g Nuovo Pignone No.

STD-MI-315
PRE COMMISSIONING page 1
FIRENZE
INSTRUCTIONS

OIL PIPING FLUSHING

IN SITE ASSEMBLED/FABRICATED

MODIFICATIONS Drawn Checked Approved DATE N.

Emission 05.10.93 STD-MI-315
Mod. Table 1 - 15.09.95 Rev 0 1
Add. Chap.8 e Tables 2 - 3 01.12.97 Replaces the No.
The present document is Nuovo Pignone Property. Copyright is reserved. Replaced by No.
 CONTENTS

1.0 SCOPE

2.0 IN SEQUENCE FLUSHING AND LINES SEPARATION

3.0 FLUSHING OIL TO BE USED

4.0 OIL HEATING AND COOLING

5.0 VIBRATIONS PRODUCING INTO THE FLUSHING PIPING

6.0 IN PIPING AIR INJECTION

7.0 POLLUTION LEVEL

8.0 FLANGED COUPLING DISASSEMBLING

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1.0 SCOPE

1.1 The information contained herein provides the Contractor with instructions to perform
the oil flushing of the pipes in site assembled or fabricated.

Note for Turbogroups with Turbines MS 6001 - MS 9001 and MS 9001 F:

The Turbine piping flushing will be carried out immediately after the machine laying on the
foundation and before carrying out the Turbine-Generator alignment activities.

Normally 100 days before the putting in service date of the generation group with the first
parallel activity execution.

What above mentioned is given by the necessity to run the Turbine shaft during the alignment
phase, operation that cannot be carried out without the bearings lubrication.

A retard of this activity will stop the Turbogroup erection operations, because the subsequent
erection activities can create difficulties in the turbine baseplate movement due to the piping
and ducts connections.

1.2 The oil supply interconnection piping between the turbine and generator are provided with
austenitic stainless steel, with first run circonferential welding carried out in T.I.G. , both in
prefabrication phase and in site.

1.3 The gas turbine group oil supply piping down stream the filters, forming the turbine package
piping whole, are provided in stainless steel with first run prefabrication welding in T.I.G.,
moreover they have already been submitted in factory to the flushing and inside protected
before the turbine package and its own auxiliaries baseplate shipping.

1.4 The auxiliaries baseplate oil piping, have already been submitted to the operational test in
factory, carrying out the oil circulation with its own pumps, to perform the oil system functional
test.

1.5 The main washing operations of the interconnecting oil piping to perform in site between the
turbine battery limit and the generator users are synthetically the followings:

a) Washing in sequence of the supply oil piping with flow higher than the normal flow.

b)) Hammering of oil supply piping between the turbine battery limit and generator users.

c) Compressed air injection in the supply oil piping as per point "b" with lube oil circulation.

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2.0 "IN SEQUENCE" FLUSHING AND LINES SEPARATION

2.1 This procedure describes the flushing of a lube oil system employing "In sequence washing"
technique.
The term "In sequence" means that the washing is performed using a defined sequence , to
obtain a dirt effective removal by the washing oil.
Here below is described the principles concerning the technique "in sequence washing".

2.2 Seeing the following piping system:

A-B line will be covered by the maximum flow if the valves on the lines B-C e B-D are open.
In the same way, to obtain the maximum oil flow through the B-C line, the B-D line will be
closed and vice-versa.

2.3 As higher is the flow velocity, higher is the oil capacity to remove the dirt, the right flushing
sequence of the simple illustrative piping system, will be of washing firstly the A-B section
realizing in this way the maximum obtainable velocity, and than to pursue with the sections
B-C and B-D separately.

2.4 The conception of "in sequence flushing" is to wash the piping at maximum velocity (highest
clenness capacity), only when the pipe downstream the mentioned section have been not yet
washed using the maximum obtainable flow velocity; this method to operate, give the
certitude of dirt removal during the following washing phase, to the maximum obtainable
velocity.

2.5 Applying this principle at lube oil system, the oil supply piping will be washed, section after
section, from oil tank to generator. Moreover the discharge lines will be washed in sequence
avoiding the dirt oil transportation into the discharge pipes already washed; therefore will be
run in sequence from generator extremity to oil tank.

2.6 The conception of "in sequence washing" as above described, is based on the maximum
obtainable velocity (compatibly with the pumps possibility) that can be reached in the piping
sections by an established and favorable convenience order.

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 The way to obtain the maximum velocity is realized applying this principle to the illustrative.
But the maximum flow velocity will be reached exploiting an other principle named "lines
separation". This, mainly, consists on operating the valves of the system in order to
concentrate the flushing effort into a particular pipe section obtaining in this way an higher
flow velocity.

That will be obtained opening all valves (within the pump motor absorption limits) downstream
the considered piping section; these valves can be installed on the main lines on the
branches of the same or on the secondary lines.

We can analyze the Fig. 2 sketch:

Fig. 2

A - B section flushing: open the valves of sections

B-C, B-D, B-F, BHE e BHG
B - H section flushing open the valves of sections H-E e H-G;
close the valves on lines B-F, B-C, B-D.

Employing the "lines separation" principle it will obtain a great advantage for washing
operation.

During the oil flushing the bearings will be by-passed using temporary pipes in order to have a
circuit resistance lower then the nominal one, so the centrifugal pumps oil flow will be higher
than normal operative flow..

The global flushing time of oil supply lines will be not less than 72 hours and however , what
requested and necessary to obtain the requested result.

STD-MI-315 Page 5 of 14
3.0 FLUSHING OIL TO BE USED

3.1 Washing oil will be the normal functioning oil.

At the end of flushing operation the oil shall be analyzed verifying that its quality have not
changed during the flushing maintaining the properties as per Supplier's specification. This is
very important in the case of units equipped with external coolers, using the interconnection
piping fabricated in site.

4.0 VIBRATIONS PRODUCING INTO THE PIPES TO BE WASHED

4.1 If applied with sense, the hammer or vibration machines utilization, to produce vibrations on
pipes during oil circulation, can give remarkable results for foreign materials separation from
the piping internal walls. (Particularly on the carbon steel).
An adequate organization and care to vibrate the piping can reduce the washing time and
increase the washing efficacy.

4.2 Piping vibration works in two ways. Firstly separe the particles from the piping internal walls.
Secondly, the vibration with high frequency, help to maintain in suspension the particles
permitting to the oil to bring them out easily.

The most efficacious of hammering number is about 80 strokes every 100 mm. of pipe
diameter, and for a length of 30 cm., using, with normal force, an hammer of 700 grams.

STD-MI-315 Page 6 of 14
 4.3 The pneumatic vibrators are very efficacious and can be used in parallel or replacing the
manual hammering.
They give normally 4000 - 7000 vibrations per minute. This kind of vibrators must be
installed directly on the pipes.
The pipe must be vibrated with energy to obtain a good result, while the welding will be
treated casually.
An vibrator can be installed in proximity of a line diameter changing.

5.0 IN PIPING AIR INJECTION

5.1 The air injection in some parts of the oil supply system creates the turbulence zones and
facilitates the solid particles separation from the pipes walls.
Collateral effect of the injection is the raising of some vibration.
Air injection under pressure (6-8 bar) for short periods (about 1 minute) opportunely separated
(about 15 minutes) will be carried out during the washing operations.

5.2 Connection will be made on each upright of oil supply piping base.

5.3 Connection to the main oil supply pipe will be made by a threaded bushing welded to the
main pipe, using temporary flexible pipes and manual valve to regulate air compressed
pressure.
Compressed air, if not yet separated from water condense and solid impurities, will pass
through a separator and fine filter before its injection in the oil supply main piping.

STD-MI-315 Page 7 of 14
 In case of branches near the gas turbine battery limits, can be adopted the following solution:

STD-MI-315 Page 8 of 14
 6.0 POLLUTION LEVEL

6.1 The oil must be clean till a residual pollution level in order to permit the continuous
functioning of bearings and alternator lifting pumps, without time limits avoiding deterioration
risks.
The experience made in the big units shows that the clean systems functioning with little
contaminated oil as showed in table n° 1, gives satisfactory results for the bearings.

6.2 Particles computation

6.2.1The dirt suspended particles quantity or "pollution level" can be measured counting the
particles contained into a sample.

A procedure to carry out this computation is contained in SAE, ARP-598 A (Society of

Automotive Engineers - Aerospace Recommended Practice) standard and can be using for
this scope. The procedure provides the filtration through a membrane-filter of a liquid known
volume. In this way, on the membrane surface settles the dirt contained in the liquid, and
consequently can be measured by means of a microscope.

The procedure recommends a classification in different sizes from the one’s recommended in
this instruction, but, generally, the methodology to obtain the computation is still applicable.

When a laboratory is available in site, it advisable to take the sample in clean bottles and to
carry out the computation in this laboratory.

6.3 Acceptable pollution level for the generator systems only

6.3.1For lube oil the followings instructions will be followed: (see Table n°1)

TABLE 1
Particles number for 100 milliliters (100 cc)

Granulometry Good Acceptable

(micron) (Lifting pumps) (except for functioning
with lifting pumps)

5 ÷ 10 50.000 150.000
10 ÷ 25 20.000 60.000
25 ÷ 50 3.500 10.000
50 ÷ 100 650 2.500
100 ÷ 250 40 150
> 250 0 0

NOTE: If a large quantity of particles measuring 50-70 microns are of particular matters as
metal, blowing ashes or something also, it must be found the origin and it is
recommended to reduce the quantity .

STD-MI-315 Page 9 of 14
 6.3.2 In case that a laboratory near the power station cannot be found, a "millipore Sample kit"
(catalogue number XX 6403730) can be used. The kit takes and filters a sample of 100 mm.
through a paper furnished with a pre-printed reticule ready for particles computation with a
microscope provided with a scale to determinate the dimensions. In case that a microscope is
not available, the total number of particles can be evaluated checking the change of paper
filter color compared with the calibrated samples.

6.3.3 The particles computation with laboratory analysis is part of the pollution control program
used for oil cleaning and the cleanness progress during the piping washing phase.

6.3.4 An other practical technique provides temporary small baskets or nets to use for each
bearing. To utilize this technique it must collect the dirt piled up in each basket or filter.
For each bearing it must prepare a graphic showing the dirt quantity for each sample
regarding the total hours of washing duration. That shall give an indication of cleanliness
condition of each oil supply line.
The graphic curve inclination will decrease compared with the line cleanliness level
increasing.
With these curves it can see that each supply line will release further dirt, every time shall be
used a different washing method (changing the oil temperature, hammering, etc.). This dirt
shall decrease keeping up the washing time and the curve shall indicate when the supply line
shall be cleaned.

6.4 Nets and filters

6.4.1 The net and filter openings are both evaluated in Mesh scale or micrometric scale. In the
following table are shown some measure normally used:

Linear Unit
Mesh/Linear inch UNI - Effective corresponding opening
US and ASTM
N° standard sieve Inches Microns
30 0,0232 590
60 0,098 250
100 0.059 149
200 0,029 74
325 0,017 44
400 0,0142 36

STD-MI-315 Page 10 of 14
NOTE: The net or filter openings do not identify necessarily the net capacity to remove the dirty; the
property will depend by the opening shapes as by the particles form and characteristic.

6.4.2 In a lube oil system, shall be installed 100 mesh filters in the piping upstream the orifices in
the bearings oil supply at the conclusive washing phase.

Note: The following point & sketch is referred to a generator driving only.
6.4.3 The control net positions on the main oil supply piping, from the turbine battery to the
generator, are here below shown:

For generator only

7.0 FLANGED COUPLING DISASSEMBLING

In an intermediate phase of piping washing, the flanged couplings of interconnection line

between L.B.T.G. and driven machine will be disassembled to check the dirt residual
absence that eventually entrapped in the step among the two flanges and internal diameter
of gasket ring. With the gasket disassembling and reassembling (after eventual coupling
border cleaning) will be evacuated the eventual residual dirt .

This operation shall be carefully carried out providing to protect and close the piping ends
temporary open, to avoid the entry of foreign material or dust in the already washed piping.

After the flanged coupling reassembling, the washing operations can pursue till its completion,
after the examination of nets/filters temporary installed upstream the generator users.

8.0 ANNEXES

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 The forms to certify the preparation and carrying out of flushing operations is the following:
è la seguente:
STD-MT-315. Oil flushing of piping in site fabricated.

Annexes: Table 2: Codes of Solid contaminant code.

Table 3: Comparison list with the international standards.

Table 2
Solid contaminant code - Tabular presentation
Number of particles per 100 ml.

CODE Over 5 m Over ai 15 m

Minimo Massimo Minimo Massimo

20/17 500 x 103 1 x 106 64 x 103 130 x 103
20/16 500 x 103 1 x 106 32 x 103 64 x 103
20/15 500 x 103 1 x 106 16 x 103 32 x 103
20/14 500 x 103 1 x 106 8 x 103 16 x 103

19/16 250 x 103 500 x 103 32 x 103 64 x 103

19/15 250 x 103 500 x 103 16 x 103 32 x 103
19/14 250 x 103 500 x 103 8 x 103 16 x 103
19/13 250 x 103 500 x 103 4 x 103 8 x 103

18/15 130 x 103 250 x 103 16 x 103 32 x 103

18/14 130 x 103 250 x 103 8 x 103 16 x 103
18/13 130 x 103 250 x 103 4 x 103 8 x 103
18/12 130 x 103 250 x 103 2 x 103 4 x 103

17/14 64 x 103 130 x 103 8 x 103 16 x 103

17/13 64 x 103 130 x 103 4 x 103 8 x 103
17/12 64 x 103 130 x 103 2 x 103 4 x 103
17/11 64 x 103 130 x 103 1 x 103 2 x 103

16/13 32 x 103 64 x 103 4 x 103 8 x 103

16/12 32 x 103 64 x 103 2 x 103 4 x 103
16/11 32 x 103 64 x 103 1 x 103 2 x 103
16/10 32 x 103 64 x 103 500 1 x 103

15/12 16 x 103 32 x 103 2 x 103 4 x 103

15/11 16 x 103 32 x 103 1 x 103 2 x 103
15/10 16 x 103 32 x 103 500 1 x 103
15/9 16 x 103 32 x 103 250 500

14/11 8 x 103 16 x 103 1 x 103 2 x 103

14/10 8 x 103 16 x 103 500 1 x 103
14/9 8 x 103 16 x 103 250 500
14/8 8 x 103 16 x 103 130 250

13/10 4 x 103 8 x 103 500 1 x 103

13/9 4 x 103 8 x 103 250 500
13/8 4 x 103 8 x 103 130 250

12/9 2 x 103 4 x 103 250 500

12/8 2 x 103 4 x 103 130 250

11/8 1 x 103 2 x 103 130 250

STD-MI-315 Page 12 of 14
From: Annexe “B” of ISO/DIS 4406 standards

Note: The above table covers the most usual series of codes between ranges 8 and
20. Other codes wich are not shown can be constructed from annexe “A”.

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 Table 3

Comparison list - International standards

ISO 4406 of IMPURITY NAS 1638 SAE ACFTD MIL STD

CETOP RP 70 H cm3 - 10m (1964) contents 1246 A

(1963) 3
mg/dm (1967)
26/23 140000 1000
25/23 85000 1000
23/20 14000 100 700
21/18 4500 12
20/18 2400 500
20/17 2300 11
20/16 1400 10
19/16 1200 10
18/15 580 9 6
17/14 280 8 5 300
16/13 140 7 4 1
15/12 70 6 3
14/12 40 200
14/11 35 5 2
13/10 14 4 1 0,1
12/9 9 3 0
18/8 5 2
10/8 3 100
10/7 2,3 1
10/6 1,4 0,01
9/6 1,2 0
8/5 0,6 00
7/5 0,3 50
6/3 0,14 0,001
5/2 0,04 25
2/8 0,01 10

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