GE Power LM6000 – Universal Gen II
Gas Power Systems Operation & Maintenance
TP TECHNICAL PROCEDURE 7701
Field Flushing TLO System
Purpose & Scope
The purpose of this procedure is to provide instructions for pre-start flushing of the Turbine
Lube Oil (TLO) System (including Shell & Tube and/or Fin-Fan Lube Oil Cooler).
Prerequisites
The Turbine Lube Oil System should be installed and inspected.
NOTICE
When flushing the TLO System, it may be necessary to utilize a separate tank and heater in order to
not contaminate the system, and to help achieve the desired flushing temperatures.
It is possible to use the TLO tank and heater if conditions allow a constant flushing temperature of
120 °F to 160 °F. This temperature should be maintained if possible throughout flushing.
It will be necessary to have the correct voltage available for the tank heater. If an alternate source of
power is used to energize the heater, tank temperature must be closely monitored.
NOTICE
Monitor lube oil tank temperature. If flushing activities are suspended, ensure tank heaters are
secured.
If system incorporates a Fin-Fan Cooler instead of a Shell & Tube Cooler, the cooler must be flushed
separately (first). Fin-Fan Coolers incorporate turbulators, therefore flow rates for fin-fan coolers
must not exceed 17.5 gpm, or 4 psid.
CAUTION
LUBRICATING OIL, MIL-23699, IS TOXIC TO SKIN, EYES AND RESPIRATORY TRACT. SKIN AND EYE
PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. ENSURE AREA IS WELL
VENTILATED.
CARE MUST BE TAKEN NOT TO ALLOW CONTAMINATION OF THE LUBE OIL SYSTEM PRIOR TO, DURING,
OR AFTER COMPLETION OF SYSTEM FLUSHING. COVER ALL OPEN PIPING CONNECTIONS TO PREVENT
ENTRY OF FOREIGN DEBRIS AND OBJECTS.
TP7701 Rev. 0
Field Flushing TLO System Page 1 of 9
GE Power LM6000 – Universal Gen II
Gas Power Systems Operation & Maintenance
Procedure
• Remove Thermostatically Controlled Valve (TCV-1001).
NOTICE
Match-mark valve position for reinstallation reference.
Figure 1 - Thermostatic Control Valve
• Perform the following steps for site-specific Turbine Lube Oil systems:
SHELL AND TUBE COOLERS FIN-FAN COOLERS
a Remove 4 fasteners from “AMOT” valve top a Install 3-way plug valve from flushing kit (F/F,
and remove top. Item 1)
b Remove thermostat from valve body and b Position 3-way valve to port oil through “C”
reinstall top. Ensure O-ring is properly port and restrict flow through “B” port
seated on valve top prior to installation. (reference GE Drawing X-504244).
c Reinstall “AMOT” valve top in correct
position as previously marked, inserting a
paddle blind (GLO-6000, Item 4) on “B” side
of valve (reference GE Drawing X-504244).
Note: Installing paddle blind on “B” side of
valve will force oil to flow through the
cooler.
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GE Power LM6000 – Universal Gen II
Gas Power Systems Operation & Maintenance
Fill oil tank with turbine synthetic oil and heat to 120 °F to 160 °F. Allow sufficient
time for oil to reach correct temperature.
NOTICE
100 mesh screen is provided in the flush kit. It comes in a roll and must be cut to proper size.
• Install “100-Mesh” screen (CON, Item 1) on supply side to cooler and lube oil drain line
to lube oil tank.
• Connect pump inline.
NOTICE
There are two methods to connect the pump in-line for flushing (Method A – Outside or Method B –
inside). Either method may be used.
METHOD A – Outside Skid Connection
• Remove inner-connect hose between lube oil tank and main unit (connections 71 and
71A).
• Install connector (TLO-6000, Item 1) to suction side of pump.
• Attach 2" inner-connect hose (TLO-6000, Item 9) from connector on suction side of
pump to lube oil supply connection 71.
• Install connector (TLO-6000, Item 5) to discharge side of pump.
• Attach inner-connect hose (TLO-6000, Item 8) from connector on discharge side of
pump to main unit (connection 71A).
• Inside skid, connect L1 (suction) connection to L6 (discharge) connection using jumper
(TLO-6000, Item 7).
NOTICE
Use GE-supplied flanges and O-rings.
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Field Flushing TLO System Page 3 of 9
GE Power LM6000 – Universal Gen II
Gas Power Systems Operation & Maintenance
L2 to L3
Connection
L1 to L6
Connection
METHOD B – Inside Skid Connection
• Connect suction side of pump to L1 (suction) piping connection, using connector
(TLO-6000, Item 4).
• Connect discharge of pump to L6 (discharge) piping connection using connector
(TLO-6000, Item 2)
NOTICE
Connecting the L2 and L3 connections will bypass the lube/scavenge pump and close the loop on
the lube oil system.
• Connect L2 connection to L3 connection using jumper (TLO-6000, Item 6).
• If hydraulic valves are used, close all small ball valves on turbine hydraulic auxiliaries;
i.e. gas valve, liquid fuel valve, water valve, and hydraulic pump.
• Remove 100-mesh filters for first 24 hours of flush. After 24 hours, reinstall filters.
• Verify 100-mesh filters have been installed into duplex lube oil filter assemblies; select
and lock one side of scavenge filter and one side of supply filter.
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Field Flushing TLO System Page 4 of 9
GE Power LM6000 – Universal Gen II
Gas Power Systems Operation & Maintenance
METHOD B – Inside Skid Connection (Cont)
NOTICE
If system incorporates a Fin-Fan Cooler instead of a Shell & Tube Cooler, the cooler must be flushed
separately (first). Fin-Fan Coolers incorporate turbulators, therefore flow rates for fin-fan coolers
must not exceed 17.5 gpm, or 4 psid.
• Perform the following steps for site specific turbine lube oil systems:
SHELL AND TUBE COOLERS FIN-FAN COOLERS
a Verify one cooler on skid is selected a Remove inlet and discharge piping at cooler and
for use. cover open ends at manifold with plastic.
b Install a 1½-inch bypass line (from flushing kit)
around cooler (F/F, Item 3).
• Verify pump pressure gage instrumentation isolation valves are open and all other
affected instrumentation valves are closed.
NOTICE
When checking pump for proper rotation and during initial running of pump, two persons are
required. One is to be stationed at the MCC and the other at the pump. They should be in direct
communication with each other (radio). This is for safety and environmental concerns.
• When directed, bump-start the pump. Verify correct rotation.
NOTICE
Pump must be primed prior to start. Failure to do so will result in damage of the pump and other
equipment.
• Prime pump.
• Allow pump to operate 5 to 10 seconds first three runs, then check for leaks.
• Start pump and quickly observe for leaks. If leaks occur, shut down pump, repair
leaks
and restart.
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Field Flushing TLO System Page 5 of 9
GE Power LM6000 – Universal Gen II
Gas Power Systems Operation & Maintenance
METHOD B – Inside Skid Connection (Cont)
• Allow pump to operate for 2 to 5 minutes, then shut down pump and inspect screens
for cleanliness.
NOTICE
The screen in the drain-back line to tank will indicate cooler cleanliness condition, while the screen in
the supply-to-cooler will indicate integrity of lube oil piping and tank.
• Clean and reinstall screens.
• Start pump and allow to run for 30 minutes.
• After 30 minutes of run time, shut down pump and inspect screens for cleanliness.
• Clean and reinstall screens.
• Start pump and allow to run for 2 - 12-hour intervals, as dictated by inspection.
During first 12- hour run, also run dc pump for 2 hours.
• Every hour, tap all piping and welds around the package and auxiliary skid with a
dead blow/soft mallet to loosen up foreign matter that may be present in piping.
• Every 12 hours, or as dictated by inspection, shut down pump, inspect and clean or
replace screens. Continue this operation until all foreign matter has been removed.
• Cleanliness is determined when there is no scale, rust, metal shavings, and/or sand
visible and grittiness is not detectable to the touch.
• For systems with fin-fan coolers, swap coolers and perform steps 18 through 23
again after clean screen is observed.
• During last 12-hour flush, change supply and scavenge filters with ______ micron
filters.
NOTICE
Lab Analysis of every lube oil sample is required to determine acceptance of the oil by GE. Refer to
Lubricating Oil Specification MID-TD-0000-6 (Appendix A6 in Engine O&M) for requirements.
• Once all foreign matter has been removed, shut down pump, inspect and clean or
replace screens.
• Remove ¾" plug at turbine lube oil fin-fan cooler manifold inlet.
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GE Power LM6000 – Universal Gen II
Gas Power Systems Operation & Maintenance
METHOD B – Inside Skid Connection (Cont)
FIN-FAN COOLERS (FLOW METER) FIN-FAN COOLERS (ALTERNATE METHOD)
a Install flow gauge (pitot-tube type from a Remove ¾" plug at turbine lube oil fin-fan
flushing kit) at manifold inlet plug cooler manifold outlet.
(F/F, Item 2).
b Install a pressure gauge at fin-fan cooler inlet
and outlet manifolds.
NOTICE
Elevate bypass line to drain excess oil from line prior to disconnecting. Place container under flange
to catch excess oil when disconnecting.
• Remove bypass line from inlet and discharge piping and install piping to cooler
flanges.
• Set three-way plug valve on auxiliary skid to port oil flow to port “B” and stop flow to
port “C” (bypassing oil flow around cooler).
• Have observer posted at flow gauge and in direct contact with person at 3-way plug
valve.
• Start pump and quickly observe for leaks. If leaks occur, shut down pump, repair
leaks and restart.
FIN-FAN COOLERS (FLOW METER) FIN-FAN COOLERS (ALTERNATE METHOD)
a Slowly open port “C” at 3-way plug valve. a Slowly open port “C” at 3-way plug valve.
Adjust opening until person at flow meter Adjust opening until person at pressure
registers approximately a 17.5-gpm flow gauges registers a differential pressure of
rate. approximately 4 psid between the inlet and
outlet. (4 psid = 17.5 gpm)
• Slowly open port “C” at 3-way plug valve. Adjust opening until person at flow meter
registers approximately a 17.5-gpm flow rate.
• Allow pump to operate for 2 to 5 minutes, then shut down pump and inspect screens
for cleanliness.
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GE Power LM6000 – Universal Gen II
Gas Power Systems Operation & Maintenance
METHOD B – Inside Skid Connection (Cont)
NOTICE
The screen in the drain-back line to tank will indicate cooler cleanliness condition, while the screen in
the supply-to-cooler will indicate integrity of lube oil piping and tank.
• Clean and reinstall screens. Install filtration media into duplex filter assemblies.
• Start pump and allow to run for 30 minutes.
• After 30 minutes of run time, shut down pump and inspect screens for cleanliness.
• Clean and reinstall screens.
• Start pump and allow to run for 12-hour intervals, or as dictated by inspection.
During first 12 hour run, also run dc pump for 2 hours.
• Occasionally, tap all piping and welds around the package and auxiliary skid with a
dead blow/soft mallet to loosen up foreign matter that may be present in piping.
• Every 12 hours, or as dictated by inspection, shut down pump, inspect and clean or
replace screens. Continue this operation until all foreign matter has been removed.
Cleanliness is determined when there is no scale, rust, metal shavings, and/or sand
visible and grittiness is not detectable to the touch.
• During last 12-hour flush, change supply and scavenge filters.
• Draw sample of lube oil from sump and send to lab for analysis. Reference
Lubricating Oil Specifications in the Appendix for maximum particulate by analysis.
Evaluation and Setup for Test
• Evaluation of cleanliness is accomplished by having a sample taken and sent to a lab
for analysis. Upon completion of flushing, sign-off sheets must be filled out and
signed by all witnessing parties.
• After system has been deemed clean and ready for operation, disconnect two
jumpers from L1 to L6 (outside or inside piping, whichever method was used) and L2
to L3 connections. Reconnect hoses to lube/scavenge pump.
• Perform the following steps for site specific turbine lube oil systems:
NOTICE
Ensure Thermostatic Control Valve is installed in same direction as removed. Failure to install valve
correctly will result in serious equipment failure.
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Field Flushing TLO System Page 8 of 9
GE Power LM6000 – Universal Gen II
Gas Power Systems Operation & Maintenance
SHELL AND TUBE COOLERS FIN-FAN COOLERS
a Remove “AMOT” valve and paddle blind a Remove 3-way plug valve.
(GLO6000, Item 4).
b Reinstall thermostat in “AMOT” valve body b Reinstall “AMOT” valve (w/thermostat
and reinstall valve in accordance with installed).
markings to ensure proper positioning.
c Remove flow gauge (pitot tube-type) from
cooler inlet and reinstall plug.
• Remove pump and two flushing inner-connect hoses. Reconnect permanent inner-
connect hose for operation.
• Open duplex filter canisters and install new filter elements.
• Properly align three-way water valve and three-way oil valve to lube oil cooler.
• Open all small ball valves on turbine hydraulic auxiliaries; i.e. gas valve, liquid fuel
valve, water valve, and Woodward hydraulic pump.
• Remove mesh screens used during flushing.
• Install a strainer in air/oil separator return line to tank (connection 78A).
NOTICE
Prior to initial run of gas turbine, a wire-mesh screen should be installed on the return line of the Air-
Oil Separator. This will ensure that the turbine lube oil tank is not contaminated by the field-installed
piping. Allow gas turbine to run approximately 24 hours. Inspect the screen. Continue to inspect
screen at timely intervals until no further debris or contaminants are present. At the time when the
system is considered clean and free of contaminants, the mesh screen should be removed. Strainer
should be monitored frequently during operation of the gas turbine. Oil level and flow can be
monitored through small sight glass on return line. Strainer has been known to fill up very quickly
due to contaminants and cause backup of oil system.
• Open affected instrumentation isolation valves.
• System is now ready for commissioning of the machine.
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