Flushing Procedure 9E Units

11-Feb-2013-16:53

al ci

11/02/2013

CAINERO CHRISTOPHE

RIVIERE BERTRAND

CAINERO CHRISTOPHE

RIVIERE BERTRAND

ffi

None

07/12/2012

VALIDE

O

A4

G

E

FLUSHING GUIDELINE B&E CLASS GAS TURBINE

FLUSHING GUIDELINE B&E CLASS GAS TURBINE

super user

A

403A5502 DT-7C

GRD E

Commissioning Guideline

Flushing Guideline B & E-Class Gas Turbine

GPO / GFO / M&I 403A5502 Revision: A Unit: B & E – GT Page : 1 / 32

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.

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, propriété exclusive de notre Société, est strictement confidentiel. Il ne peut être communiqué, copié ou reproduit sans notre autorisation écrite.

DT-7C

Este documento, proprietad exclusiva de nuestra Compania, es estricamente confidential. No puede ser communicado, copiado o reproducido sin su autorizacion escrita.


Flushing Guideline B & E-Class Gas Turbine 1.4 1

2

3

4

5

6


Summary: General Information: .................................................................................................................................... 1

1.1

Purpose of the document:.................................................................................................................... 1

1.2

Safety policy:........................................................................................................................................ 1

1.3

Flushing acceptance criteria: ............................................................................................................... 1

1.4

Summary:............................................................................................................................................. 2

1.5

Revision status: ................................................................................................................................... 3

Lube Oil Flushing: ........................................................................................................................................ 4 2.1

Safety complement: ............................................................................................................................. 4

2.2

Acceptance Criteria: ............................................................................................................................ 4

2.3

Flushing process for B-class unit: ........................................................................................................ 5

2.4

Flushing process for E-class unit: ...................................................................................................... 12

2.5

Lube oil flushing record sheet: ........................................................................................................... 21

Gas Fuel Flushing:..................................................................................................................................... 22 3.1

Safety complement: ........................................................................................................................... 22

3.2

Acceptance Criteria: .......................................................................................................................... 22

3.3

Gas fuel flushing: ............................................................................................................................... 22

Liquid Fuel Flushing:.................................................................................................................................. 23 4.1


4.2


4.3

Flushing process: ............................................................................................................................... 23

4.4

Flushing completion: .......................................................................................................................... 26

Water-Cooling Flushing: ............................................................................................................................ 27 5.1


5.2


5.3

Flushing Process: .............................................................................................................................. 27

5.4

Flushing completion: .......................................................................................................................... 31

Reference Documents: .............................................................................................................................. 32

Observations :






Flushing Guideline B & E-Class Gas Turbine 1.5

Revision status:

REV. A

DATE

DOCUMENT

(dd/mm/yyyy)

02/04/2012

Flushing guideline

OBJET First issue – BR

Observations :





Flushing Guideline Lube Oil Flushing


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.

Observations :






Flushing Guideline Lube Oil Flushing 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 40°C. 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 54°C.  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.

Observations :






Flushing Guideline Lube Oil Flushing 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.

Observations :






Flushing Guideline Lube Oil Flushing 

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)

Observations :









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

Observations :






Flushing Guideline Lube Oil Flushing 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




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

Observations :







Observations :






Flushing Guideline Lube Oil Flushing 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: …………………………

Observations :







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 40°C. 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 54°C.  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.

Observations :





Flushing Guideline Lube Oil Flushing 2.4.1



General view of 9E turbine oil system

Observations :






Flushing Guideline Lube Oil Flushing 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

Observations :







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

Observations :







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)

Observations :







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)

Observations :






Flushing Guideline Lube Oil Flushing 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




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

Observations :







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

Observations :






Flushing Guideline Lube Oil Flushing 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




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: …………………………

Observations :







Lube oil flushing record sheet:

LUBE OIL FLUSHING PHASE #________

DATE

TIME

88 QA / AC CURRENT

LUBE OIL TEMPERATURE

88QA OUTLET PRESSURE

OIL FILTER PRESSURE DROP

Observations :





Flushing Guideline Gas Fuel Flushing


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


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.

Observations :





Flushing Guideline Liquid Fuel Flushing


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


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.

Observations :





Flushing Guideline Liquid Fuel Flushing 4.3.1

Mono-liquid fuel system:

4.3.2

Bi-liquid fuel system:


Observations :






Flushing Guideline Liquid Fuel Flushing 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

Observations :






Flushing Guideline Liquid Fuel Flushing 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 airblown 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


When both Off-base and On-base flushing are completed, commissioning can be initiated.

Observations :





Flushing Guideline Water-Cooling Flushing


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


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.

Observations :





Flushing Guideline Water-Cooling Flushing 5.3.1


Mechanical preparation for phase 1 flushing:

Observations :





Flushing Guideline Water-Cooling Flushing


Observations :






Flushing Guideline Water-Cooling Flushing 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

5.3.2

FinFan Cooler By-pass

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







Observations :






Flushing Guideline Water-Cooling Flushing 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!)



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)






5.4



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: ………………………… Observations :






Flushing Guideline Reference Documents

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): GE Water

Commissioning Manual Cooling Water Chemicals –

 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 Installation, Commissioning, and Maintenance

Requirements

for

Power

Plant

 GE Energy GEK-116771 (Dec. 2012): Cleaning for Gas Turbines

GE Energy recommendations, Fuel Supply System

 GE Energy GEK-116944 (Nov.2011): Systems with Motor Driven Main Oil Pumps

Flushing Recommendations for Turbine Lube Oil

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Observations :




Flushing Procedure 9E Units

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