according to site conditions and discussed with
mechanical team to match specific site configuration.
Photos and drawings provided in this document are not
contractual, they are only given to show how to install flushing
parts and they may not reflect site reality as connections may
differ depending supplier selected.
Gas turbine, generator and skids are generally delivered at site
in a clean condition. Flushing at site concerns mainly the off base
piping. As per design, pipes used for on-base piping are stainless
steel or already factory cleaned. In spite of keeping pipes in a
clean condition during installation, dust and debris may remain
inside the system; therefore the purpose of flushing is to remove
these foreign particles. Piping lengths which cannot be flushed are
blown with compressed air and visually inspected.
It is once more recalled that during construction, piping must
be stored in dry, dustless and safe area (shelter is recommended),
plugged at each end with relevant caps.
This document can be used as a check-list during flushing, but
it is not an official record of the operation. The official record
is the commissioning book of the unit that must include evidence of
flushing and results.
1.2 Safety policy: All EHS (Environment, Hygiene and Safety)
rules and recommendations, recorded in the EHS Construction Plan
must be applied, particularly wearing required PPE (Personal
Protective Equipment). No job can be started if people or equipment
safety is compromised. This is a GE Global Policy requirement and
nothing can lead to ignore these safety rules.
Commissioning activity generates mainly 2 types of risk:
Electrical hazards: all needed precautions have to be taken to
avoid contact with electrical parts
under voltage. Be conscious that on generator, residual voltage
is present even if machine is at standstill and not excited ;
Mechanical hazards: all needed precautions have to be taken to
prevent contact with rotating parts
(shaft line, motor, pumps, etc.).
1.3 Flushing acceptance criteria: For all circuits, please refer
to GEK-110483 for flushing acceptance criteria to be met. The
criteria mentioned in this guideline are for information only and
must be verified with the latest version of the GEK before use.
DT-7C
-
Commissioning Guideline GPO / GFO / M&I 403A5502 Revision: A
Unit: B & E GT Page : 2 / 32
Flushing Guideline B & E-Class Gas Turbine
Observations :
This document, sole property of our company, is strictly
confidential. It must not be
communicated, copied or reproduced without our written
consent.
Ce document, proprit exclusive de notre Socit, est strictement
confidentiel. Il ne peut
tre communiqu, copi ou reproduit sans notre autorisation
crite.
Este documento, proprietad exclusiva de nuestra Compania, es
estricamente confidential. No puede
ser communicado, copiado o reproducido sin su autorizacion
escrita.
1.4 Summary: 1 General Information:
....................................................................................................................................
1
1.1 Purpose of the document:
....................................................................................................................
11.2 Safety
policy:........................................................................................................................................
11.3 Flushing acceptance criteria:
...............................................................................................................
11.4 Summary:
.............................................................................................................................................
21.5 Revision status:
...................................................................................................................................
3
2 Lube Oil Flushing:
........................................................................................................................................
42.1 Safety complement:
.............................................................................................................................
42.2 Acceptance Criteria:
............................................................................................................................
42.3 Flushing process for B-class unit:
........................................................................................................
52.4 Flushing process for E-class unit:
......................................................................................................
122.5 Lube oil flushing record sheet:
...........................................................................................................
21
3 Gas Fuel Flushing:
.....................................................................................................................................
223.1 Safety complement:
...........................................................................................................................
223.2 Acceptance Criteria:
..........................................................................................................................
223.3 Gas fuel flushing:
...............................................................................................................................
22
4 Liquid Fuel Flushing:
..................................................................................................................................
234.1 Safety complement:
...........................................................................................................................
234.2 Acceptance Criteria:
..........................................................................................................................
234.3 Flushing process:
...............................................................................................................................
234.4 Flushing completion:
..........................................................................................................................
26
5 Water-Cooling Flushing:
............................................................................................................................
275.1 Safety complement:
...........................................................................................................................
275.2 Acceptance Criteria:
..........................................................................................................................
275.3 Flushing Process:
..............................................................................................................................
275.4 Flushing completion:
..........................................................................................................................
31
6 Reference Documents:
..............................................................................................................................
32
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Commissioning Guideline GPO / GFO / M&I 403A5502 Revision: A
Unit: B & E GT Page : 3 / 32
Flushing Guideline B & E-Class Gas Turbine
Observations :
This document, sole property of our company, is strictly
confidential. It must not be
communicated, copied or reproduced without our written
consent.
Ce document, proprit exclusive de notre Socit, est strictement
confidentiel. Il ne peut
tre communiqu, copi ou reproduit sans notre autorisation
crite.
Este documento, proprietad exclusiva de nuestra Compania, es
estricamente confidential. No puede
ser communicado, copiado o reproducido sin su autorizacion
escrita.
1.5 Revision status:
REV. DATE (dd/mm/yyyy) DOCUMENT OBJET
A 02/04/2012 Flushing guideline First issue BR
-
Commissioning Guideline GPO / GFO / M&I 403A5502 Revision: A
Unit: B & E GT Page : 4 / 32
Flushing Guideline Lube Oil Flushing
Observations :
This document, sole property of our company, is strictly
confidential. It must not be
communicated, copied or reproduced without our written
consent.
Ce document, proprit exclusive de notre Socit, est strictement
confidentiel. Il ne peut
tre communiqu, copi ou reproduit sans notre autorisation
crite.
Este documento, proprietad exclusiva de nuestra Compania, es
estricamente confidential. No puede
ser communicado, copiado o reproducido sin su autorizacion
escrita.
2 LUBE OIL FLUSHING:
2.1 Safety complement: Oil generates mainly 3 types of risk:
Pollution: all precautions must be taken to avoid accidental
leakages and spillage during preliminary tests. These safety
precautions must be taken regarding the HSE Plan of the site and
the local regulation. Pollution fighting means (basin, absorbent,
etc.) must be available near the hazardous area. Fire: oil does not
present fire risk by itself. Risks can arise when oil is near an
ignition source (heat,
spark, naked flame, etc.). Respect of work permit and
particularly, hot work permit should allow to bring the risk under
control. Firefighting means (hydrocarbon fire extinguishers, sand,
etc.) must be available near the hazardous area. Chemical: please
refer to Material Safety Datasheet and take required
precautions
2.2 Acceptance Criteria: GEK-110483 reminds what the acceptance
criteria are for the cleanliness of the lube-oil and HP-oil
systems. It also provides guidelines to evaluate this
cleanliness.
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Commissioning Guideline GPO / GFO / M&I 403A5502 Revision: A
Unit: B & E GT Page : 5 / 32
Flushing Guideline Lube Oil Flushing
Observations :
This document, sole property of our company, is strictly
confidential. It must not be
communicated, copied or reproduced without our written
consent.
Ce document, proprit exclusive de notre Socit, est strictement
confidentiel. Il ne peut
tre communiqu, copi ou reproduit sans notre autorisation
crite.
Este documento, proprietad exclusiva de nuestra Compania, es
estricamente confidential. No puede
ser communicado, copiado o reproducido sin su autorizacion
escrita.
2.3 Flushing process for B-class unit: GT flushing is performed
with operating oil, except if dedicated flushing load is specified
by the contract. GT lube oil tank, GT auxiliary lube oil pump
(88QA) and GT lube oil filters can be used for the flushing
process. The oil demister (88QV) must not be used during the
flushing. Main lube oil filter must be equipped with standard
cartridges which are replaced after flushing completion as per
MLI106.
Before flushing, take samples of the clean oil using procedure
91-438752 as a guideline. Use a clean, dry and appropriated
recipient. Do not spoil sample with a dirty filing pipe / point.
Ensure the dead volume between circulating line and sampling point
has been flushed prior to take sample. Keep oil samples in a clean
and safe place (respect EHS rules) during the total presence of GE
Personnel at site. Protect samples from direct sun light.
During flushing, oil temperature must be higher than 40C. Lube
oil flows through coolers with cooling water not running. If oil
tank heaters are used to warm up flushing oil, this important
guideline must be followed:
Lube oil level must be higher than the heaters when pump 88 QA
is running. Lube oil must circulate when heaters are switched on.
Heaters should be switched off when oil temperature reaches 54C.
Oil temperature must not be over SpeedTronic alarm.
A temporary emergency push button to stop lube oil pump may be
installed in the auxiliary compartment. Flushing supervisor and
watchers must know where and how to stop the lube oil pump.
To insure a sufficient flow, flushing is performed in two main
sequences: Phase 1: bearing #2 & load gear by-passed, generator
line blocked Phase 2: bearing #2 & generator bearings
by-passed, load-gear blocked
According to site experience, if all the necessary precautions
have been taken during installation to keep piping in a clean
condition, the minimum flushing durations are:
12 hours for phase 1 12 hours for phase 2
Remaining short length of feeding pipes, not flushed with a lube
oil flow, must be cleaned using 6 bars compressed air and installed
after visual inspection.
During flushing, parameters must be monitored and recorded
frequently (15 minutes). Pump motor amps must be monitored at every
change in the flushing circuit to be sure that full load amps are
not exceeded. Proceed to phases 1 and 2 of the flushing sequences
(See hereafter for a detailed procedure).
NB: Bearing #1 feeding pipe is not specifically flushed at site
as the auxiliary module comes coupled with the gas turbine. The oil
circulates through the bearing #1 during the 2 flushing phases.
-
Commissioning Guideline GPO / GFO / M&I 403A5502 Revision: A
Unit: B & E GT Page : 6 / 32
Flushing Guideline Lube Oil Flushing
Observations :
This document, sole property of our company, is strictly
confidential. It must not be
communicated, copied or reproduced without our written
consent.
Ce document, proprit exclusive de notre Socit, est strictement
confidentiel. Il ne peut
tre communiqu, copi ou reproduit sans notre autorisation
crite.
Este documento, proprietad exclusiva de nuestra Compania, es
estricamente confidential. No puede
ser communicado, copiado o reproducido sin su autorizacion
escrita.
2.3.1 Mechanical preparation Phase 1:
General view of 6B turbine oil system
Remove all servo valves, and install relevant flushing blocks
and gaskets Keep servo valves in a plastic bag to avoid any
contamination. Make sure not to lose any O-ring gaskets.
-
Commissioning Guideline GPO / GFO / M&I 403A5502 Revision: A
Unit: B & E GT Page : 7 / 32
Flushing Guideline Lube Oil Flushing
Observations :
This document, sole property of our company, is strictly
confidential. It must not be
communicated, copied or reproduced without our written
consent.
Ce document, proprit exclusive de notre Socit, est strictement
confidentiel. Il ne peut
tre communiqu, copi ou reproduit sans notre autorisation
crite.
Este documento, proprietad exclusiva de nuestra Compania, es
estricamente confidential. No puede
ser communicado, copiado o reproducido sin su autorizacion
escrita.
Disconnect feeding line to bearing #2, to allow oil to flow in
the return line
Detail Bearing #2 feeding line WITH gap
By-pass the load gear and close the inlet (use relevant drawing
for construction of blue pipe)
-
Commissioning Guideline GPO / GFO / M&I 403A5502 Revision: A
Unit: B & E GT Page : 8 / 32
Flushing Guideline Lube Oil Flushing
Observations :
This document, sole property of our company, is strictly
confidential. It must not be
communicated, copied or reproduced without our written
consent.
Ce document, proprit exclusive de notre Socit, est strictement
confidentiel. Il ne peut
tre communiqu, copi ou reproduit sans notre autorisation
crite.
Este documento, proprietad exclusiva de nuestra Compania, es
estricamente confidential. No puede
ser communicado, copiado o reproducido sin su autorizacion
escrita.
Install a system to take sample at the oil pump outlet
Disconnect and plug the control line of VPR2-1 to allow this valve
to stay fully open during flushing
Set the transfer valves to one cooler, one main filter, and one
HP filter Close inlet valve of torque converter strainer Check that
electrical power supply is available for AC lube oil pump and
heaters Check GT auxiliaries frame earth connections Check that the
filters are equipped with cartridges :
o Lube oil filter #1 o Lube oil filter #2
-
Commissioning Guideline GPO / GFO / M&I 403A5502 Revision: A
Unit: B & E GT Page : 9 / 32
Flushing Guideline Lube Oil Flushing
Observations :
This document, sole property of our company, is strictly
confidential. It must not be
communicated, copied or reproduced without our written
consent.
Ce document, proprit exclusive de notre Socit, est strictement
confidentiel. Il ne peut
tre communiqu, copi ou reproduit sans notre autorisation
crite.
Este documento, proprietad exclusiva de nuestra Compania, es
estricamente confidential. No puede
ser communicado, copiado o reproducido sin su autorizacion
escrita.
o HP oil filter #1 o HP oil filter #2 Check that the low tank
drain pipes are closed and locked Check the cleanliness of the tank
before filling up (you might perform TEP01 and tank inspection
before) Fill up the tank with 6000 liters (30 drums) of oil.
(the quantity of oil used for flushing may be less
important than final load)
2.3.2 Flushing Phase 1: Walk-down all the lines, including
instrumentation lines, to prevent any risk of leakages Proceed to
motor-heater tests if not done (see TPE01 and TEP02) Start the lube
oil pump (88QA-1). Check for leak. The motor AC current should not
be higher than
nominal current. During flushing sequence, record AC current,
oil pressure, oil temperature, oil filter pressure
drop, according to data sheets hereafter. Flushing is completed
when oil sample reach GEK-110483 criteria
Flushing phase 1 completion date:
2.3.3 Mechanical preparation Phase 2: Apply proper LOTO
procedures Keep by-pas at bearing #2 Prepare generator for
flushing:
o Remove load gear by-pass and block inlet and outlet o Open
generator feeding and return lines o By-pass feed lines to return
lines as close as possible from the bearings
-
Commissioning Guideline GPO / GFO / M&I 403A5502 Revision: A
Unit: B & E GT Page : 10 / 32
Flushing Guideline Lube Oil Flushing
Observations :
This document, sole property of our company, is strictly
confidential. It must not be
communicated, copied or reproduced without our written
consent.
Ce document, proprit exclusive de notre Socit, est strictement
confidentiel. Il ne peut
tre communiqu, copi ou reproduit sans notre autorisation
crite.
Este documento, proprietad exclusiva de nuestra Compania, es
estricamente confidential. No puede
ser communicado, copiado o reproducido sin su autorizacion
escrita.
-
Commissioning Guideline GPO / GFO / M&I 403A5502 Revision: A
Unit: B & E GT Page : 11 / 32
Flushing Guideline Lube Oil Flushing
Observations :
This document, sole property of our company, is strictly
confidential. It must not be
communicated, copied or reproduced without our written
consent.
Ce document, proprit exclusive de notre Socit, est strictement
confidentiel. Il ne peut
tre communiqu, copi ou reproduit sans notre autorisation
crite.
Este documento, proprietad exclusiva de nuestra Compania, es
estricamente confidential. No puede
ser communicado, copiado o reproducido sin su autorizacion
escrita.
2.3.4 Flushing Phase 2: Start the lube oil pump (88QA-1). Check
for leak. The motor AC current should not be higher than
nominal current. During flushing sequence, record AC current,
oil pressure, oil temperature, oil filter pressure
drop, according to data sheets hereafter. Flushing is completed
when oil sample reach GEK-110483 criteria.
Flushing phase 2 completion date:
2.3.5 Flushing completion: Remove all blank plates special
fitting and by-pass Restore all piping and check the system
conformity according to P&ID (orifice plates,
instrumentation),
do not forget VPR2-1 control line Regarding jacking oil, length
of site installed tubing must be air blown and thoroughly inspected
before
final installation. Run 88 HQ pump for 2 hours. Carefully
monitor 88 HQ motor current and HP filter differential
pressure: o If differential pressure is above 4 bars investigate
for any concern (leaks, opened valves in
instrument lines, filters clogged, etc), change filter if
clogged. o Run 88HQ till differential pressure is normal (see item
0414) o While performing hydraulic oil flushing, jacking oil length
of site installed tubing should be
flushed with jacking oil pumps Reinstall servo valves Drain the
filters Replace lube oil main filter cartridges Add oil in the tank
After restoration, check for any leak and verify bearings return
oil flow through sight glasses. Check the oil tank level, 10
minutes after stopping the pump, and adjust it if necessary.
Flushing restoration completed date:
-
Commissioning Guideline GPO / GFO / M&I 403A5502 Revision: A
Unit: B & E GT Page : 12 / 32
Flushing Guideline Lube Oil Flushing
Observations :
This document, sole property of our company, is strictly
confidential. It must not be
communicated, copied or reproduced without our written
consent.
Ce document, proprit exclusive de notre Socit, est strictement
confidentiel. Il ne peut
tre communiqu, copi ou reproduit sans notre autorisation
crite.
Este documento, proprietad exclusiva de nuestra Compania, es
estricamente confidential. No puede
ser communicado, copiado o reproducido sin su autorizacion
escrita.
2.4 Flushing process for E-class unit: GT flushing is performed
with operating oil, except if dedicated flushing load is specified
by the contract. GT lube oil tank, GT auxiliary lube oil pump
(88QA) and GT lube oil filters can be used for the flushing
process. The oil demister (88QV) must not be used during the
flushing. Main lube oil filter must be equipped with standard
cartridges which are replaced after flushing completion as per
MLI106.
Before flushing, take samples of the clean oil using procedure
91-438752 as a guideline. Use a clean, dry and appropriated
recipient. Do not spoil sample with a dirty filing pipe / point.
Ensure the dead volume between circulating line and sampling point
has been flushed prior to take sample. Keep oil samples in a clean
and safe place (respect EHS rules) during the total presence of GE
Personnel at site. Protect samples from direct sun light.
During flushing, oil temperature must be higher than 40C. Lube
oil flows through coolers with cooling water not running. If oil
tank heaters are used to warm up flushing oil, this important
guideline must be followed:
Lube oil level must be higher than the heaters when pump 88 QA
is running. Lube oil must circulate when heaters are switched on.
Heaters should be switched off when oil temperature reaches 54C.
Oil temperature must not be over SpeedTronic alarm.
A temporary emergency push button to stop lube oil pump may be
installed in the auxiliary compartment. Flushing supervisor and
watchers must know where and how to stop the lube oil pump.
To insure a sufficient flow, flushing is performed in two main
sequences: Phase 1: gas turbine bearings #2 and #3 feeding lines,
Phase 2: gas turbine bearing #3 and generator bearings feeding
lines.
According to site experience, if all the necessary precautions
have been taken during installation to keep piping in a clean
condition, the maximum average time to flush is around 48 hours
circulation. However, the minimum flushing durations are:
12 hours for phase 1 12 hours for phase 2
Remaining short length of feeding pipes, not flushed with a lube
oil flow, must be cleaned using 6 bars compressed air and installed
after visual inspection.
During flushing, parameters must be monitored and recorded
frequently (15 minutes). Pump motor amps must be monitored at every
change in the flushing circuit to be sure that full load amps are
not exceeded. Proceed to phases 1 and 2 of the flushing sequences
(See hereafter for a detailed procedure).
NB: Bearing #1 feeding pipe is not flushed at site but has to be
cleaned by hand, air-blown and carefully inspected before final
installation.
-
Commissioning Guideline GPO / GFO / M&I 403A5502 Revision: A
Unit: B & E GT Page : 13 / 32
Flushing Guideline Lube Oil Flushing
Observations :
This document, sole property of our company, is strictly
confidential. It must not be
communicated, copied or reproduced without our written
consent.
Ce document, proprit exclusive de notre Socit, est strictement
confidentiel. Il ne peut
tre communiqu, copi ou reproduit sans notre autorisation
crite.
Este documento, proprietad exclusiva de nuestra Compania, es
estricamente confidential. No puede
ser communicado, copiado o reproducido sin su autorizacion
escrita.
2.4.1 Mechanical preparation Phase 1:
General view of 9E turbine oil system
-
Commissioning Guideline GPO / GFO / M&I 403A5502 Revision: A
Unit: B & E GT Page : 14 / 32
Flushing Guideline Lube Oil Flushing
Observations :
This document, sole property of our company, is strictly
confidential. It must not be
communicated, copied or reproduced without our written
consent.
Ce document, proprit exclusive de notre Socit, est strictement
confidentiel. Il ne peut
tre communiqu, copi ou reproduit sans notre autorisation
crite.
Este documento, proprietad exclusiva de nuestra Compania, es
estricamente confidential. No puede
ser communicado, copiado o reproducido sin su autorizacion
escrita.
For 9E-frame, material is part of MLI A125 Remove all servo
valves, and install relevant flushing blocks and gaskets
Keep servo valves in a plastic bag to avoid any contamination.
Make sure not to lose any O-ring gaskets. Disconnect feeding line
to the gas module (if part of the requisition), to allow oil to
flow in the return
line
Detail A Gas module connection WITH gap
Install a closure plate in GT Bearing #1 feeding line
Detail E Bearing #1 feeding line blocked
-
Commissioning Guideline GPO / GFO / M&I 403A5502 Revision: A
Unit: B & E GT Page : 15 / 32
Flushing Guideline Lube Oil Flushing
Observations :
This document, sole property of our company, is strictly
confidential. It must not be
communicated, copied or reproduced without our written
consent.
Ce document, proprit exclusive de notre Socit, est strictement
confidentiel. Il ne peut
tre communiqu, copi ou reproduit sans notre autorisation
crite.
Este documento, proprietad exclusiva de nuestra Compania, es
estricamente confidential. No puede
ser communicado, copiado o reproducido sin su autorizacion
escrita.
Install a blank plate in GT Bearing #2 feeding line, leave a gap
for lube oil flowing to return line
Detail B Bearing #2 feeding line WITH gap
Disconnect feeding line to bearing #3, to allow oil to flow in
the return line
Detail C Bearing #3 feeding line WITH gap
-
Commissioning Guideline GPO / GFO / M&I 403A5502 Revision: A
Unit: B & E GT Page : 16 / 32
Flushing Guideline Lube Oil Flushing
Observations :
This document, sole property of our company, is strictly
confidential. It must not be
communicated, copied or reproduced without our written
consent.
Ce document, proprit exclusive de notre Socit, est strictement
confidentiel. Il ne peut
tre communiqu, copi ou reproduit sans notre autorisation
crite.
Este documento, proprietad exclusiva de nuestra Compania, es
estricamente confidential. No puede
ser communicado, copiado o reproducido sin su autorizacion
escrita.
Disconnect IGV connections and partially plug them
Detail D IGV connection PARTIALLY plugged
Install bypasses made on site on each generator bearing to
prevent oil from going into the bearing (U-pipe between supply and
return line) Leave valves closed if any. Check that generator
lifting oil feeding pipe is closed or plugged on supply side
Generator bearing #4 (turbine side)
-
Commissioning Guideline GPO / GFO / M&I 403A5502 Revision: A
Unit: B & E GT Page : 17 / 32
Flushing Guideline Lube Oil Flushing
Observations :
This document, sole property of our company, is strictly
confidential. It must not be
communicated, copied or reproduced without our written
consent.
Ce document, proprit exclusive de notre Socit, est strictement
confidentiel. Il ne peut
tre communiqu, copi ou reproduit sans notre autorisation
crite.
Este documento, proprietad exclusiva de nuestra Compania, es
estricamente confidential. No puede
ser communicado, copiado o reproducido sin su autorizacion
escrita.
Generator bearing #5 (excitation side)
Install a system to take sample at the oil pump outlet
Disconnect and plug the control line of VPR2-1 to allow this valve
to stay fully open during flushing
Set the transfer valves to one cooler, one main filter, and one
HP filter Close inlet valve of torque converter strainer Check that
electrical power supply is available for AC lube oil pump and
heaters Check GT auxiliaries frame earth connections Check that the
filters are equipped with cartridges :
o Lube oil filter #1 o Lube oil filter #2 o HP oil filter #1 o
HP oil filter #2 Check that the low tank drain pipes are closed and
locked Check the cleanliness of the tank before filling up (you
might perform TEP01 and tank inspection
before) Fill up the tank with 10000 liters (50 drums) of oil.
(the quantity of oil used for flushing may be less
important than final load)
-
Commissioning Guideline GPO / GFO / M&I 403A5502 Revision: A
Unit: B & E GT Page : 18 / 32
Flushing Guideline Lube Oil Flushing
Observations :
This document, sole property of our company, is strictly
confidential. It must not be
communicated, copied or reproduced without our written
consent.
Ce document, proprit exclusive de notre Socit, est strictement
confidentiel. Il ne peut
tre communiqu, copi ou reproduit sans notre autorisation
crite.
Este documento, proprietad exclusiva de nuestra Compania, es
estricamente confidential. No puede
ser communicado, copiado o reproducido sin su autorizacion
escrita.
2.4.2 Flushing Phase 1: Walk-down all the lines, including
instrumentation lines, to prevent any risk of leakages Proceed to
motor-heater tests if not done (see TPE01 and TEP02) Start the lube
oil pump (88QA-1). Check for leak. The motor AC current should not
be higher than
nominal current. During flushing sequence, record AC current,
oil pressure, oil temperature, oil filter pressure
drop, according to data sheets hereafter. Flushing is completed
when oil sample reach GEK-110483 criteria.
Flushing phase 1 completion date:
2.4.3 Mechanical preparation Phase 2: Apply proper LOTO
procedures Install a plug to the gas module (if part of the
requisition)
Detail A Gas module connection WITHOUT gap
Keep the blank plate in GT Bearing #1 feeding line
-
Commissioning Guideline GPO / GFO / M&I 403A5502 Revision: A
Unit: B & E GT Page : 19 / 32
Flushing Guideline Lube Oil Flushing
Observations :
This document, sole property of our company, is strictly
confidential. It must not be
communicated, copied or reproduced without our written
consent.
Ce document, proprit exclusive de notre Socit, est strictement
confidentiel. Il ne peut
tre communiqu, copi ou reproduit sans notre autorisation
crite.
Este documento, proprietad exclusiva de nuestra Compania, es
estricamente confidential. No puede
ser communicado, copiado o reproducido sin su autorizacion
escrita.
Keep the blank plate and close the gap at GT Bearing #2
Detail B Bearing #2 feeding line WITHOUT gap
Keep the by-pass in the GT Bearing #3 feeding line
Plug the remaining IGV connections
Detail D IGV connection TOTALLY plugged
Open valves located in generator bearings bypasses
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Commissioning Guideline GPO / GFO / M&I 403A5502 Revision: A
Unit: B & E GT Page : 20 / 32
Flushing Guideline Lube Oil Flushing
Observations :
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confidential. It must not be
communicated, copied or reproduced without our written
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Ce document, proprit exclusive de notre Socit, est strictement
confidentiel. Il ne peut
tre communiqu, copi ou reproduit sans notre autorisation
crite.
Este documento, proprietad exclusiva de nuestra Compania, es
estricamente confidential. No puede
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2.4.4 Flushing Phase 2: Start the lube oil pump (88QA-1). Check
for leak. The motor AC current should not be higher than
nominal current. During flushing sequence, record AC current,
oil pressure, oil temperature, oil filter pressure
drop, according to data sheets hereafter. Flushing is completed
when oil sample reach GEK-110483 criteria.
Flushing phase 2 completion date:
2.4.5 Flushing completion: Remove all blank plates special
fitting and by-pass Restore all piping and check the system
conformity according to P&ID (orifice plates,
instrumentation),
do not forget VPR2-1 control line Regarding jacking oil, length
of site installed tubing must be air blown and thoroughly inspected
before
final installation. Run 88 HQ pump for 2 hours. Carefully
monitor 88 HQ motor current and HP filter differential
pressure: o If differential pressure is above 4 bars investigate
for any concern (leaks, opened valves in
instrument lines, filters clogged, etc), change filter if
clogged. o Run 88HQ till differential pressure is normal (see item
0414 ) o While performing hydraulic oil flushing, jacking oil
length of site installed tubing should be
flushed with jacking oil pumps Reinstall servo valves Drain the
filters Replace lube oil main filter cartridges Add oil in the tank
After restoration, check for any leak and verify bearings return
oil flow through sight glasses. Check the oil tank level, 10
minutes after stopping the pump, and adjust it if necessary.
Flushing restoration completed date:
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Commissioning Guideline GPO / GFO / M&I 403A5502 Revision: A
Unit: B & E GT Page : 21 / 32
Flushing Guideline Lube Oil Flushing
Observations :
This document, sole property of our company, is strictly
confidential. It must not be
communicated, copied or reproduced without our written
consent.
Ce document, proprit exclusive de notre Socit, est strictement
confidentiel. Il ne peut
tre communiqu, copi ou reproduit sans notre autorisation
crite.
Este documento, proprietad exclusiva de nuestra Compania, es
estricamente confidential. No puede
ser communicado, copiado o reproducido sin su autorizacion
escrita.
2.5 Lube oil flushing record sheet:
LUBE OIL FLUSHING PHASE #________
DATE TIME 88 QA / AC CURRENT LUBE OIL
TEMPERATURE88QA
OUTLET PRESSURE
OIL FILTER PRESSURE
DROP
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Commissioning Guideline GPO / GFO / M&I 403A5502 Revision: A
Unit: B & E GT Page : 22 / 32
Flushing Guideline Gas Fuel Flushing
Observations :
This document, sole property of our company, is strictly
confidential. It must not be
communicated, copied or reproduced without our written
consent.
Ce document, proprit exclusive de notre Socit, est strictement
confidentiel. Il ne peut
tre communiqu, copi ou reproduit sans notre autorisation
crite.
Este documento, proprietad exclusiva de nuestra Compania, es
estricamente confidential. No puede
ser communicado, copiado o reproducido sin su autorizacion
escrita.
3 GAS FUEL FLUSHING:
3.1 Safety complement: Please be remembered that flammable gas
blows are prohibited on GE sites and that
GE personal cannot stay at site if such means are used for gas
pipes cleaning.
Please refer to GEK-116771: GE Energy recommendations, Fuel
Supply System Cleaning for Gas Turbines and EPRI Guideline 1023628:
Guidelines for Fuel Gas Line Cleaning Using Compressed Air or
Nitrogen for more details on proved alternative cleaning
methods
Fuel gas generates mainly 2 types of risk: Fire or explosion
hazards: all needed precautions have to be taken to avoid fire or
explosion at
site, especially when working on Gas, Liquid Fuel, Oil systems ;
risks can arise when gas is near an ignition source (heat, spark,
naked flame, etc.). Respect of work permits and particularly, hot
work permits should allow to bring the risk under control.
3.2 Acceptance Criteria: GEK-110483 reminds what the acceptance
criteria are for the cleanliness of the gas system. It also
provides guidelines to evaluate this cleanliness.
3.3 Gas fuel flushing: Our recommendation for the cleaning of
the gas system is to perform air-blows of limited lengths of pipes.
These air-blows will allow chasing out most of the pieces left in
the pipes during erection. We want to emphasize once more that
building a clean circuit makes it easier and cheaper to clean by
reaching the acceptance criteria quicker.
The 2 documents cited in the first part of this section are
explicit enough and we do not want to reproduce them here. Please
refer to these documents to perform the safest and the most
efficient cleaning as possible.
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Commissioning Guideline GPO / GFO / M&I 403A5502 Revision: A
Unit: B & E GT Page : 23 / 32
Flushing Guideline Liquid Fuel Flushing
Observations :
This document, sole property of our company, is strictly
confidential. It must not be
communicated, copied or reproduced without our written
consent.
Ce document, proprit exclusive de notre Socit, est strictement
confidentiel. Il ne peut
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crite.
Este documento, proprietad exclusiva de nuestra Compania, es
estricamente confidential. No puede
ser communicado, copiado o reproducido sin su autorizacion
escrita.
4 LIQUID FUEL FLUSHING:
4.1 Safety complement: Light Distillate Oil and Heavy Fuel Oil
generate mainly 3 types of risk:
Pollution: all precautions must be taken to avoid accidental
leakages and spillage during preliminary tests. These safety
precautions must be taken regarding the HSE Plan of the site and
the local regulation. Pollution fighting means (basin, absorbent,
etc.) must be available near the hazardous area. Fire: oil does not
present fire risk by itself. Risks can arise when oil is near an
ignition source (heat,
spark, naked flame, etc.). Respect of work permit and
particularly, hot work permit should allow to bring the risk under
control. Firefighting means (hydrocarbon fire extinguishers, sand,
etc.) must be available near the hazardous area. Chemical: please
refer to Material Safety Datasheet and take required
precautions
4.2 Acceptance Criteria: GEK-110483 reminds what the acceptance
criteria are for the cleanliness of the fuel oil system. It also
provides guidelines to evaluate this cleanliness.
4.3 Flushing process: Liquid fuel systems flushing are performed
with light distillate oil. The existing tank and the LDO forwarding
pumps (centrifugal) may be used for flushing. Tank level must be
sufficient to ensure proper circulation without priming problem.
Please note that in the case there are 2 liquid fuels (LDO and HFO
for example), it can be interesting to flush the 2 feeding lines at
the same time to maximize flow. Once feeding lines are clean,
return lines are flushed in a second phase.
Please note that in case of 2 liquid fuels (LDO + HFO), HFO
volumetric pump must not be used to flush HFO lines with LDO. There
is a high risk of damaging the pumps.
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Commissioning Guideline GPO / GFO / M&I 403A5502 Revision: A
Unit: B & E GT Page : 24 / 32
Flushing Guideline Liquid Fuel Flushing
Observations :
This document, sole property of our company, is strictly
confidential. It must not be
communicated, copied or reproduced without our written
consent.
Ce document, proprit exclusive de notre Socit, est strictement
confidentiel. Il ne peut
tre communiqu, copi ou reproduit sans notre autorisation
crite.
Este documento, proprietad exclusiva de nuestra Compania, es
estricamente confidential. No puede
ser communicado, copiado o reproducido sin su autorizacion
escrita.
4.3.1 Mono-liquid fuel system:
4.3.2 Bi-liquid fuel system:
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Commissioning Guideline GPO / GFO / M&I 403A5502 Revision: A
Unit: B & E GT Page : 25 / 32
Flushing Guideline Liquid Fuel Flushing
Observations :
This document, sole property of our company, is strictly
confidential. It must not be
communicated, copied or reproduced without our written
consent.
Ce document, proprit exclusive de notre Socit, est strictement
confidentiel. Il ne peut
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crite.
Este documento, proprietad exclusiva de nuestra Compania, es
estricamente confidential. No puede
ser communicado, copiado o reproducido sin su autorizacion
escrita.
4.3.3 Mechanical preparation for Off-base flushing:
4.3.3.1 Mono-liquid fuel system: Mechanical preparation consists
mainly in following items:
Check that baskets are present in forwarding pumps strainers Add
a by-pass on fuel heaters Add a by-pass on filtering skid Add a
filter system on the return line to prevent pollution of the tank,
this system must be isolable to
clean the filter without emptying the lines Ensure that any
leakage on flanges will be recovered (basin + mechanical
helpers)
By-pass for LDO heating skid By-pass for LDO Filtering skid
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Commissioning Guideline GPO / GFO / M&I 403A5502 Revision: A
Unit: B & E GT Page : 26 / 32
Flushing Guideline Liquid Fuel Flushing
Observations :
This document, sole property of our company, is strictly
confidential. It must not be
communicated, copied or reproduced without our written
consent.
Ce document, proprit exclusive de notre Socit, est strictement
confidentiel. Il ne peut
tre communiqu, copi ou reproduit sans notre autorisation
crite.
Este documento, proprietad exclusiva de nuestra Compania, es
estricamente confidential. No puede
ser communicado, copiado o reproducido sin su autorizacion
escrita.
4.3.3.2 Bi-liquid fuel system: Mechanical preparation consists
mainly in following items:
Add a by-pass on fuel heaters Add a by-pass on filtering skid
Add a filter system on the return line to prevent pollution of the
tank, this system must be isolable to
clean the filter without emptying the lines and return to HFO
tank Ensure that any leakage on flanges will be recovered (basin +
mechanical helpers)
Please note that in both cases, the stainless steel pipe between
the filtration skid and the unit must be air-blown and carefully
inspected prior to final assembly.
4.3.4 Off-base flushing: Ensure proper commissioning of at least
one forwarding pump (see TEP01 & TEP02) Start one pump and
circulate fuel till filters are clogged Clean the filters and star
again circulation till filters GEK-110483 criteria are met
To be more efficient it is possible to use the 2 LDO forwarding
pumps in parallel, current must be carefully monitored to avoid
electric motor overheat and damage.
Off-base flushing completed on the:
4.3.5 On-base flushing: For On-base flushing, please refer to
document 586A1072: Liquid Fuel Flushing Procedure. This document is
not dedicated to B and E-Class units but can provides guideline if
you have any doubt on the On-Base cleanliness.
On-base flushing completed on the:
4.4 Flushing completion: When both Off-base and On-base flushing
are completed, commissioning can be initiated.
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Commissioning Guideline GPO / GFO / M&I 403A5502 Revision: A
Unit: B & E GT Page : 27 / 32
Flushing Guideline Water-Cooling Flushing
Observations :
This document, sole property of our company, is strictly
confidential. It must not be
communicated, copied or reproduced without our written
consent.
Ce document, proprit exclusive de notre Socit, est strictement
confidentiel. Il ne peut
tre communiqu, copi ou reproduit sans notre autorisation
crite.
Este documento, proprietad exclusiva de nuestra Compania, es
estricamente confidential. No puede
ser communicado, copiado o reproducido sin su autorizacion
escrita.
5 WATER-COOLING FLUSHING:
5.1 Safety complement: Cooling water generates mainly 2
risks:
Burn: all precautions must be taken to avoid contact with hot
pipes and hot water at release points. If permanent barriers or
insulation are not in place, use temporary signalization to prevent
access to hazardous zone (for example vent of the heat-exchanger on
atomizing air cooler) Chemical: please refer to Material Safety
Datasheet and take required precautions
5.2 Acceptance Criteria: GEK-110483 reminds what the acceptance
criteria are for the cleanliness of the fuel oil system. It also
provides guidelines to evaluate this cleanliness.
5.3 Flushing Process: Please note that for some 6B units with
only shaft-driven water cooling pump, you will need to use an
external skid for the flushing of the circuit. Truck equipped with
autonomous pumps and separated tanks is a good option to save time
and money when this case arises.
If your cooling water installation has its own circulating
pumps, you may proceed as follows.
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Commissioning Guideline GPO / GFO / M&I 403A5502 Revision: A
Unit: B & E GT Page : 28 / 32
Flushing Guideline Water-Cooling Flushing
Observations :
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confidential. It must not be
communicated, copied or reproduced without our written
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crite.
Este documento, proprietad exclusiva de nuestra Compania, es
estricamente confidential. No puede
ser communicado, copiado o reproducido sin su autorizacion
escrita.
5.3.1 Mechanical preparation for phase 1 flushing:
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Commissioning Guideline GPO / GFO / M&I 403A5502 Revision: A
Unit: B & E GT Page : 29 / 32
Flushing Guideline Water-Cooling Flushing
Observations :
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confidential. It must not be
communicated, copied or reproduced without our written
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Ce document, proprit exclusive de notre Socit, est strictement
confidentiel. Il ne peut
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crite.
Este documento, proprietad exclusiva de nuestra Compania, es
estricamente confidential. No puede
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escrita.
-
Commissioning Guideline GPO / GFO / M&I 403A5502 Revision: A
Unit: B & E GT Page : 30 / 32
Flushing Guideline Water-Cooling Flushing
Observations :
This document, sole property of our company, is strictly
confidential. It must not be
communicated, copied or reproduced without our written
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crite.
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estricamente confidential. No puede
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escrita.
Mechanical preparation consists mainly in following items: Check
that witch hats are installed upstream circulating pumps
Install by-pass on generator coolers (install vent points if
needed) Install by-pass on turbine coolers (Remove VTR1-1 and
VTR2-1) Install by-pass on finfan radiators Close valves to flame
detectors Close valves to HP fuel pump (HFO option) Close line to
fuel check valve coolers (Liquid option) and close valve on the
return line
Generator By-pass FinFan Cooler By-pass
5.3.2 Phase 1 flushing (Turbine On-base then generator piping):
Ensure proper commissioning of at least one circulating pump (see
TEP01 & TEP02) Close valves to generator coolers to maximize
flow in turbine Start one pump and circulate water till filters are
clogged, monitor pressure and noise to keep safe
situation (site experience proved that first runs can stay less
than 15 seconds!) Clean the filters and start again circulation
till filters can run 2 hours without dirt inside Open valves to
generator and close valves to turbine to maximize flow in generator
piping Start one pump and circulate water till filters are clogged,
monitor pressure and noise to keep safe
situation (site experience proved that first runs can stay less
than 15 seconds!) Clean the filters and start again circulation
till filters can run 2 hours without dirt inside
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Commissioning Guideline GPO / GFO / M&I 403A5502 Revision: A
Unit: B & E GT Page : 31 / 32
Flushing Guideline Water-Cooling Flushing
Observations :
This document, sole property of our company, is strictly
confidential. It must not be
communicated, copied or reproduced without our written
consent.
Ce document, proprit exclusive de notre Socit, est strictement
confidentiel. Il ne peut
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crite.
Este documento, proprietad exclusiva de nuestra Compania, es
estricamente confidential. No puede
ser communicado, copiado o reproducido sin su autorizacion
escrita.
5.3.3 Mechanical preparation for phase 2 flushing (Finfan
radiators): Apply needed LOTO procedure to change configuration
Remove Finfan radiators by-pass
5.3.4 Phase 2 flushing (Finfan radiators): Start one pump and
circulate water till filters are clogged, monitor pressure and
noise to keep safe
situation (site experience proved that first runs can stay less
than 15 seconds!) Clean the filters and start again circulation
till filters can run 2 hours without dirt inside
5.3.5 Mechanical preparation for normalization: Apply needed
LOTO procedure to change configuration Remove all by-pass Install
VTR1-1 and VTR2-1
Open valves to HP fuel pump Remove plug to fuel check valve
coolers (optional) and open the return line Fill the circuit with
clean tap water
5.3.6 Phase 3 flushing: Open all valves to get final
configuration (force open the solenoid valve to optional fuel check
valve
coolers) Start one pump and circulate water till filters are
clogged, monitor pressure and noise to keep safe
situation (site experience proved that first runs can stay less
than 15 seconds!) Clean the filters and start again circulation
till filters can run 2 hours without dirt inside
5.4 Flushing completion: When circulation can be let for several
hours a day without filters clogged, the flushing is considered OK.
Normalize the circuit and circulate in normal configuration.
Change water for demineralized one and add needed chemicals
according procedure #249A4685
Cooling water flushing completion date:
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Commissioning Guideline GPO / GFO / M&I 403A5502 Revision: A
Unit: B & E GT Page : 32 / 32
Flushing Guideline Reference Documents
Observations :
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confidential. It must not be
communicated, copied or reproduced without our written
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estricamente confidential. No puede
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escrita.
6 REFERENCE DOCUMENTS: Please find here below the list of the
documents used to establish this guideline. Please check that there
are still up-to-date prior to use information published in this
guideline.
EPRI Guideline 1023628 (Update Dec. 2011): Guidelines for Fuel
Gas Line Cleaning Using Compressed Air or Nitrogen. EPRI, Palo
Alto, CA: 2011
GE Energy drawing # 145E6599 (Rev.A): Piping Lube-Oil Flush
Field (6B)
GE Energy drawing #249A4685 (Rev.A): Commissioning Manual
Cooling Water Chemicals GE Water
GE Energy drawing #586A1072 (Rev.B): Liquid Fuel Flushing
Procedure
GE Energy drawing #91-438752 (Rev.C): Monitoring of Lubricating
Oil
GE Energy GEK-110483 (Rev.D): Cleanliness Requirements for Power
Plant Installation, Commissioning, and Maintenance
GE Energy GEK-116771 (Dec. 2012): GE Energy recommendations,
Fuel Supply System Cleaning for Gas Turbines
GE Energy GEK-116944 (Nov.2011): Flushing Recommendations for
Turbine Lube Oil Systems with Motor Driven Main Oil Pumps
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