Part 3

O.S.
: 936
Turbine: SST 300N MANUAL OF TURBO-GENERATOR Revision: 0
Customer: PROPAL PART 3 Page: 1/1
Serial nº Designation Document no. Volume

or Cross Reference
PART 3 - INSTALLATION MANUAL
3.1 Instructions for transport and storage Transport_instruction
3.2 Preparation for the assembly work Assembly_work
3.3 Mounting instructions for turbine and accessories Mounting_instructions
Flushing of the oil system

Flushing_oil
1CHE3272-002
Blow-out of the steam piping
Blow-out
1CHE3281-002
3.1 - Instructions for transport and storage
Instructions for transport and storage

INSTALLATION MANUAL
Instructions for
IM-01
Transportation and storage
Preface
The present mounting instructions describe the installation of the

turbosets made by SIEMENS.
Target Group The mounting instructions are addressed to all persons involved
in the installation of the turboset.
Advisory notes The advisory notes are divided into three levels and identified
accordingly by different pictographs.
Danger
Advisory notes of the level "danger" signalize that nonobservance
may cause injury to persons.
Warning
Advisory notes of the level "warning" signalize that
nonobservance may cause material damage.
Note
Advisory notes of the level "Note" give hints on a particularly
economical operation of the machine.
Orientation guides To find your way through the mounting instructions more easily,
please use:
the table of contents

the catchwords in the margin on pages of the individual
chapters
the list of tables on the last pages of the mounting instructions
Transport_instruction 5/21/08 pagina 1/2

INSTALLATION MANUAL
1 Open case inspection
All components were treated with preservation. The components

shall be suitably stored after unpacking and checking.
In the event that the completely assembled turbine is

disassembled or opened during "open case inspection" and
provided that no SIEMENS representative is present at that time,
SIEMENS will not assume any responsibility for faulty handling or
any damage possibly occurring.
Intervals Preservation Maintenance Storage Intervals

(weeks) Inspection (weeks)
A Maintenance during storage B Maintenance after erection
1 Storage under shelter __ 1 Erection site under shelter __ __
2 Visual inspection of external 26 2 Visual inspection of external __ 12

surfaces regarding protective surfaces surfaces regarding
coats, corrosion, check of plastic protective coats and corrosions.
caps at pipe ends, pipe nozzles Repair of damaged surfaces.
etc. Repair of damaged surfaces,
re placement of plastic caps
3 Opening of the casing, internal ins 52 3 Preservations latest 26

of the casing, bearings, rotor and
Removal of possible moisture
condensate. Application
of a sealing coat of preservation
4 Application of a primer coat of 52 4 Repair of final coat of paint latest 52

paint on all external surfaces
5 5 Inspection and check of all latest 52

mechanical parts (valves, bearings
Table 1-1: Inspection intervals
Transport_instruction 5/21/08 pagina 2/2

3.2 - Preparation for the assembly work
Preparation for the assembly work

INSTALLATION MANUAL
IM-02 Preparation of
mounting work
Preface
The present mounting instructions describe the installation of the

turbosets made by SIEMENS.
Target Group The mounting instructions are addressed to all persons involved
in the installation of the turboset.
Advisory notes The advisory notes are divided into three levels and identified
accordingly by different pictographs.
Danger
Advisory notes of the level "danger" signalize that nonobservance
may cause injury to persons.
Warning
Advisory notes of the level "warning" signalize that
nonobservance may cause material damage.
Note
Advisory notes of the level "Note" give hints on a particularly
economical operation of the machine.
To find your way through the mounting instructions more easily,

Orientation guides please use:
the table of contents

the catchwords in the margin on pages of the individual
chapters
the list of tables on the last pages of the mounting instructions
Assembly_work 05/21/08 page 1/9

INSTALLATION MANUAL
1 General instructions on
erection time and personnel,
erection equipment,
preparation of work
Field erection time and personnel
Scope and duration of field erection and plant commissioning and

the necessary erection and commissioning personnel are given in
the erection and commissioning time schedule. Site conditions
permitting, the planned erection work shall be adapted to this
schedule. The daily or weekly working time is stipulated either in
the contract or governed by the statutory regulation of working
hours.
If the customer or the site management or other contractors

provide the necessary skilled and unskilled personnel, or if the
SIEMENS resident engineer has to recruit local personnel, the
following quality standards should be observed.
Fitters Trained fitters (prime movers and driven machines) who have
completed their apprenticeship and have professional experience
of about 5 years, especially in assembly and field erection work
and who are qualified accordingly.
Assistant fitters Semi-skilled machine fitters, experienced in assembly and field

erection work.
Pipe fitters Trained pipe fitters who have completed their apprenticeship and
have about 5 years, experience, especially in pipe-laying,
gauging, fitting, weld preparation, tack-welding, including
strapped joints according to pipe drawings and diagrams.
Welders Qualified welders as per ASME Section IX requirement with valid

qualification certificates and about 5 years, professional
experience in welding.
Electricians Trained electricians who have finished their apprenticeship and

who have about 5 years, experience in laying and connecting
electric cables according to drawings and diagrams.
Crane operators Who have passed an aptitude test entitling them to operate lifting
tackles required for transporting heavy-load equipment.
Transport workers Including qualified cranemen to sling all types of heavy loads.

INSTALLATION MANUAL
Erection devices
The necessary devices required for field erection, such as tools,

apparatus, instruments, measuring equipment etc. depend on the
scope and state of supply. If this equipment is supplied by other
contractors or by the customer, it will be listed in the contract
specification or in the erection devices lists attached.
Properly tested, usable and accident-proof devices shall be used

only. Any faulty or unsafe device shall be either replaced or
expertly repaired immediately.
Preparation of erection site
1 Before the arrival of the first consignment, the site and erecting
bays shall be well prepared, so that erection work may be begun
with in accordance with the safety regulations presently in force.
The site facilities, such as accommodation, wash-rooms and
lavatories shall meet the requirements and be fully usable.
2. Storage places for the temporary storage of equipment either

outdoors, sheltered or in closed dry places shall meet the
requirements both in size and nature and be made available in
such a way that re-storing due to overlapping of civil works with
the erection time schedule is avoided, such as excavating work
and concrete work, steel-work erection, pipework and cabling, for
instance. The storage areas shall be paved and drained.
3. Access roads shall be passable and firm and withstand the

maximum load expected, even in nasty weather. The same
applies to spaces occupied by lifting tackles. Free access to the
machine-house crane even by low-loader - shall be provided.
Access roads shall be suitable for heavy loads.
4. The site area and erecting bays shall be accessible without

posing the slightest thread to life and limb. The site owner shall
guarantee openness and freedom of movement on site; possible
escape routes shall be safeguarded and be easily accessible; the
foundation work shall be completed; the foundations themselves
shall be totally stripped,
gauged and be free of rubble, building material, equipment or any
other commodities stored on them and be in a well-swept
condition.
5. On their arrival on site, all consignments shall be compared with

the shipping documents for identity and completeness and
checked for external transit damage. If damage in transit has
occurred, the consignment shall be checked for internal damage
by opening the packing; all the defective and non-defective
packing material shall be made storable thereafter. Any claims
for damages shall be reported to the transportation vehicle driver
immediately.

INSTALLATION MANUAL
6. Equipment handling on site shall be carried out only by means of

suitable lifting tackles, transport vehicles and slinging means.
Officially licensed (Control Board-tested) roadworthy transport
vehicles shall be employed only. Overloading is prohibited. The
equipment transported shall be safeguarded against slipping and
falling off the vehicle by the provision of the corresponding
fastening material. Both lifting tackles and slinging means shall
be employed only in accordance with the official regulations.
Machine components and cases shall be fastened only at the
spots especially marked for this purpose. No loads shall be lifted
higher than necessary nor kept hanging unnecessarily.
7. The consignment shipped to site shall, according to their contents

and packing, either be stored outdoors, under shelter or in closed
dry rooms. When the consignments are piled up, both the load
exercised on the ground and weights shall be checked. Free
access to the stored equipment shall be provided by envisaging
access lanes of the necessary transportation width.
8. The equipment shipped to site shall be stored and preserved in

such a way that neither damage nor contamination due to soil,
water, sludge, dust, aggressive air etc. or a possible theft may
occur.
9. When unpacking the equipment, the remaining empty cases and

packing material shall be checked carefully for minor equipment,
before throwing them away. When a case is unpacked in part
only, the packing shall be restored again.
2. Check-up of scope of delivery,

the state of goods
Check off all individual components in the packing list.
In the event of taking out erection equipment from its relevant

packing, crates or cases, see to it that all accessories are
removed from the latter before dumping the packing material.
If there is anything missing or damaged, please do not hesitate to

report this to SIEMENS Turbines to the SIEMENS-Office in your
area.
3. Check-up of foundation
The structural dimensions of the foundation, the position of the
foundation as against other plant components, the position of the
cut-outs for piping, the height of the foundation base referred to
the "zero line" shall be checked by the civil work contractor for
conformity with the foundation drawing. The results shall be
written down in a report which is to be sent to SIEMENS for
examination.
The grouting height under the baseplate shall be checked for

conformity with the foundation drawing. The anchor-bolt holes
must be free from any covering material.

INSTALLATION MANUAL
4. Standard tools for erection
Quantity Tool trolley (recommendation)

11 Ring spanners 8/9 10/11 12/13 14/17 19/22 22/24 24/27 27/30
30/32 32/36 36/41
13 Fork spanners 6/7 8/9 10/11 12/13 14/17 19/22 22/24 24/27
27/30 30/32 32/36 36/41 46/50
1 Socket spanner 19/24
12 Allen wrench 2 3 4 5 6 8 10
12 14 17 19 22
5 Hammers 200g 400g 1000g alum. rubber
5 Drive-pin punches 3 4 5 8 10
1 Center punch
8 Hollow punches 6 8 10 13 17 21 26 28
1 Pipe cutter 2”
3 Pliers, combination, flat-nose,
labyrinth
1 Seeger ring pliers Al A2 A3 A4
2 Pipe wrenches 1"... 2”
1 Electronic torch
1 First-aid kit
1 Safety belt
6 Screw drivers 3.5 4.5 5.5 7 10 12
3 Offset screw drivers 8 10 12
1 Bow saw and 1 0 saw blades
1 Hand saw
16 Files, various types
16 Handles
10 Needle files, various types
1 Tapping file
3 Scrapers: 1 flat scraper, 1
triangular scraper, 1 spoon scraper
4 Dial gauges, large
2 Dial gauges, small
1 Set of extensions for dial gauge
1 Dial indicator
2 Magnetic bases, make Bosch
3 Levels: Wave type - Frame type -
Wood type
3 Squares: thin steel - try - center
square
1 Tinners' snip
3 Brushes: file brush - thread brush -
steel brush

INSTALLATION MANUAL
50 Cleaning rags
2 Force feed oilers
3 Drill chucks 1-2 2-3 3-4
1 Drill chucks
4 Leveling spindles
62 Drills,
2 of each size: 3.0 3.1 3.5 4.0 4.2 4.5 4.8 5.0
5.2 5.5 6.0 6.2 6.5
1 of each size: 7.0 7.5 8.0 8.2 8.5 8.8 9.0 9.5
9.8 10.0 10.5 11.0 11.5 12.0 13.0 14.0
15.0 16.0 17.0 17.5 18.0 18.8 19.0 19.8
20.0 21.0 22.0 23.0 24.0 25.0 26.0 27.0
28.0 29.0 30.0 32.0
2 sets Tap drills M4 M5 M6 M8 M10
1 set Tap drills R1/8" R1/4" R3/8" R1/2" R3/4" R1”
8 Re-threading dies M8 M10 M12 M16 M20 M24 M27 M30
6 Cylindrical reamers 10 12 16 20 25 30
4 Cylindrical machine reamers 10 12 16 20
5 Conical reamers 10 13 16 20 25
3 Adjustable tap wrenches Nos. 1, 2, 3
3 Extensions for tap drills 4.9 5.5 7.0
10 Grinding points, various types
3 Dish grinding wheels
1 Plug, type Schuko
1 Pair of safety goggles for grinding
2 Brushes 1” ... 2”
1 Pair of vise jaws
1 Vise
1 Measuring tape 20m
long
1 Folding rule 2m
long
1 Hand tachometer
2· Feeler gauges
1 Ermeto bending device with roller 8 10 12
Table 2-1: Tool trolley (recommendation) (cont)

INSTALLATION MANUAL
Quantity Attachment case no.1 to the tool trolley

2 Hemp ropes with loops 30 mm dia. x 5 m
11 Striking face ring spanners 36 41 46 50 55 60 65 70
75 80 85
11 Striking face fork spanners 36 41 46 50 55 60 65 70
75 80 85
Table 2-2: Attachment case no. 1 to the tool trolley
Quantity Attachment case no, 2 to the tool trolley

12 Shackles 1t 1,6t 3t
4 each Eye bolts M10 M12 M16 M20
2 Steel ropes with loops 13 mm dia. x 3 m
2 Steel ropes with loops 22 mm dia. x 4 m
2 Hemp ropes with loops 26 mm dia. x 3 m
2 Hemp ropes without loops 26 mm dia. x 3 m
1 Hemp rope without loop 20 mm dia. x 5 m
Quantity Attachment case no. 3 to the tool trolley

4 Ring spanners 46/50 55/60 65/70 75/80
4 Fork spanners 55/60 65/70 75/80 85
1 Socket box
2· Extension cables
1 Hand lamp
Quantity Attachment case no.4 to the tool trolley

1 Base for drilling machine
1 Shop grinder
1 Angle grinder
1 Hand grinder
Hand drill
Angular type drill
Hand drill
1 Hose type leve
1 Toolmakers' vise

INSTALLATION MANUAL
Quantity Ropes case no.

2 Crowbars
2 Sledge hammers
3 Spare parts
2 Steel ropes 24 x 4 m
1 Steel rope 18 x 2 m
1 Steel rope 18 x 3 m
1 Steel rope 20 x 1,5m
2 Steel ropes 16 x 4m
1 Steel rope lO x 2 m
1 Steel rope 16 x 2m
2 each Shackles 6t 10t
4 each Eyebolts M24 M27 M30 M33 M36
Table 2-6: Ropes case no.
Danger
Select the fastening means in accordance with the dimensions
and weights of the main components.
Quantity Autogenous welding equipment

1 Welding tool box, containing the following
1 Blowpipe shank
1 Cutting attachment
One-piece nozzles 3-10110-25-40/40-60/60-1 00
1 Circular template
1 Nozzle needle
1 Pair of welding goggles
8 Cutting attachments
1 Cutter guide
1 Universal spanner
1 Blowpipe lighter
2 Pressure reducer
1 Oxygen hose 20 m
1 Acetylene hose 20 m
1 Ball-peen hammer
1 Pair of fire tongs
1 Grip wrench
1 Engineer's square for squaring flanges
1 Level, wood type
1 Plumb bob
1 Ruler
1 Square punch
5 Files with handles
5 Fork spanners 14/17 19/22 24/27 30/32
5 Ring spanners 30/36
1 Pair of gloves
1 Steel brush
5 Cleaning rugs
1 Hand saw
5 Saw blades
1 Lock
Table 2-8: Autogenous welding equipment

INSTALLATION MANUAL
Quantity TIG-Compact Equipment

1 Argonarc manual welding blowpipe ABL 220 ABL 220
with hose assembly
1 Argon pressure reducer
1 Anti-slag gas pressure reducer
1 Earth lead with clamp
1 Argon hose with 2 hose connections 2 m long
1 Anti-slag gas hose 10 m long
1 Connecting cable with plugs type SE to DIN
3 Ceramic nozzles size 5
5 Tungsten electrodes 2.4 mm in dia.
1 Pair of argon welding gloves
3 Fork spanners 17/19 30/32 14/17
1 Head shield
5 Welding glass panes
1 Wire brush V2A
2 Fuses 1.0 A
2 Fuses 2.5 A
1 Hose assembly extension
Table 2-9: TIG-Compact Equipment
Miscellaneous
Ladders, var. length
Hilti hand drilling machine
Work-benches with vice
Book-shelves to store material
Bending devices with roller φ 15, φ 18, φ 22 pipe, hydr. bending device < φ 22 - 1” pipe
Wire brushes for stainless steel
Cutting discs for carbon and stainless steel
Scaffolding
Nut-runner Hytorc, Plarad
8001tr. Thinner
Cleaning rags (paper or cotton, slub free)
Site illumination, hand lamps
Buffer gas for TIG-welding
Var. buckets, tanks for cleaning jobs
Emery-cloth (band var. grains)
Permanent compressed air supply, hose and gun
Table2-10: Miscellaneous

3.3 - Mounting instructions for turbine and
accessories
Flushing of the oil system

Blow-out of the steam piping
TECHNICAL INSTRUCTION 1CHE3272-002(ing)
Subject Revision:
Flushing of the Oil System 01
Issued by Approved by Date Address Page:
Luiz E. Paschoalato 01/09/03 TBR 011-06 1/10
Index Page
1. Scope and Application 2

2. Cleaning of the pipes 2
2.1. Cleaning of the pipes 2
2.1.1. Prefabricated pipes 2
2.1.2. Pipes which are adjusted and welded on site 2
2.2. Cleaning of the oil system components 3
2.2.1. Oil tank 3
2.2.2. Oil cooler 3
2.2.3. Temperature control valve 3
2.2.4. Bearing casing 3
3. Flushing circuit 4
3.1. Flushing circuit of the oil unit 4
3.2. Flushing circuit of the control oil system 5
4. Preparation for 5
4.1. Preparation of the oil system 5
4.1.1. General 5
4.1.2. Inlet pipe of the jacking oil pump 6
4.1.3. Oil cooler 6
4.1.4. Oil flushing 6
5. Criteria for the duration of the flushing 7
5.1. General 7
5.1.1. High flow velocity 7
5.1.2. Temperature changes during the flushing 7
5.1.3. Hammering of the pipes 8
5.2. Flushing procedure 8
5.2.1. Emergency oil pump 8
5.2.2. Jacking oil pipes 8
5.2.3. Flushing of lubrication system 9
5.2.4. Flushing of the control system 9
5.3. Evaluation of system cleanness 9
6. Getting the system ready for operation 9
7. Final tests 10
Subject Revision:
1. Scope and application

These flushing specifications describe the flushing conditions and cleanliness criteria for
industrial turbines demanded by SIEMENS to ensure trouble-free operation of the
turboset.
In spite of installed oil filters, heavy foreign matter may cause bearing damage if the
system has not been flushed properly.
As a general rule it shall be observed that no turboset must ever be started before the oil
system has been flushed in accordance with the present standard.
2. Cleaning of the pipes

Successful cleaning of the oil system including bearing casing and cooler from scale, rust,
sand and other foreign matter is only ensured if the following preconditions are complied
with.
2.1. Cleaning of the pipes
2.1.1. Prefabricated pipes
All prefabricated pipes supplied shall have been cleaned already and treated with a
preservation agent according to specification.
If the pipes cannot be mounted immediately, they shall be suitably stored to avoid new
contamination (pipe ends to be covered with a plastic lid; storage not in the vicinity of sand
blasting or grinding work).
Pipes, which need not be adjusted or welded any more on site, shall be thoroughly
checked for cleanliness and be cleaned if necessary prior to their installation.
Care shall be taken that no dirt particles are retained due to the preservation agent.
Removal of the preservation and dirt shall be done with a cold cleansing agent (Solvetane,
Chlorotene) followed by blowing out with air (the regulations governing the use of
hazardous material must be observed).
2.1.2. Pipes which are adjusted and welded on site
Before starting the work to be done, the areas to be welded of the pipes prepared for
welding shall be cleaned from the preservation by means of a solvent (mind the
regulations governing the use of hazardous material). Inert-gas-shielded welding shall be
used for all welds.
Subject Revision:
2.2. Cleaning of the oil system components
2.2.1. Oil tank
Prior to the final shop assembly of the oil tank components (oil pumps, pressure control
valve, etc.) they shall be thoroughly cleaned and checked for contamination. The oil tank
shall be cleaned and checked inside as well. Before filling the oil tank with turbine oil for
the first time, the oil tank shall be subjected to an acceptance test and a corresponding
report is issued. The same procedure shall be carried out before refilling the turbine oil
after flushing.
2.2.2. Oil cooler
Acceptance checks of the oil coolers before final assembly at the subcontractor's shop.
Special attention shall be paid to the cleanliness of the tube bundle. The flanges and pipe
nozzles shall be plugged with plastic covers after the inspection to avoid contamination of
the oil coolers.
Prior to circulate oil through oil system, it shall be done a quick flushing and cleanliness
checkout between coolers and reservoir, therefore avoiding the eventual particulate
contained inside coolers will not contaminate other oil lines.
2.2.3. Temperature control valve
When included in the oil system circuit, the temperature control valve shall be thoroughly
blown out with air and be checked for contamination prior to assembly.
2.2.4. Bearing casing
Independent of the flushing procedure, the bearing casings shall be thoroughly cleaned
and subsequently checked.
Subject Revision:
3. Flushing circuit
3.1. Flushing circuit of the oil system
The flushing oil is admitted directly via the radial bearings of the turbine. For this purpose.
the upper radial bearing halves and the two axial bearing halves must be removed. If a
combined axial and radial bearing is provided, only the upper bearing half is removed for
oil flushing. Turbine bearings can also be deviated by means of bypass intalled on bearing
inlets, being at supervisor’s criteria on each installation.
At the bearings of the gear unit and driven machine. the flushing oil is bypassed by means
of bypass connections between the bearing oil inlets and outlets. The flushing oil is also
bypassed around the oil-containing equipment which are susceptible to functional
disturbances in the case of minor oil contamination.
The bypassed equipment includes the following systems:
- Hydraulic shaft turning gear device

- Manually operated pump for the hydraulic shaft turning gear device
- Jacking oil pump
- Hydraulic flow control valve and non-return flap valve
- Safety block
- Hydraulic sealing steam controller
- primary pump, if applicable
- auxiliary and emergence pumps
- control oil filters
- Secondary drives (governor, tachometer, spray nozzles for gearwheel lubrication), if
applicable
For flushing the suction and pressure pipes of a shaft-driven main oil pump, the pressure-
side non-return flap valve will be removed and replaced by a fitting. As the main oil pump
is removed, there will be sufficient space for placing a bypass between the suction pipe
and the discharge pipe.
During the flushing procedure, the flushing oil is circulated by means of the auxiliary oil
pump.
Damage of the auxiliary or emergency oil pump due to dirt particles carried into the tank by
the flushing oil need not be expected. The strainer screens will retain the dirt particles in
the tank and deposit them on the tank floor.
The suction and pressure pipes of the emergency oil pump are cleaned by means of the
emergency oil pump.
The non-return valve flaps of the auxiliary and emergency oil pumps are not dismantled for
the flushing procedure. An orifice plate at suction pipe to ensure that line is filled must be
installed.
Subject Revision:
3.2. Flushing circuit of the control oil system
The removal of the following components is part of the preparatory work for flushing the
control oil circuit:
- pilot plungers and control bushes of the control valve actuators (servo-motors)
- check valve internals and pressure reducer valve for bearing oil lines
- sensitive components of the hydraulic control system (speed governor rotor, needle
valves, Electro-hydraulic converters. non-return valves, orifices)
4. Preparations for flushing

The lube oil system shall not be flushed before it is completely assembled. Erection work
of the turboset should be completed as much as possible. Any temporary solutions shall
be avoided and all arrangements interfering with the system shall be limited to a minimum.
In order to avoid that any blind flanges and other flushing facilities remain in place by
mistake after flushing, all modifications made to the system for the purpose of flushing
shall be noted down on a special list. After completion of the flushing procedure, the
operating conditions of the system shall be restored with the help of this list.
4.1. Preparation of the oil system
4.1.1. General
The system will be flushed with the help of the auxiliary oil pump(s). If two 3-ph a.c. driven
pumps are available, they shall be operated together to increase the effectiveness - higher
flow velocity. The pump drive motors must be equipped with the normal protection
equipment. Care shall be taken not to exceed the admissible power input indicated on the
maker's name and rating plates of the motors.
Monitoring of the oil level in the tank must be ensured. (For this purpose, the suction
basket length from the oil tank cover it to be measured and the oil quantity suitably
determined to ensure an oil level of at least 300 mm above the upper edge of the shortest-
suction cage).
The oil vapour extraction fan must be in operation during flushing.
Setting of the maximum possible oil flow is accomplished by closing the pressure control
valve (tightening the setting screw). Care shall be taken that the oil pressure does not
exceed 2.5 bar. All filter inserts must be removed.
Subject Revision:
A throttling plate (orifice plate) with an open cross section of 10% to 15% of the inner pipe
cross section shall be installed in the drain oil pipe(s) at the last flange upstream of the oil
tank. The plate opening must be situated in the bottom area of the pipe. Because of this
throttling plate the entire inner cross-section of the pipe will be filled with oil during flushing.
The oil inlet and outlet pipes of the gear unit, generator and couplings shall be sealed off at
the casings by means of blind flanges and the existing orifices shall be removed. The inlet
and outlet ends shall be connected by means of the bypass sections supplied.
The suction and pressure sides of the main oil pump shall be connected by means of a
bypass. The non-return flap valve in the pressure pipe shall be removed. After the
flushing procedure, the turbine bearing casings and the oil channels shall be cleaned
manually and by blowing out with air.
4.1.2. Inlet pipe of the jacking oil pump
The inlet pipe of the jacking oil pump shall be led direct to the oil tank by means of a
bypass connected upstream of the pump.
4.1.3. Oil cooler
Both coolers are completely mounted and connected on their oil and watersides.
Admitting hot water to the cooling waterside increases the oil temperature. The maximum
water temperature shall not increase 100 oC. Heating of the water shall be done carefully
and slowly to avoid a temperature shock inside the cooler. The heating water circuit shall
incorporate one cooler only so that quick cooling down of the oil is possible through the
second cooler.
4.1.4. Flushing oil
Unless the use of special flushing oil is contractually agreed upon, or if the customer does
not provide such oil, the system will be flushed with the tube oil.
Subject Revision:
5. Criteria for the duration of flushing

5.1. General
Pipes that are properly ground and pickled are free from scale and weld splatter. Oil
flushing is primarily intended to remove from the oil system any loose foreign particles that
are lying in the pipes or dirt sticking to the wall. Efficient oil flushing is only possible if the
following requirements are fulfilled:
5.1.1. High flow velocity
The oil must flow through the pipes at the highest velocity possible.
Before cutting in the oil pumps for the first time, the pressure control valve is fully opened.
As soon as the auxiliary pump is in operation, the control valve is slowly closed while
observing the oil flow as well as the pump capacity (take care that the power consumption
of the oil pumps is in accordance with the admissible rating data of the motors, i.e. that the
pumps are not overloaded), in order to achieve maximum flow velocity in the oil pipes.
High flow velocities will be achieved if the overall oil system is divided into partial systems.
5.1.2. Temperature changes during flushing
Particles that are sticking to the inside of the pipe walls are to be loosened by the effect of
thermal shocks (differential expansion). The thermal shocks can be created in two
different ways:
a) Heating of the oil. The minimum oil temperature to be reached during the hot cycle
shall be 70 ºC.
Subsequently, the heating source is disconnected and the second oil cooler with the
cold cooling water is connected instead so that now cold lube oil can flow through
the previously hot pipes.
b) After heating of the oil system and oil pipes, cooling down is achieved by
disconnecting the lube oil pump. This abbreviates the duration of the flushing
procedure and saves time.
Note: The heating and cooling method described under a) should always be used
because this type of temperature change has the greatest effect.
Subject Revision:
5.1.3. Hammering of the pipes
During flushing, the pipes shall be hammered with a high-frequency pneumatic vibrator
fitted with a copper or hard-rubber top, so that any dirt sticking to the walls is loosened and
can be carried more easily by the lube oil flow to the oil tank strainer. If a pneumatic
vibrator is not available, the pipes shall be hammered by hand.
During this, care shall be taken to avoid any damage to the pipes and pipe supports.
5.2. Flushing procedure
In the European region oil flushing shall preferably be done by means of the PALL system.
If the PALL system is not employed, the oil is cleaned with the filters installed in the main
stream.
During the flushing procedure, the oil pressure pipe as well as the suction and pressure
pipes of the main oil pump shall be subjected to at least 10 temperature cycles. Each
flushing phase (hot/cold) shall have a minimum duration of one hour, i.e., one hot/cold
temperature cycle in about 2 hours.
5.2.1. Emergency oil (if applicable)
The relatively short pressure pipe of the emergency oil pump shall be flushed separately.
For this purpose, the pump shall be operated for 2 hours. All other oil pumps shall be shut
down during that time.
5.2.2. Jacking oil pipes (if applicable)
Once the jacking oil pipes are adjusted and finally installed, they shall be flushed with
solvent and dried with clean compressed air. After final erection, the connecting piece(s)
between the inlet pipe in the bearing casing and in the bearing shall be removed.
Now the whole system shall be flushed by means of the jacking oil pump for at least 1 hour
with the oil flowing into the corresponding bearing casing. A strong stream of oil shall be
discharged from each pipe. The dismantled piece(s) shall be blown out and checked for
free passage prior to re-installation.
Subject Revision:
5.2.3. Flushing of lubrication system
Temporary 10 μm meshes shall be installed at each bearing inlet, to assess cleanliness of

lube oil pipes. The meshes shall b e installed without the orifice plates, to ensure total oil
flow.
Filling of the oil tank up to 60% of the operating oil quantity, considering the complete filling
of oil pipes. Thereafter, the oil is circulated in the lube oil system without main oil filters.
Attention shall be paid that no major differences exist between the levels of the clean oil
and contaminated oil areas in the tank (the separating filter is to be cleaned, if necessary) .
After three flushing cycles (hot I cold), the main oil filters shall be mounted.
5.2.4. Flushing of the control oil system
Before terminating the flushing procedure of the lube oil system, the control oil system
shall be incorporated into the flushing circuit.
5.3. Evaluation of system cleanness
For evaluating the system purity, the service life of the main oil filter is examined.
Flushing can be terminated when the differential pressure of the main oil filter keeps
constantly for 12 hours, and there are no impurities at temporary meshes at bearing inlets.
Note: If an oil cleaning plant exists in parallel to the normal lube oil supply, it shall be kept
in operation throughout the entire flushing procedure. The progress of the cleaning
process can also be observed by means of the diminishing amount of dirt collected in the
oil cleaning plant.
6. Getting the system ready for operation
All flushing pipes, bypasses, blind flanges and orifices installed or attached for the purpose
of flushing shall be removed and the “dead ends” resulting thereof or the fittings and pipe
sections dismantled shall be manually cleaned and re-installed.
The bearings and oil channels of the bearing casings that are part of the flushing circuit
shall be manually cleaned and mounted together with the upper part of the bearing ready
for operation.
The inlet orifices at the individual bearings shall be mounted.
The bypasses at the main oil pumps shall be removed and the “dead ends” resulting
thereof or fittings shall be manually cleaned and re-installed.
Subject Revision:
The suction filter of the main oil pump shall be cleaned internally and re-installed.
The non-return flap valves in the pressure pipe of the main oil pump shall be re-installed.
Important: Be careful to install the non-return flap valve for operation in the correct
direction.
The oil deposits of the bearing casings shall be cleaned.

The stationary filters must be thoroughly cleaned and checked for cleanliness prior to
assembly.
After termination of the flushing procedure without PALL system, the oil tank shall be
drained and cleaned. In case the same tube oil is to be used for later operation, it shall be
purified, filtered and analyzed to guarantee the properties described in the technical
instruction 1CHE3272-001(ing). If there is no guarantee of this features of the instruction,
SIEMENS recommend the flushing oil change by a new charge, keeping the useful life of
the turbine.
Before draining the oil tank, it is advisable to allow for a certain settling time of about one-
day so that all dirt particles can settle on the oil tank floor.
Before filling in the filtered turbine oil the oil tank shall be checked and a corresponding
report be issued.
All non-return flap valves installed in the oil systems shall be checked for correct
installation and trouble-free operation.
Any expansion joints (rubber or metal) incorporated in the piping system shall be
dismantled and cleaned.
7. Final tests
After re-filling the oil tank and mounting of the lube oil coolers, the latter shall be carefully
filled and vented so as to get the overall system ready for operation.
Remove the temporary meshes from each bearing and set lube pressures by means of the
orifice plates.
Particular attention shall be paid to the correct installation of the bearing oil orifices and the
removal of any temporarily installed blind flanges.
By installing pressure gauges at the measuring points downstream of the inlet orifices, it is
possible to check the tube oil flow to the bearing.
Technical Instruction 1CHE3281-002(ing)
Subject Revision
Piping Blowing and Cleaning Procedure 04
Issued by Aproved by Date Page
Abaeté Correia Janete Oliveira 05/03/07 1/9
Preliminary remark
In spite of the greatest care being taken during installation and welding
of the steam lines, it is inevitable that foreign matter will remain in the
systems.
Oxide layers, which peel off, occur as a result of heat treatment and
annealing or preheating. Moreover, corrosion products may be
produced.
Steam strainers installed upstream of the emergency stop valves

provide protection only against ingress of larger solid particles, which
would cause severe damage to the turbine.
Solid particles, which are smaller than the mesh openings of the
strainers, cause damage to the blades inside the turbine. This results in
surface roughening of the blades, plugged blade channels, solid
particle erosion, etc.; occasionally damage to blading seal strips also
occurs.
The strainers cannot be allowed to become plugged, since this would

cause throttling losses and differential pressure, which would cause
destruction of the strainers. Fine-mesh strainer fabric cannot be used in
the steam strainers of the turbine in normal operation. There is a
danger that the fine-mesh fabric would become partially plugged, tear
and then be carried into the turbine.
In order to avoid this happening so far as is possible, the steam

systems upstream of the turbine must be cleaned thoroughly before
initial commissioning of the plant. The inside surfaces of the steam
pipes must be cleared of loose rust, scale, coatings, dirt and foreign
matter to such an extent that the components connected thereto can be
started up safely.
The cleaning methods to be employed, the boundary conditions to be

taken into consideration and the evaluation criteria are described below
from the point of view of the turbine manufacturer.
The piping system supplier is responsible for cleaning of the steam

piping system: where appropriate, agreement on the cleaning method
to be employed should be reached between the supplier and the
manufacturer of the steam generator and/or the plant owner.
Evaluation of the degree of cleanliness is to be undertaken in
cooperation with the skilled staff of the turbine manufacturer.
Two proven methods of cleaning are available:
• chemical and
• blowing,
which can be employed either alone or in combination.
Subject Revision
Chemical cleaning of piping systems
Oxidation and corrosion products and also welding residues can be

dissolved by chemical treatment of the inside surfaces of the piping,
which is subsequently flushed out. This may be carried out either by
specialised contractors, the boiler supplier or the piping system
supplier.
lt must be ensured that all the initial steam and, where applicable, the
induction steam piping or sections thereof are chemically cleaned.
Piping or sections thereof which cannot be blown are to be flushed

extra thoroug hly.
Chemical residues occur and these cannot be removed adequately

even with intensive flushing. Following acid cleaning, flushing and
passivation, the systems should consequently be cleaned additionally
(using high-velocity steam or air), where this is permissible.
Blowing of piping systems
The piping system is normally blown using steam. In special cases,

compressed air is used for cleaning, with a reservoir charged and
relieved to the atmosphere abruptly through flap valves.
In both cases, use is made of the high velocity of the cleaning medium.
In so doing, it is necessary to achieve flow velocities greater than those
in full-load operation.
The piping must be blown in such a manner that contamination and

residues cannot accumulate in the dead ends of the piping system.
Components need not be blown.
Instrumentation and control devices installed in the piping system,

which could be damaged by blowing, must be removed beforehand.
Internals such as strainers, filters, measuring orifices, condensate and
moisture separators, valves, check valves and similar equipment, which
could impede the blowing out of solid matter, must likewise be removed
before blowing.
Parts removed should be replaced by blanks, where appropriate.

Sensitive equipment which cannot be removed should be protected by
means of inserts.
Subject Revision
Types of steam discharge
With steam blowing, provision must be made for steam discharge.

Three methods are available:
• Discharge to atmosphere
This method entails a high noise level. Although silencers reduce the
noise impact, this method should be used only in cases where noise
does not pose a problem.
• Discharge of steam into water
Noise impact is considerably reduced on discharging the steam under

water. However, on the one hand, the permissible thermal loading of
natural or artificial waters must not be not be exceeded and, on the
other hand, the pollution of these waters with possibly hazardous
foreign matter must be kept within the permissible limits.
• Discharge of steam to condenser
This method is chosen when the other discharge modes are

impracticable or for other reasons, e.g. where operation of the boiler
system allows no other alternative.
This method has both advantages and disadvantages:
• Advantages:
-low noise impact,

-minimal expenditure for provisional steam blow aids
-recovery of condensate.
• Disadvantages:
-danger of damaging the valve seats,

-only those lines can be blown through which steam flows during
bypass operation,
-possible damage to condenser tubes by foreign matter,
-accumulation of foreign objects in the hotwell,
-possible contamination of the water cycle.
Subject Revision
Where the blow-steam is discharged to the condenser, the following

components or systems must be in operation in addition to the water
treatment plant in addition to the appropriate feedwater tanks:
-the cooling water supply system,

-the vacuum pumps,
-the condensate pumps,
-the seal steam system,
-the oil system and, where provided,
-the turning gear and
-the vacuum monitor.
All three methods necessitate additional steam blow piping. In cases

where the steam is discharged to the condenser, this blow exhaust pipe
is integrated in the main steam network. Additional piping must be
installed for discharge of the steam into water or into the atmosphere.
Dimensioning of these blow exhaust pipes must be based on the

blowing conditions. The diameter of the blow exhaust pipe must at least
be as great as that of the piping to be blown. Blow-out lines and
additional auxiliary piping must be secured so that no faults occur as a
result of temperature changes or pipe thrust.
Provisional installations for blowing must be fabricated from clean

piping sections. The nominal diameter should at least be as great as
that of the line to be blown; formed fittings should if possible not be
used, owing to the pressure losses. Piping should preferably be
equipped with flanged-pair joints in order to facilitate rapid installation.
Design-related water pockets in the discharge lines should be
adequately drained in order to avoid water hammer.
All lines through which steam is supplied to the main and auxiliary
turbines must be blown. Blowing diagrams should be available for
planning purposes.
Blowing should always be performed through a main steam line, to

which auxiliary lines have been connected. Where subsystems are to
be blown, the remaining auxiliary piping must be provided with blanking
flanges.
Subject Revision
Normally the systems should not be blown via the turbine control valves
or turbine stop valve bodies. Separate pipe outlets are provided for this
purpose. The lines may remain connected during blowing. In
exceptional cases, and only where there is no other possibility, blowing
is allowed through the turbine casing. However, for this purpose special
blanks must be ordered from the turbine supplier, matched to the
design of the turbine stop and bypass valves. These blanks are
designed to prevent contamination entering the inside of the turbine
and to prevent damage to the valve seats.
Danger of injury!
The solid particles are blown out from the discharge pipe at high
velocity.Appropriate measures must be taken to ensure that the blown
out solid particles cannot cause injury to persons or damage to
property.
Blowing is effective only where the velocity of the cleaning medium is

higher than the velocity in full-load operation. On account of the high
mass flows occurring at the nominal main steam parameters, it is
advisable to operate with reduced main steam parameter values.
Another reason for so doing is that the boiler is often not yet capable of
operating at its nominal conditions. The main steam pressure during
blow-out should be >50% of the normal main steam pressure; it must
not however exceed the maximum permissible pressure in the
individual sections.
In order to avoid erosion damage, the steam must be superheated by

at least 80 to 100°C; it must likewise not however not exceed the
maximum permissible operating temperature.
The required mass flow rate is determined from the mass flow / volume
ratio, also known as the CRF or K factor. From this, it is also possible to
determine the velocities in tubes and steam generators.
2
⎛ • ⎞
⎜ m B ⎟ ∗ VB
K=⎝ ⎠
2
> 1,2 to 1,7
⎛ •
⎞
⎜ mV ⎟ ∗ VV
⎝ ⎠
•
m Mass flow during steam blowing

B
m V Mass flow at fulI load
VB Specific volume during steam blowing
VV Specific volume at full load

Subject Revision
The mass flow during blowing m B is determined using the following

equation:
• •
VV
mB ≥ mV ∗ VB
* (1,1 to 1,3)
•
The actual value of m

B is determined by checking the previously
determined K factor. The thermodynamic values are taken from the well
known steam tables (Mollier h,s diagram, or similar sources).
Blowing is carried out in a number of phases. The steam piping system

should be allowed to cool down between such phases.
For reasons of safety, the first blow attempt should be made at approx.
15 to 20 % of the specified blowing pressure. The pressure should be
increased to the full value only in the subsequent attempts. The piping
system and fastenings should be checked to detect any faults or
irregulatities, which should be rectified.
In each of the subsequent phases, blowing must be carried out a

number of times at the maximum velocity. The effectiveness of blowing
is not dependent on the duration but rather on the number of blows,
during each of which the pipe material is heated and subsequently
allowed to cool down to room temperature (or at least below 100 °C) in
order to ensure that oxidation layers, corrosion products and welding
residues are removed. Experience has shown that this is achieved,
when not more than two or three blowing phases are carried out daily,
i.e. a period extending over a number of days (for up to a week) must
be taken into consideration for planning purposes for complete blow-
out.
Checking of cleanliness
Satisfactory results from steam blowing can only be expected when the
specified steam conditions and velocities approximate to those
specified. It is therefore necessary to measure the pressures,
temperatures and mass flows during blowing, or at least to determine
these approximately, in order to be able to check the velocities in the
individual systems.
The results of steam blowing are checked by means of a device

installed as depicted in Fig. 1. This assembly basically comprises the
holder 4, to which verification strips of polished steel, copper or
aluminium are screwed. Bare aluminium of approx. 40 mm width, more
than 1 mm thick and a Brinell hardness of HB25 to 35, is preferred.
Both sides of the strips should be usable. They should be renewed
prior to each blowing process.
Subject Revision
The foreign matter with the blowing steam leaves pits on the strips; the
number, size and edge form of such impacts are important for
evaluation of the results. It must be taken into account that the steam
velocity varies as a function of the piping cross-section. It can therefore
be assumed that the steam velocity in the middle of the pipe is higher
than along the sides. The pits must therefore be evaluated accordingly;
those at the edge are more significant than those in the middle.
Test device
1 Blowing steam flow

2 inspection cover
3 Verification plate
4 Duplex T support
In the first phase of blowing, the strips will have a considerable number
of large pits, SO that comparison with the strips installed for the final
blowing phase will not allow significant conclusive evaluation. For this
reason, the strips should be installed only after the 4th or 5th biowing
phase, each consisting of between 3 and 5 biows.
Subject Revision
Evaluation of the results of steam blowing
The following two methods can be used for evaluation of the results of
steam blowing:
• Evaluation on the basis of num ber and size of pits
The number of pits on the surface of the strips installed after the 4th or
5th purging phase and the proportion of the surface area affected (to be
counted and measured) are weighted with 100% in the high-velocity
zone. In the subsequent phases, the decline in the number of pits and
their size on the strips must be evaluated. Blowing has been
successful, if the number of pits and their surface area fall to between
10 and 15 %. The pit craters at the edges should not exhibit any
marked deformation humps; the number of indentations should not alter
significantly in subsequent blowing processes.
• Evaluation of the absolute number of impacts
Blowing has been successful if in the high-velocity zone not more than
5 pits without deformation humps are found and there are no pits in the
edge zones. This result should not alter significantly (max. 20 %) in
numerous subsequent blowing operations and phases. Otherwise,
blowing must be continued until the criteria specified are attained and
the conditions have stabilised.
• Evaluation against reference specimens
The degree of cleanliness of piping sections can be evaluated on the

basis of the following reference specimens. The degree of cleanliness
of the reference specimens increases as the numbers increase from 1
to 10. For main steam lines, we recommend a degree of cleanliness
corresponding to reference specimen 7. Evaluation based on number
and size is also to be taken into account as described above.
Blowing should on no account be terminated, so long as large numbers

of pits and pits larger than 1.5 mm diameter are found on the strips.
The strips shouid be evaluated only after 10 minutes (minimum blowing
duration) have elapsed.
The strips must be evaluated by the plant operator and by

representatives of the supplier of the steam generator and of the
turbine. Previously agreed evaluation criteria considerably speed up the
decision as to whether blowing should be discontinued. The evaluation
results shouid be documented for each piping section.
On completion of the cleaning process, all the previously removed

components should be reinstalled and connected. All the attached
blanking flanges, additional piping and closures should be removed and
additional connections should be sealed off.
Do not mix up individual parts!

Piping system parts such as bolts, nuts, gaskets and valves must not
be mixed up and must be reinstalled properly in accordance with the
pipe type or parts list and isometric drawings (flow direction).
Subject Revision
Reference specimens for evaluation of the degree of cleanliness of piping

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Serial nº Designation Document no. Volume

PART 3 - INSTALLATION MANUAL

3.1 Instructions for transport and storage Transport_instruction

3.2 Preparation for the assembly work Assembly_work

3.3 Mounting instructions for turbine and accessories Mounting_instructions

Flushing of the oil system

Instructions for transport and storage

The present mounting instructions describe the installation of the

 the table of contents

Transport_instruction 5/21/08 pagina 1/2

1 Open case inspection

All components were treated with preservation. The components

In the event that the completely assembled turbine is

Intervals Preservation Maintenance Storage Intervals

1 Storage under shelter __ 1 Erection site under shelter __ __

2 Visual inspection of external 26 2 Visual inspection of external __ 12

3 Opening of the casing, internal ins 52 3 Preservations latest 26

4 Application of a primer coat of 52 4 Repair of final coat of paint latest 52

5 5 Inspection and check of all latest 52

Transport_instruction 5/21/08 pagina 2/2

Preparation for the assembly work

The present mounting instructions describe the installation of the

To find your way through the mounting instructions more easily,

 the table of contents

Assembly_work 05/21/08 page 1/9

Field erection time and personnel

Scope and duration of field erection and plant commissioning and

If the customer or the site management or other contractors

Assistant fitters Semi-skilled machine fitters, experienced in assembly and field

Welders Qualified welders as per ASME Section IX requirement with valid

Electricians Trained electricians who have finished their apprenticeship and

Assembly_work 05/21/08 page 2/9

The necessary devices required for field erection, such as tools,

Properly tested, usable and accident-proof devices shall be used

Preparation of erection site

2. Storage places for the temporary storage of equipment either

3. Access roads shall be passable and firm and withstand the

4. The site area and erecting bays shall be accessible without

5. On their arrival on site, all consignments shall be compared with

Assembly_work 05/21/08 page 3/9

6. Equipment handling on site shall be carried out only by means of

7. The consignment shipped to site shall, according to their contents

8. The equipment shipped to site shall be stored and preserved in

9. When unpacking the equipment, the remaining empty cases and

2. Check-up of scope of delivery,

In the event of taking out erection equipment from its relevant

If there is anything missing or damaged, please do not hesitate to

The grouting height under the baseplate shall be checked for

Assembly_work 05/21/08 page 4/9

4. Standard tools for erection

Quantity Tool trolley (recommendation)

Assembly_work 05/21/08 page 5/9

Assembly_work 05/21/08 page 6/9

Quantity Attachment case no.1 to the tool trolley

Quantity Attachment case no, 2 to the tool trolley

Quantity Attachment case no. 3 to the tool trolley

Quantity Attachment case no.4 to the tool trolley

Assembly_work 05/21/08 page 7/9

Quantity Ropes case no.

Quantity Autogenous welding equipment

Assembly_work 05/21/08 page 8/9

the table of contents

1 Storage under shelter 1 Erection site under shelter __

the table of contents