DOC NO.

PROCEDURE FOR LUBE OIL FLUSHING

PW:TSX:GT: RFCL
OF 1 X 32.5 MW FR-6B GAS TURBINE
PS-WR Sheet 1 of 11
Site: RFCL RAMAGUNDAM Area : Gas Turbine
Sl. No. Description Sheet no.
1.0 PLANT DETAILS 2
2.0 OBJECTIVE 3
3.0 SET UP PROCEDURE 4
4.0 FLUSHING PROCEDURE 5
5.0 PRE START UP PROCEDURE 6
6.0 FILLING THE LUBE OIL TANK 7
7.0 CHECKLIST 8
8.0 LOGSHEET 11
 PROCEDURE FOR LUBE OIL FLUSHING OF DOC NO.
PW:TSX:GT: RFCL
1X32.5 MW FR-6B GAS TURBINE
PS-WR Sheet 2 of 11
Site: RFCL RAMAGUNDAM Area : Gas Turbine
Sl. No. Description
1.0 PLANT DETAILS:
In RFCL Ramagundam 1 X 32.5 MW GT, lube oil is used for lubrication as well as for
control of gas turbine through hydraulic and trip oil. The system consist of :-
1.1 a) Oil tank: It is to contain the lube oil and pumps are mounted inside the tank and
coupled with drives mounted vertically at the top of tank. It also contains Lube oil
filter, Lube oil cooler heater and PRV. Lube Oil tank is a part of accessory base.
b) Oil Pumps: These are meant to circulate the oil through the system at required
pressure & flow
d) Duplex Filter: To retain the solid particles entering into the system. One is kept in
line while the other is standby.

1.2 e) Heater & heaters:- These are meant for maintaining the temperature of lube oil.
The L.O. circulates in the system is divided for different purposes. Such as trip oil,
1.3 hydraulic oil etc.
1.4 The quantity of oil required for flushing will be approximately 8500 liters.
The drawing appropriate for the unit being flushed for the following items shall be
used as a general guide.
‐Lube oil scheme
‐Trip oil scheme
‐Hydraulic supply scheme
‐Starting means Scheme
- IGV scheme
- Fuel gas scheme
- PPG lube oil field flushing (PGMA-036417)
- PPG Arrg’t Lube oil interconnecting (PGMA- 35543)
- Lube oil feed and drain#1 Brg( PGMA 35504)
- Piping Arrgt feed and drain load (PGMA 35816)
- Lube oil inlet ,outlet and vent piping for Gen & Gear Box (PGMA 13805)
 PROCEDURE FOR LUBE OIL FLUSHING DOC NO.
PW:TSX:GT: RFCL
OF 1X32.5 MW FR-6B GAS TURBINE
PS-WR Sheet 3 of 11
Site: RFCL RAMAGUNDAM Area : Gas Turbine
Sl. No. Description

2.0 OBJECTIVE:
2.1 After completion of erection of lube oil feed, hydraulic oil, trip oil supply and return
pipes, complete L.O. system shall be flushed to remove contamination from a new
unit which may have occurred in shipping, storage or installation, by creating
condition similar to the machine in operation.

Refer attached sketch (Annexure-A) of Lube oil, Hydraulic oil and trip oil
piping with marking where strainer, Flushing fixture & jump over will be
placed.
 PROCEDURE FOR LUBE OIL FLUSHING DOC NO. PW:TSX:GT:
RFCL
OF 1X32.5 MW FR-6B GAS TURBINE
PS-WR Sheet 4 of 11
Site: RFCL RAMAGUNDAM Area : Gas Turbine
Sl. No. Description
3.0 SET UP PROCEDURE:
Refer to the Lube oil, Trip oil & Hydraulic oil piping schematic
3.1 Drain any existing oil and check cleanliness of MOT & Junction boxes
3.2 Verify that the main lubricant oil filters, hydraulic oil filters are installed.
If the unit has been stored for more than one year replace the lubricant and hydraulic oil filter
elements.
3.3 If duel lubricant oil filters are used verify that the transfer valve operates freely.
3.4 Remove the orifice (dia 76.2mm) from main lube oil header for full flow.
3.5 Remove the sensing line of Pressure regulating valve (VPR2-1) so that it will be always full
open.
3.6 Blank line OL-6 to the Charge pump.
3.7 Blank Line OR-2 to the Ratchet pump.
3.8 Disconnect the line (OR-3) from Aux Hydraulic Pump and redirect to the tank. So that flushing
oil will not enter into the hydraulic pump
3.9 Disconnect the Trip oil line (OLT) from the lube oil header and blank it, thus flushing oil will not
enter in the trip oil circuit inside the tank.
3.10 Disconnect the suction line (OR-1) of main hydraulic pump from ACC gear box and blank it.
Modify the lube feed line to accessory gear box, fix the valve & Y strainer and re-direct the flow
3.11 in the Bearing #1 drain. (Refer Detail B-5 in the attached drawing 3641761004)
Break the feed line to Bearing #1&2, Install the valve and Y strainer and redirect the flow in the
3.12 bearing #1 drain line and JB#3 respectively.(Refer attached Annexure-A)
Install the flushing fixture on the bottom half of the Generator front and rear bearings and redirect
3.13 the flow in the pedestal. (Clamp the 100 mesh screen at the outlet of the flushing fixture)-Refer
attached annexure-A
3.14 Modify the lube oil supply line to Load gear box, install additional piping with valve & Y-
strainer and further connect to lube oil return line of load gear box.(Refer attached Annex-A)
3.15 Hydraulic oil line and trip oil line (from JB#1 to JB#2) to be jumpered with lube oil feed line at
JB#1. Modify the Trip oil & Hydraulic oil line at JB#2, install isolation valve and Y strainer and
3.16
redirect the flow into the JB#2. Blank the Hydraulic and Trip oil line going to IGV( Refer detail
A-3 ,A-7 &A-5 in the attached drawing 3641761004 )

3.17 .Fill lube oil in the main oil tank. This oil should be used as specified in the lube oil
recommendation.
 PROCEDURE FOR LUBE OIL FLUSHING OF DOC NO.
PW:TSX:GT: RFCL
1X32.5 MW FR-6B GAS TURBINE
PS-WR Sheet 5 of 11
Site: RFCL RAMAGUNDAM Area : Gas Turbine
Sl. No. Description
4.0 FLUSHING PROCEDURE:
To obtain satisfactory flush with minimum expenditure of time the various feed lines must be
flushed individually. The following procedure may be adopted:
4.1 Combined Phase flush:- Using the AC Powered Auxiliary oil pump, Run all phases (i.e. GT
Brg#1 &2 , Load Gear, GTG front and rear bearing & acc gear box) for 01 hour. It will flush
most of the loose debris and will reduce the possibility of material back washing during the
phase flushing.
4.2 Phase flushing:
Open the isolation valve installed in the Brg#1 loop, this will direct the flushing oil which
flows out of the feed pipe to return line through Y strainer. ( Remaining isolation valves
installed in the flushing loops should be kept close)
4.3 Using the AC powered auxiliary oil pump circulate oil for minimum one hour.
4.4 Raise the oil temperature to 69 to 74 deg C. (Oil heater should be required to make on)
4.5 If during the flush the differential pressure across lube oil filter exceeds 1.0 atm (15psi),
remove the filter elements and clean it for reuse.(If it is reusable, otherwise replace the same
with new one)
4.6 Check the screen after one hour flush. A clean screen (100 mesh) is defined as no visible
particles. If the screen is not clean, circulate for additional 30 minutes minimum and check for
clean screen. If this new screen shows contamination, install another screen, flush again for
another 30 minutes and check the screen. Repeat this until there is a clean screen.
4.7 After obtaining clean mesh, isolate the feed line to prevent further flow.
4.8 Cleaning of one bearing will be carried out at a time. Repeat step No 4.1 to 4.5 for all others
bearings.
4.9 Flush the following lines also as per above procedure.
a) The accessory gear box
b) The load gear box
4.10 After successful completion of phase flushing, Run the pump for 01 hour more to flush the
trip oil and hydraulic line.
5.0 PRE STARTUP PROCEDURE:
5.1 Drain the flushing fluid from tank, JBs filters and coolers. Carry out servicing of changeover
valve if required.
5.2 Remove all the flushing loops and return all bearing feed and return lines, the lines for
accessory gear &load gear box and lines for trip & hydraulic oil to its original configuration.
 PROCEDURE FOR LUBE OIL FLUSHING DOC NO.
PW:TSX:GT: RFCL
OF 1X32.5 MW FR-6B GAS TURBINE
PS-WR Sheet 6 of 11
Site: RFCL RAMAGUNDAM Area : Gas Turbine
Sl. No Description
5.3 Return the line of Main hydraulic pump and ratcheting pump to its original configuration.
5.4 Verify that any plugs/blinds in the lines to and from the valves have been removed.
5.5 Replace the used main lube oil filter with new ones.

6.0 FILLING THE LUBE OIL TANK:

6.1 Clean the Main oil tank and Junction boxes after satisfactory flushing.
6.2 When entering the L.O. tank:
a) Take precaution for safety
b) All persons entering should be properly clothed.
c) Shoes shall be removed outside before entering to the tank.
6.3 Check for foreign objects, all flanges, tube fittings, pipe plugs etc inside the tank.
6.4 Restore the trip oil line (OLT), Orifice (76.2mm dia), sensing line of VPR2-1 valve, Suction
line of Aux. hydraulic pump and line for charge pump which was removed/disconnected for
lube oil flushing.
6.5 Re-check the lube oil ,hydraulic oil, trip oil , IGV, Fuel gas and starting means system as per
scheme to ensure the system are normalized after flushing.
6.6 Check the mechanical operation of the oil level float gauge.
6.7 Secure all openings properly after leaving the tank.
6.8 Fill the tank until the level indicator indicates “F” provided on the side of the tank. Cross
check the level, top up if required.
 DOC NO.
PROCEDURE FOR LUBE OIL FLUSHING
PW:TSX:GT: RFCL
OF 1X32.5 MW FR-6B GAS TURBINE
PS-WR Sheet 8 of 11
Site: RFCL RAMAGUNDAM Area : Gas Turbine
Sl. No. Description
7.0 CHECKLIST:
7.1 PREPARATION FOR FLUSHING Date
7.1.1 Tank is completely drained and inspected ___________
7.1.2 Main L.O. filter and hydraulic oil filter are installed ___________
7.1.3 Operation of transfer valve checked ___________
7.1.4 Initial filling done into tank
Oil specification ___________
Quantity of oil ___________
7.1.5 Jump over provided for
GT bearing No. 1 ___________
GT bearing No. 2 ___________
Gen front bearing ___________
Gen rear bearing ___________
Accessory gear box ___________
Load gear box ___________
Hydraulic oil line ___________
Trip oil Line ___________
7.1.6 Oil supply line to turning gear/ratcheting is blanked ___________
Oil supply line to Aux Hydraulic pump is blanked __________
Oil supply line (OL-6) to charge pump is blanked ___________
Trip oil line (OLT) is disconnected and blanked ___________
Trip oil& Hydraulic oil line to from JB#2 to IGV is blanked ___________
Sensing line for the VPR2-1 valve is removed and blanked. ___________
Orifice Dia (76.2mm) from the main lube oil header is removed. ___________
Suction pipe of main hydraulic pump is disconnected from the ___________
Acc gear box and blaked.
 DOC NO.
PROCEDURE FOR LUBE OIL FLUSHING
PW:TSX:GT: RFCL
OF 1X32.5 MW FR-6B GAS TURBINE
PS-WR Sheet 9 of 11
Site: RFCL RAMAGUNDAM Area : Gas Turbine
Sl. No. Description
7.2 FLUSHING
Start AC auxiliary lube oil pump
a. Discharge pressure ___________
b. Load current ___________
c. Delta P across filter ___________
d. Lube oil temperature ___________
7.2.1 For bearing no.1
a. Total number of hours flushed ___________
b. Temp achieved during flushing ___________
c. Mesh condition ___________
7.2.2 For bearing no.2
a. Total number of hours flushed ___________
b. Temp achieved during flushing ___________
c. Mesh condition
7.2.3 For ACC Gear Box
a. Total number of hours flushed ___________
b. Temp achieved during flushing ___________
c. Mesh condition ___________
7.2.4 For Gen front bearing
a. Total number of hours flushed ___________
b. Temp achieved during flushing ___________
c. Mesh condition ___________
7.2.5 For Gen rear bearing
a. Total number of hours flushed ___________
b. Temp achieved during flushing ___________
c. Mesh condition ___________
7.2.6 For Load gear box
a. Total number of hours flushed ___________
b. Temp achieved during flushing ___________
c. Mesh condition ___________
7.2.7 For Trip/Hyd oil
a. Total number of hours flushed ___________
b. Temp achieved during flushing ___________
c. Mesh condition ___________

Note: Format of log sheet is given below it is to be used.

 DOC NO.
PROCEDURE FOR LUBE OIL FLUSHING
PW:TSX:GT: RFCL
OF 1X32.5 MW FR-6B GAS TURBINE
PS-WR Sheet 10 of 11
Site: RFCL RAMAGUNDAM Area : Gas Turbine
Sl. No. Description
7.3 PREPERATION FOR STARTUP:
7.3.1 Flushing oil is drained ___________
7.3.2 All jump over is removed and lines normalized ___________
7.3.3 Replaced filter elements before servo valves ___________ Replaced main
7.3.4 and hydraulic oil filter elements ___________
7.3.5 Lube oil tank cleaned, inspected and boxed up. ___________
7.3.6 Oil tank filled with fresh charge of oil
a. Oil specification ___________
b. Quantity filled ___________
c. Flushing completed on ___________
 Sheet No. 11 of 11
LOGSHEET FOR GT LUBE OIL FLUSHING

Name Pump Pump MOT ΔP

Pump
Sl. of oil Start Motor Discharge Oil across Mesh
stop date Remarks
No. flushing /Date Amp Pressure temp filter condition
/time
part /time Kg/cm2 (0C) Kg/cm2

10

11

12

13

EIL BHEL RFCL