INSTRUCTION - FLUSHING, GAS TURBINELUBRICANT OIL SYSTEM

1. Instruction/Concept of Flush

The gas turbine lubricant oil system may require flushing for one or more of the following reasons:

Remove contamination from a new unit which may have occurred in shipping, storage or installation.

Remove contamination from a previously operated unit where contamination has occurred due to repair, modification, other field work or component failure.

Remove remains of the previous charge of oil when an oil change is necessary due to the previous charge of oil exceeding condemnation limits.

It is presumed that the on base piping is flushed and clean from the factory. The emphasis of the flush, then, is interconnecting piping which will be unavoidably contaminated during site installation.

This document is for the Model 6001 gas turbine; for other frame sizes refer to the ML A125 drawing for the particular unit.

2. Applicable Documents

Details are shown on the following drawing: ML A125 Piping - Lube Oil, Flush Fld. 104E8730

The drawings appropriate for the unit being flushed for the following Mode1 List (ML) items shall be used as a general guide.

ML 0416 Diagram, Schematic PP - Lubricant OilML 0418 Diagram, Schematic PP - Trip OilML 0422 Diagram, Schematic PP - Fuel Gas ML 0424 Diagram, Schematic PP - Liquid FuelML 0434 Diagram, Schematic PP – Hydraulic SupplyML 0469 Diagram, Schematic PP – IGVML 0421 Diagram, Schematic PP - Starting MeansML 0440 Diagram, Schematic PP - Load Equipment ML 0969 Piping Arrg't - Lube Oil InterconnectingML 0905 Piping Arrg't - Lube Oil Feed & Drain ML 0904 Piping Arrg't - Lube ExternalML 0906 Piping Arrg't- Feed & Drain LoadA053 Piping Arrg't - InterconnectingML 0997 Piping Arrg't- Starting Means ModuleML 0985 Hydraulic Module

ASME Standard #LOCS-4C-1 Recommended Practices for Flushing and Cleaning of Gas Turbine Generator Lubricating Oil Systems. GEK-28143 - Lubricating Oil recommendations for Gas Turbine

3. Procedure - Set Up

Refer to the ML 0416 drawing

3.1 De-energize tank heaters whenever reservoir is empty. 3.2 Drain any existing oil and clean reservoir & junction boxes. 3.3 Verify that the main lubricant oil filters, hydraulic oil filters and "last chance" inline

hydraulic filters are installed. 3.4 If the unit has been stored for more than one year replace the lube oil filters and hydraulic

oil filters. 3.5 Verify lube oil & hydraulic filter transfer valves operate freely. 3.6 Approximately 2500 gallons of lube oil will be necessary (to cover the auxiliary lube

pump suction strainer) for the flush. The all should comply with GEK-28143. Note that the factory flush oil (and test oil) was Shell VSI 32. A sample of this oil is contained in. a bottle secured to the lube oil gauge panel. This is provided so that compatibility checks can be made (by the oil supplier) with the operating oil. Read this complete instruction before filling system.

3.7 Heating of the flush oil to 160 ± 5°F fs recommended. Use of pipe vibrators will shorten the flush cycle. Do not use the pipe vibrator on or near piping containing instrumentation. The full sized auxiliary lube pump must run whenever the heater is on.

4. Flush Procedure

For displacement flush the auxiliary centrifugal lube pump will be used. In order to obtain increased lube oil velocity (2 times normal is preferred) it will be necessary to flush portions of system separately. Remove the sensing line on the VPR2-1 regulating valve so that it will always be wide open.

4.1 Collection of Flushed Debris All oil discharged during each phase of the flush should be captured in the supplied strainers (with 100 mesh liner) or within the external junction boxes which form a natural barrier. During the initial flow of oil through a circuit, the screens or strainers should be monitored since they may be quickly filled with debris.

4.2 Phase I, Phase II, Phase Ill Summary To obtain the higher flush velocities mentioned above it is recommended that the 6001 model be flushed in phases as follows:

Phase I Phase IIPiping - Turbine #1 Bearing (See ML 0969) Flush Blank Piping - Turbine #2 Bearing (See ML 0905) Flush Blank Piping - Hydraulic System Phase I No Flow No Flow

Phase IA Flush No Flow Piping - Trip System Flush Flowing Piping - Generator Lube Oil (See ML 0906) Blank Flush

PUMP MOTOR AMPS MUST BE MONITORED AT EVERY CHANGE IN THE FLUSHING CIRCUIT TO BE SURE THAT FULL LOAD AMPS ARE NOT EXCEEDED

4.3 Phase I Flush - See 104E8730, Sheet 1 for parts required.

In this phase the #1 turbine bearing supply, accessory gear supply and trip system will be flushed.

4.3.1 Setup at #1 Bearing Install bypass hardware (jumper, valve, strainer) shown at D-1. Open the valve.

4.3.2 Setup at Accessory Gear Feed Install hose assembly jumper with valve {part 11) and strainer {part 20} routed to the #1 bearing drain per B-7.

4.3.3 Setup jumper manifold at aft end of accessory base as shown at views D-8 and E-8. This is necessary to bypass the orifices and check valve in the hydraulic module and promote a good flow to flush the external portion of the trip piping between the accessory and turbine base.

4.3.4 Setup at #2 Junction BoxTrip Oil Lines - The trip oil to the gas valve (if used) shall be jumpered (via Part 18, C-6} from the box external connection back into the junction box. For IGV trip oil remove the hose assembly and cover the continuation piping. Secure a piece of 100 mesh screen around end of each of these discharges to collect foreign material. Examine the hoses and blow out any material. This system will be flushing in Phase I.

Hydraulic Lines - The hydraulic oil to the gas valve {if used) shall be jumpered the same way {same part) as the trip oil above. For IGV hydraulic oi1, remove the hose and blank the continuation piping. Apply screens S/A description under trip oil above - see Phase lA Flush, per Paragraph 4.3.8, for description of flushing hydraulics.

4.3.5 Setup #2 Bearing Install jumper with valve and screen as shown at Detail C-5. Open the valve for Phase I flush.

4.3.6 Setup in Load Package (Load Gear/Generator)At Detail D-3 set up as follows:

A. Remove feed hose assemblies and replace with spools parts 27 and 28. Examine hoses and blow out with compressed air.

B. Loosen and rotate load gear feed pipe and install jumper part 29 and valve assembly spool made from parts 31, 11, and 32. Close the valve.

C. Loosen and rotate generator forward feed line and install jumper part 34 and valve assembly spool made from parts 31, 11, and 35. Note that the load gear feed jumper is connected to fab part 35 in its discharge side. Close the valve,

D. Loosen and rotate generator aft feed line and install jumper part 30 and valve assembly spool made from parts 31, 11, and 32. Close the valve.

E. Install strainer (part 33) in combined drain at hose inlet.

FOR PHASE I FLUSH ALL JUMPER VALVES (3) ON THE LOAD PACKAGE TO BE CLOSED. ALTERNATIVELY, INSTALL BLANK IN FEED LINE WHERE OIL ENTERSLOAD PACKAGE.

4.3.7 Phase I Flush Procedure

Start the full sized aux lube pump and check actual amps against Full Load nameplate amps. If amps are too high, throttle one of the flush valves and try again. After l2 hours remove the screens at the #1 and #2 Bearing and accessory gear feed. Clean these screens carefully and reinstall. Run for one hour and recheck screens. The fine internal strainer screen is 100 Mesh. When this screen is clean the flush of the section is complete. This procedure is good for all phases of the flush. 100 mesh screen mater1al is supplied for any supplemental testing. The criteria has been shown to be comparable to Gas Turbine in house contamination level acceptance as verified by Millipore "patch test" particle count.

4.3.8 Phase IA Flush (Hydraulic)Flush the hydraulic system as follows. Restore the accessory gear feed piping {after Phase I cleanliness check} per view B-8. This is the oil source of the hydraulic pump. Refer to Paragraph 4.3.4 for setup. Prior to operating the auxil1ary hydraulic pump the auxiliary lube pump must be running and the accessory gear lube feed pipe (per B-8} must be installed. Start the auxiliary hydraulic pump and flush this section. Check for cleanliness (see detail C-6) via screen check described in paragraph 4.3.7. The motor driven hydraulic pump can be run safely into an open line since it has a built in volume limit.

4.3.8.1 Hydraulic System/Servo Flushing Blocks Flushing blocks and associated hardware are provided on the bill of material. This procedure is limited to flushing the interconnecting piping. We are not describing a flush through the fuel oil, fuel gas, or \GV servo valves. These valves are protected by a "last chance" spin on filter cartridges {replaceable). Since we presume that the on base piping and gas valve piping is clean and that the interconnecting piping has been successfully flushed - it should not be necessary to employ the flushing blocks during the normal unit installation flush.

4.4 Phase II Flush (Load Package)

In this phase the load gear and the generator piping will be flushed.

4.4.1 Setup in Accessory Area Close valves to #1 Bearing (at A-57). Turn accessory gear feed piping out (see B-7), install valve Part II and close it. DO NOT RUN AUXILIARY HYDRAULIC PUMP WITH PIPING IN THIS CONFIGURATION.

4.4.2 Setup ln junction Box #2 - Same as Phase I. 4.4.3 Setup at #2 Bearing Feed - Close valve. 4.4.4. Flushing Load Package· See 104E8730 (D-3)

Set up load package as described in paragraph 4.3.6. Open all three flush valves. 4.4.5 Flush as Described in Paragraph 4.3.7.

5. Procedure - Before Start Up - Restore the unit to operating condition as follows:

5.1 Remove all flushing hardware - flush hose assemblies, porting blocks, jumpers, blanks,

screens. 5.2 Reinstall permanent piping, spools, etc. 5.3 Restore VPR2-1 and its sensing line if removed or modified for flush. 5.4 Inspect drain line junction boxes, oil channels, and reservoir for debris and clean if

necessary, replace all covers. 5.5 Restore all piping and hoses to operating condition. Be sure hoses are installed with

proper offset.5.6 Install new lube oil filter cartridges.5.7 Fill oil to operating level.5.8 Re-energize tank heaters.