Tp7702 Field Flushing MLO System

GE Power LM6000 – Universal Gen II
Gas Power Systems Operation & Maintenance
TP TECHNICAL PROCEDURE 7702

Field Flushing MLO System
Purpose & Scope
The purpose of this procedure is to provide instructions for pre-start flushing of the Mineral
Lube Oil (MLO) System with either a Plate & Frame or Fin-Fan Lube Oil Cooler.
Prerequisites
MLO system installation should be complete and the system inspected. Always refer to your
site-specific F&IDs to ensure proper installation of all blinds, screens, and jumper hoses.
When performing the flushing procedure, a hard copy of the site-specific F&ID is to be made
for the specific purpose of marking all locations of installed flushing kit items to ensure all kit
hardware is removed and accounted for prior to unit start up.
It is possible to use the MLO reservoir and heater if ambient conditions allow a constant
flushing oil temperature of approximately 120 °F to 140 °F. It will be necessary to have the
correct voltage available for the heaters. If an alternate source of power is used to energize
the heaters, care must be taken and tank temperature must be closely monitored. If
flushing activities are suspended, ensure tank heaters are secured.
NOTICE
It is recommended that all customers use only GE-approved Flush Kits.
Care must be taken not to allow contamination of the system prior to, during, or after completion of
flushing. Cover all open piping connections to prevent entry of foreign objects and debris.
The Lube Oil Cooler should come from the Supplier clean, and with a pre-charge of nitrogen to keep
out contamination. In the event that the cooler somehow becomes contaminated, the cooler should
be flushed separately from the rest of the system, and with clean oil.
Do not flush dirty oil through the Cooler or the Gearbox.
CAUTION
CARE MUST BE TAKEN TO PREVENT CONTAMINATION OF THE LUBE OIL SYSTEM PRIOR TO, DURING, OR
AFTER COMPLETION OF SAMPLING. COVER ALL OPENINGS TO PREVENT ENTRY OF FOREIGN DEBRIS
AND OBJECTS.
TP7702 Rev. 1.1

Field Flushing MLO System Page 1 of 17
CAUTION
USE ONLY APPROVED PADDLE BLANKS, BLINDS AND PLUGS. DO NOT USE HOME-MADE OR LOCALLY
MANUFACTURED BLANKS. ALL BLANKS AND BLINDS SHALL HAVE RED PAINTED SHANKS AND
IDENTIFICATION NUMBERS. THESE IDENTIFICATION NUMBERS SHALL BE USED WHEN MAKING
ANNOTATIONS ON THE HARD COPY F&ID FOR FLUSHING KIT HARDWARE INSTALLATION AND
REMOVAL.
NOTICE
For units with Reduction Gearboxes (RGB), more time should be allotted for flushing. Do not flush
through the gearbox until system has been flushed and is clean.
NOTICE
Lab analysis shall be performed to determine cleanliness of the system.
For units with a Reduction Gearbox (RGB) the RGB specifications supersede those of the generator.
The cleanliness requirement for Mineral Lube Oil systems with RGB is ISO 4406 17/14/11.
Otherwise, refer to the Generator Manufacturer’s O&M Manual for requirements.
Isolation of the Reduction Gearbox
This section covers the steps needed to isolate the gearbox, out of the initial flushing loop on
50 Hz units. Gearbox flushing should ONLY happen after the rest of the lube oil system has
received an acceptable oil analysis report.
a) Remove Generator/Gearbox Supply check valve on Gearbox supply line and braided
hose (refer to F&ID X-504248).
b) Install 4” 150 lb. flange x 1 ½ JIC male (refer to TP7108, MLO6000 Item 7) onto
braided hose flange. Mark location of flushing kit hardware installation on F&ID for
future reference.
c) Use kit-supplied flushing hoses 1 ½” x 10’ long (ref. TP7108, MLO6000 Item 3) and 1
½” JIC male x 1 ½” JIC male (refer to TP7108, GEN Item 1) as required to reach
Generator non-driven end bearing drain line. See Figure 1b. This hose end will be
attached using the 1 ½” JIC male T (refer to TP7108, MLO6000 Item 8) in a later step
in this procedure. Mark locations of flushing kit hardware installation on F&ID for
future reference.
d) Install 100-Mech screen on the 12” return line of the Gearbox. (refer to TP7108, CON
Item 1) Mark location of flushing kit hardware installation on F&ID for future
reference.
TP7702 Rev. 1.1

4” 150 lb flange x 1 ½ JIC male fitting
Flushing hoses 1 ½” x 10’ long and 1 ½” JIC male x 1 ½” JIC male
TP7702 Rev. 1.1

Figure 1a. – Simplified diagram for flushing kit items installation (Fin Fan option shown)
Recommendation:
Install kit-supplied
Remove thermostat
100-Mesh on
from AMOT valve
cooler supply side
body and insert 2”
ball valve.
paddle blind on “B”
side of valve;
reinstall AMOT valve
in correct position.
Using identified
items from the
flushing kit install
a 1 ½” paddle
Install kit-supplied 100-Mesh
- Paddle Blind/Blank # - 100 Mesh Screen on GLO tank return lines and
blind on bearing
supply line & a 4”
- Disconnect on supply side to cooler paddle blind on
the bearing drain
line of generator
non-driven end.
Close off ball

valve from
jacking oil supply
to jacking oil
pump
Using identified
items from the
flushing kit create
Using identified
a jumper from
items from the
Gearbox supply
flushing kit
line to Generator
create a jumper
driven end
from bearing
bearing drain line.
supply line to
bearing drain
line on
Install 100-Mesh
generator driven
screen on
end.
Gearbox oil drain
line
- Paddle Blind / Blank # - 100 Mesh Screen - Disconnect
Figure 1b. – Simplified diagram for flushing kit items installation
TP7702 Rev. 1.1

NOTICE
Match-mark Thermostatic Control Valve for proper positioning upon reinstallation.
MLO Flushing Instructions:
1. Remove “AMOT” thermostatically controlled lube oil valve (TCV-0000) (Reference

figure 1 and project specific F&ID Mineral Lube Oil System).
2. Remove four fasteners from “AMOT” valve top and remove top.
3. Remove thermostat from valve body and reinstall top. Ensure O-ring is properly
seated on valve top prior to installation.
4. Reinstall “AMOT” valve in correct position as previously marked, inserting a 2” paddle
blind (ref. TP7108 MLO-6000, Item 4) on “B” side of valve. Mark location of flushing kit
hardware installation on F&ID for future reference.
NOTICE
Installing paddle blind on “B” side of valve will force oil to flow through the cooler.
Generator Lube Oil AMOT Valve & Paddle Blind
5. Fill oil tank with GE recommended generator lube oil and heat to 120 °F to 140 °F.
Allow sufficient time for oil to reach correct temperature. Lock fill cap, if applicable.
TP7702 Rev. 1.1

6. Install kit-supplied “100-Mesh” screen on generator lube oil tank return lines and on
supply side to cooler. It is also recommended that 100-Mesh screen also be installed
on the cooler supply ball valve flange. Mark locations of flushing kit hardware
installation on F&ID for future reference.
NOTICE
“100-mesh” screen is provided in flush kit. it comes in a roll and must be cut to proper size.
NOTICE
Protect check valve from exposure to atmosphere and contamination.
7. Remove bearing supply line and check valve from Generator driven end.
8. Remove bearing drain line from Generator driven end.
9. Install 1½" flange connection (ref. TP7108 MLO-6000, Item 2) and gasket on one end
of jumper hose (ref. TP7108 MLO-6000), Item 3) and 4" flange connection (ref TP7108
MLO-6000, Item 1) and gasket on other end of hose. Mark locations of flushing kit
hardware installation on F&ID for future reference.
1½" flange connection and 4" flange connection
10. Install jumper hose (ref. TP7108 MLO-6000, Item 3) onto flange connections on
supply line and drain line, this will all the lube oil to bypass the driven end bearing
during flushing. Mark location of flushing kit hardware installation on F&ID for future
reference.
TP7702 Rev. 1.1

1½" Flange
Connection
& Hose
Figure 2 – Bypass Generator Drive End Bearing
11. Remove bearing supply line from Generator non-driven end bearing and remove
check valve (refer to figure 2).
NOTICE
Oil may be present in line, be prepared to catch oil. Also, protect check valve from exposure to
atmosphere and contamination.
12. Install 1 ½”flange blank off (ref. TP7108 MLO-6000, Item 5) with gasket and
reconnect bearing supply line (figure 3). Mark location of flushing kit hardware
1 ½”flange blank off
TP7702 Rev. 1.1

Check Valve
Removed
Paddle
Blind
Figure 3 - Paddle Blind Installation
13. Disconnect bearing drain line from Generator non-driven end and install 4” paddle
blind (ref. TP7108, MLO6000, Item 10) with gasket and reconnect drain line. Mark
location of flushing kit hardware installation on F&ID for future reference.
4” 150 lb. Paddle Blind
14. Connect jumper hose from Gearbox oil supply side to jumper hose on Generator
driven end using 1 ½” JIC male T (ref TP7108, MLO6000 Item 8) as noted in previous
steps.
TP7702 Rev. 1.1

1 ½” JIC Male T
15. Close off ball valve from jacking oil supply line to jacking oil pump.
16. With lube oil elements removed, select one side of filter assembly for operation and
lock into place (Refer to Figure 4).
Figure 4 - Generator Duplex Lube Oil Filters
17. Verify lube oil pump suction and discharge valves are open.
18. Verify coolers are ready for operation. Select and lock one side for operation.
19. Verify pump pressure instrumentation isolation valve is open and all other affected
instrumentation isolation 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
communications with each other (radio). This is for safety and environmental concerns.
TP7702 Rev. 1.1

20. When directed, bump-start the pump. Verify correct rotation.
Figure 5 - Generator Lube Oil Pumps (2 AC/1 DC)
21. Start pump and quickly observe for leaks. If leaks occur, shut down pump, repair
leaks and restart.
22. 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 the tank will indicate cooler cleanliness condition, while the
screen in the supply to cooler will indicate integrity of lube oil piping and tank.
23. Clean, or replace, and reinstall screens.

24. Start pump and allow to run for 30 minutes.
25. After 30 minutes of run time, shut down pump and inspect screens for cleanliness.
27. Start pump and allow to run for 2- to 3-hour intervals.
28. 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.
29. Every 2 to 3 hours, shut down pump, inspect, clean or replace and reinstall 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 on
screen and grittiness is not detectable to the touch.
30. Install one filter into system and check Delta P.
31. Run for two hours. If Delta P is 5 or below, remove filter and continue with other
steps.
TP7702 Rev. 1.1

NOTICE
Lab analysis shall be performed to determine cleanliness of the system. Refer to the Generator
Manufacturer’s O&M Manual for requirements.
NOTICE
When circulating the lube oil around the system pipework after flushing has been completed, or after
a service, ensure you check that the sight glasses have oil running through them and pipework is
getting hotter. This should indicate the system is functioning properly.
CAUTION
FAILURE TO VERIFY POSITIVE OIL FLOW TO THE BEARINGS (USING SIGHT GLASSES ON THE
GENERATOR RETURN OIL LINES) WILL RESULT IN SERIOUS EQUIPMENT DAMAGE/FAILURE.
Evaluation and Setup for Test
1. Evaluation of cleanliness shall be accomplished by the Mechanic of Testing and

approved by the Quality Control Inspector. The seller’s representative and site Quality
Control Inspector must witness the flushing of the system and approve the
cleanliness of the flush.
CAUTION
DO NOT FLUSH THE GEARBOX UNTIL AFTER THE JACKING OIL SYSTEM HAS BEEN FLUSHED AND
APPROVED AS CLEAN BY SELLER’S REPRESENTATIVE AND SITE QUALITY CONTROL INSPECTOR.
2. After the system has been deemed clean and ready for operation, refer to the hard
copy of the F&ID that was used to mark all locations of installed flushing kit items to
ensure all kit hardware is removed and accounted for prior to unit start up.
NOTICE
Ensure check valves are installed in proper position. Verify flow direction arrow is pointing toward
the direction of flow.
TP7702 Rev. 1.1

3. Reinstate all piping and check valves as referenced in the marked up F&ID.
4. Disconnect all jumper hose set ups from Generator driven end and Gearbox supply
side. Reinstall check valves and reconnect supply lines and drain lines. Annotate on
the hard copy of the F&ID that all kit hardware has been removed.
5. Remove the “AMOT” valve and remove the 2” paddle blind (ref. TP7108 MLO-6000,
Item 4) on “B” side of AMOT valve and annotate on the hard copy of the F&ID that the
blind has been removed.
6. Reinstall the thermostat in the “AMOT” valve body and reinstall valve in accordance
with markings to ensure proper positioning.
CAUTION
ENSURE VALVE IS INSTALLED IN SAME DIRECTION AS REMOVED. FAILURE TO INSTALL VALVE
CORRECTLY WILL RESULT IN SERIOUS EQUIPMENT FAILURE.
7. Remove the 1 ½” flange blank off has been removed (ref. TP7108 MLO-6000, Item 5),
reinstall check valve and reconnect Generator non-driven end supply line. Annotate
on the hard copy of the F&ID that the flange blank off has been removed.
8. Remove 4” paddle blind from Generator non-driven end bearing drain line. Annotate
on the hard copy of the F&ID that the blind has been removed.
9. Do not remove the installed 100-Mesh screens as referenced on the F&ID marked up
copy; these will remain in place until after the completion of the Gearbox Flush.
10. Open filter canisters and install new filter elements.
11. Properly align three-way water valve to lube oil cooler (for Shell & Tube).
12. Properly align three-way oil valve to lube oil cooler.
13. Open affected instrument isolation valves.
14. Lube oil system is now ready for jacking lube oil system flushing.
NOTICE
“Fisher” Pressure-Regulating Valve may need to be adjusted for proper operation. When system is in
operation, set valve to regulate between 28 – 32 psig.
TP7702 Rev. 1.1

Jacking Oil System Flushing Procedure
These instructions are for pre-start flushing of the Jacking Oil System components and
piping furnished by GE. This procedure should follow the flushing of the Generator Lube Oil
System. The materials for field flushing are provided in the Flushing Kit. For inventory of the
flushing kit and required materials for field flushing the jacking lube oil system, reference
TP7108 located in the O&M.
It is possible to use the GE generator lube oil reservoir and heater if ambient conditions allow
a constant flushing oil temperature of 120° – 140° F. It will be necessary to have the correct
voltage available for the generator lube oil reservoir heater.
NOTICE
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.
1. Disconnect jacking oil supply line at non-driven end of generator (refer to Figure 6).
2. Disconnect the three jacking oil supply lines at driven end of generator (refer to Figure 6).
Figure 6 - Jacking Oil Supply Lines

Non-Driven End Driven End
3. Connect hoses from flushing kit, to disconnected jacking oil supply lines on driven
and non-driven end of generator. Mark location of flushing kit hardware installation
on F&ID for future reference.
4. Connect kit-supplied hose and connector (ref. TP7108 JOF, Item 2) to jacking oil
supply line on non-driven end of generator. Mark location of flushing kit hardware
TP7702 Rev. 1.1

5. Close affected instrumentation isolation valves.

6. Verify filters are installed in system.
7. Start AC generator lube oil pump and allow system to stabilize to normal operating
pressure (28 – 32 psig). Adjust regulator as required to obtain normal operating
pressure per TP7705 Setting Jacking Oil Pump Pressures.
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. It may be
difficult to observe for correct rotation due to the position of the pump, however an increase in
jacking oil pressure indicates correct rotation.
8. When directed, bump-start the jacking oil pump. Verify correct rotation and inspect
for leaks.
Figure 7 - Jacking Oil Pump
9. Start jacking oil pump and run for 2 to 5 minutes, then shut down pump and inspect
screens for cleanliness.
TP7702 Rev. 1.1


13. Continue this operation until all foreign matter has been removed. Cleanliness is
NOTICE
Lab analysis shall be performed to determine cleanliness of the system. Refer to the Generator
Manufacturer’s O&M Manual for requirements.
NOTICE
Check pipes before final assembly for contamination and blockage, (debris, paper etc.) And it’s
correct installation. After flushing and the MLO system is restarted, staff must check sight glasses
downstream the bearing for positive flow.

Control Inspector must witness the flushing of the system and approve cleanliness of
the flush.
2. Remove hoses and fittings from jacking oil supply lines and reconnect lines. Annotate
on the hard copy of the F&ID that the hardware has been removed.
3. Open affected instrument isolation valves.
4. Check level in generator lube oil reservoir and refill as necessary.
5. Lube Oil System is now ready for Gearbox flushing procedure.
Gearbox Flushing procedure
The following steps will allow you to flush the gearbox and be sure the most possible dirt
is collected by the 100-Mesh screens.
NOTICE
For units with speed Reduction Gearboxes (RGB), more time should be allotted for flushing. Do not
flush through the gearbox until the oil system has been flushed and is clean.
TP7702 Rev. 1.1

NOTICE
For both Flender and Lufkin gearboxes, the preservation product used on the inside dissolves during
the flushing of the lubrication system without harming the lube oil.
1. Install a 100-Mesh screen on the supply line side (refer to F&ID X-504248). Mark
location of flushing kit hardware installation on F&ID for future reference.
2. Install a 100-Mesh screen on the return line of the Gearbox. Mark location of flushing
kit hardware installation on F&ID for future reference.
3. Start pump and quickly observe for leaks. If leaks occur, shut down pump, repair
leaks and restart.
4. 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 the tank will indicate cooler cleanliness condition, while the
screen in the supply to cooler will indicate integrity of lube oil piping and tank.

7. After 30 minutes of run time, shut down pump and inspect screens for cleanliness.
9. Start pump and allow to run for 2- to 3-hour intervals.
10. 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.
11. Every 2 to 3 hours, shut down pump, inspect, clean or replace and reinstall screens.
Continue this operation until all foreign matter has been removed. Cleanliness is
12. Install one filter into system and check Delta P.
13. Run for two hours. If Delta P is 5 or below, remove filter and continue with other
steps.
TP7702 Rev. 1.1

NOTICE
Lab analysis shall be performed to determine cleanliness of the system.
For units with a Reduction Gearbox (RGB) the RGB specifications supersede those of the generator.
The cleanliness requirement for Mineral Lube Oil systems with RGB is ISO 4406 17/14/11.
Otherwise, refer to the Generator Manufacturer’s O&M Manual for requirements.
NOTICE
When circulating the lube oil around the system pipework after flushing has been completed, or after
a service, ensure you check that the sight glasses have oil running through them and pipework is
getting hotter. This should indicate the system is functioning properly.
CAUTION
FAILURE TO VERIFY POSITIVE OIL FLOW TO THE BEARINGS (USING SIGHT GLASSES ON THE
GENERATOR RETURN OIL LINES) WILL RESULT IN SERIOUS EQUIPMENT DAMAGE/FAILURE.

Control Inspector must witness the flushing of the system and approve the cleanliness of
the flush.
2. Remove all installed 100-Mesh screens as referenced on the F&ID marked up copy.
Annotate on the F&ID that the flushing hardware has been removed.
3. Generator and Jacking Lube Oil System are now ready for commissioning machine.
TP7702 Rev. 1.1


Tp7702 Field Flushing MLO System

Uploaded by

Copyright:

Available Formats

Tp7702 Field Flushing MLO System

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Tp7702 Field Flushing MLO System

Uploaded by

Copyright:

Available Formats

GE Power LM6000 – Universal Gen II

Gas Power Systems Operation & Maintenance

TP TECHNICAL PROCEDURE 7702

TP7702 Rev. 1.1

Isolation of the Reduction Gearbox

TP7702 Rev. 1.1

4” 150 lb flange x 1 ½ JIC male fitting

Flushing hoses 1 ½” x 10’ long and 1 ½” JIC male x 1 ½” JIC male

TP7702 Rev. 1.1

Close off ball

- Paddle Blind / Blank # - 100 Mesh Screen - Disconnect

Figure 1b. – Simplified diagram for flushing kit items installation

TP7702 Rev. 1.1

MLO Flushing Instructions:

1. Remove “AMOT” thermostatically controlled lube oil valve (TCV-0000) (Reference

Generator Lube Oil AMOT Valve & Paddle Blind

TP7702 Rev. 1.1

1½" flange connection and 4" flange connection

TP7702 Rev. 1.1

Figure 2 – Bypass Generator Drive End Bearing

1 ½”flange blank off

TP7702 Rev. 1.1

Figure 3 - Paddle Blind Installation

4” 150 lb. Paddle Blind

TP7702 Rev. 1.1

Figure 4 - Generator Duplex Lube Oil Filters

TP7702 Rev. 1.1

20. When directed, bump-start the pump. Verify correct rotation.

Figure 5 - Generator Lube Oil Pumps (2 AC/1 DC)

23. Clean, or replace, and reinstall screens.

TP7702 Rev. 1.1

Evaluation and Setup for Test

1. Evaluation of cleanliness shall be accomplished by the Mechanic of Testing and

TP7702 Rev. 1.1

TP7702 Rev. 1.1

Jacking Oil System Flushing Procedure

Figure 6 - Jacking Oil Supply Lines

TP7702 Rev. 1.1

5. Close affected instrumentation isolation valves.

Figure 7 - Jacking Oil Pump

TP7702 Rev. 1.1

12. Clean, or replace, and reinstall screens.

Evaluation and Setup for Test

1. Evaluation of cleanliness shall be accomplished by the Mechanic of Testing and

Gearbox Flushing procedure

TP7702 Rev. 1.1

5. Clean, or replace, and reinstall screens.

TP7702 Rev. 1.1

Evaluation and Setup for Test

1. Evaluation of cleanliness shall be accomplished by the Mechanic of Testing and

TP7702 Rev. 1.1

You might also like