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TABLE OF CONTENT 

1. PURPOSE 3

2. SCOPE 3

3. OBJECTIVES 3

4. REFERENCES 4

5. HSE 5-
6
6. ROLES & RESPONSIBILITY 7

7. THREATS & MITGATIONS 8

8. PROCEDURE 9-
1
9. ATTACHMENT

SCHEMATIC DIGRAM BY GE FOR LUBE OIL FLUSHING

 JSA

 
 
 
 
 
 
 
   
 
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1. Purpose
The purpose of this procedure is to:

 Ensure that Lube Oil Flushing is carried out safely.

 Detail the necessary steps to carry out Lube Oil flushing in accordance with Vendor
requirements RIC8990006 / 4 Rev.7.
 Outline all steps necessary to meet oil cleanliness standards in line with API 614 PARA
4.3.3.7.1 for test screen cleanliness and acceptability criteria for oil analysis in
accordance with ISO 4406 class 15/12.

Note: Class 15/12 means that there are more than 160 and up to and including 320
particles equal to or larger than 4 μm per millilitre and more than 20 and up to and including
40 particles equal to or larger than 6 μm per millilitre.

2. Scope
This procedure outlines the preparation, execution, acceptance criteria and reinstatement
activities necessary to successfully complete lube oil flushing activities at Gas Turbine
Generator 51-MJ01-A/B/C/D.
The following circuits were identified by Vendor for Lube Oil Flushing;

1. Lube oil short circulation bypassing Lube Oil Cooler

2. Lube oil short circulation including Lube Oil Cooler
3. Lube oil long circulation on main circuit
4. Hydraulic oil circuit.
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3. References

Title Document

GE OIL & GAS GENERAL NOTES FOR

RIC8990006 / 4 Rev. 7
OIL SYSTEM FLUSHING

GE OIL & GAS TURBOGENERATOR

INSTALLATION & SECTION 7
PRECOMMISSIONING

SCHEMATIC DIAGRAM LUBE OIL

GNL3Z-V-405073-0150 sh.1
AUXILIARY SYSTEM

SCHEMATIC DIAGRAM OIL COOLER

GNL3Z-V-405073-0152
SYSTEM

SCHEMATIC DIAGRAM STARTING

GNL3Z-V-405073-0154
MEANS SYSTEM

SCHEMATIC DIAGRAM LUBE OIL

GNL3Z-V-405073-0150 sh. 2
TURBINE SYSTEM

SCHEMATIC DIAGRAM GENERATOR

GNL3Z-V-405073-0150 sh. 3
SYSTEM

SCHEMATIC DIAGRAM OIL VAPOUR

GNL3Z-V-405073-0151
SEPARATOR SYSTEM

SCHEMATIC DIAGRAM HYDRAULIC

GNL3Z-V-405073-0149 sh. 3
RATCHET SYSTEM

SCHEMATIC DIAGRAM HYDRAULIC

GNL3Z-V-405073-0149 sh. 1
OIL SYSTEM
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SCHEMATIC DIAGRAM IGV SYSTEM GNL3Z-V-405073-0149 sh. 2

SCHEMATIC DIAGRAM FUEL GAS

GNL3Z-V-405073-0144 sh. 1
SKID SYSTEM

SCHEMATIC DIAGRAM FUEL GAS DLN

GNL3Z-V-405073-0144 sh. 2
SKID

GENERAL SPECIFICATION LUBE OIL

318800-GNL3Z-ST-PR-00-79026
AND SEAL OIL FLUSHING

WASTE MANA WASTE MANAGEMENT

318800-GNL-3Z-AP-EV-00-85041
PLAN GEMENT PLAN

CONSTRUCTION HSE Plan 318800-GNL-3Z-AP-SE-85001

318800-GNL-3Z-AP-SE-85022
HSE REQUIREMENTS FOR SUBCONTRACTORS

318800-GNL-3Z-AP-EV-00-85040
CONSTRUCTION ENVIRONMENTAL
MANAGEMENT PLAN

POLLUTION CONTINGENCY PLAN FOR

318800-GNL-3Z-AP-EV-00-85042
CIVIL WORKS

4. HSE
4.1. General

It is both Contractor and Client policy to integrate Health, Safety, Environment and Risk
Management into every aspect of its business activities: to this end the Contractor
(SAIPEM), Subcontractor (LEAD) and Vendor (GE Nuovo Pignone) will act positively to
prevent injury to personnel and damage to facilities and the environment.
At all times the Contractor, Subcontractor and Vendor will comply with all safety, fire and
environmental laws and regulations without regard to the degree of enforcement.
All Pre-Commissioning activities will be performed following general principles of effective
HSE management and in accordance with the applicable site execution plan requirements
for safety and working environment. HSE shall be built into the Pre-Commissioning work at
procedure and Method statement level and will be reflected in all work activities.
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Contractor Pre-Commissioning Focal Point for these activities will ensure that:
 Subcontractor and Vendor understand and adhere to all Project Health, Safety and
Environmental policies and standards.
 Relevant standards, good engineering practise and principles of risk management are
applied at all times.
 Immediately rectify areas where deficiencies exist.
 The acceptance of responsibility at and from the top, exercised through a clear chain
of command throughout the activities, including Subcontractor and Vendor.
 A conviction that high standards are achievable through proper management.
 Every member of Contractor, Subcontractor and Vendor has a duty to ensure that all
Project policies and principles are adhered to, to take all necessary steps to reduce
risk to personnel and facilities.

4.2 Specific issues

In addition to adherence to site execution and HSE plans the following specific safety
issues are to be addressed prior to the commencement of each activity.

    PPE 
 The use of PPE is mandatory for all Contractor, Vendor and Subcontractor members.
Any additional safety equipment required for specific tasks will be made available
prior to commencement of any activities by Subcontractor.

                         Material Safety Data Sheet (MSDS) 
 MSDS for all Oils and additional chemicals used during Lube Oil Flushing activities
must be available at worksite in a visible location and a copy must also be attached to
the Work Permit.

                       Tool   Box Meetings             
 Prior to the commencement of activities the Contractor Pre-Commissioning Focal
Point will ensure that Subcontractor, Vendor and Discipline Engineers involved in the
tasks participate in joint Toolbox meeting to ensure that everyone taking part
understands the activities that are taking place and what actions must be taken to
ensure a safe work place.
 When a step is reached in the procedure which requires modification to the Lube Oil
Flushing circuit then the Contractor Pre-Commissioning Focal Point will ensure that all
personnel involved in these activities clearly understand the sequence of events that
must be executed before proceeding.

                  Job Safety Analysis 
 Prior to all activities the Contractor and Subcontractor Pre-Commissioning Focal
Points will jointly prepare a JSA for the activities which must then be clearly
communicated to all personnel involved in the activities.
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                    SIMOPS 
 The Contractor Pre-Commissioning Focal Point will jointly, with the Contractor Pre-
Commissioning HSE Supervisor and Subcontractor Pre-Commissioning Focal Point,
review on a daily basis SIMOPS issues that might affect the safety of personnel or
facilities prior to the commencement of Lube Oil Flushing activities. Procedure P13
SIMOPS Management at Site will be utilized during these activities.

                        Permit to Work 
 The Construction Permit to Work procedure will be used for these activities.

                    Electrical Hazards      
 As a temporary Generator Set will be utilised for these activities it is Contractor and
Subcontractor responsibility to ensure that all equipment and temporary cabling is
suitable for use prior to the commencement of energization.
5. Roles AND Responsibilities
5.1 Contractor Pre-Commissioning Focal Point (SAIPEM)

 Has overall responsibility for coordinating Pre-Commissioning activities in

support of Lube Oil Flushing between Vendor, Subcontractor and Discipline
Engineers.
 Has responsibility for organizing and executing testing to meet acceptance
criteria as outlined by Vendor.

5.2. Subcontractor Pre-Commissioning Focal Point (LEAD)

 Has day to day responsibility for coordinating Pre-Commissioning activities in

support of Lube Oil Flushing and will be responsible for ensuring;
 Correct Tools and equipment are available for executing Lube Oil Flushing.
 Ensure that suitably qualified personnel with Supervision are available to
provide 24 hour coverage during Lube Oil Flushing.
 Confirm that shift handovers will be carried out at GTG.
 Ensure that an emergency plan is in place so that in the event of an
emergency such as fire, loss of containment or injury that everyone involved
in the activities are fully aware of contingencies.
 Communication plan is in place ensuring that contact numbers for key
personnel are in place.
 Prepare a safety Plan.
 Ensure that adequate lighting is available at night.
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 Ensure that all Subcontractor personnel understand scope of work and there
responsibilities.

5.3. Contractor Pre-Commissioning HSE Supervisor (SAIPEM)

 Has responsibility for informing all adjacent work groups what activities are
taking place and associated risks.
 Ensure that Tool box meetings are carried out correctly and that all personnel
involved in Lube Oil Flushing activities are aware of any risks.
 Will also assist the Pre-Commissioning Focal point with the preparation of JSAS,
barriers and other precautions as outlined in the safety plan.

5.4 Vendor Focal Point (GE Nuovo Pignone)

 Provide Technical support and carry out pre-determined checks prior to and
during Lube Oil Flushing activities.
 Ensure that temporary Electrical connections are correctly implemented.

5.5 Rotating Equipment Specialist (SAIPEM)

 Verify checks made by Vendor and liaise with Contractor Pre-Commissioning

Focal point to ensure that adequate spares such as gaskets, filters etc. are
available.
Threats AND Mitigations
5.1. Threats and Mitigations during Lube Oil Flushing

Environmental Impact 
 The potential for Lube Oil leaks during Lube Oil Flushing is real so measures
most be put in place to minimise spills and coordinate clean ups. Spill kits will be
supplied by Subcontractor.
 Risk of fire is low however portable fire extinguishers will be on hand and
available for use if required. Suggest that CO2 hand held extinguishers be used
to minimise damage to equipment. Ensure that all personnel involved in this
activity are aware of hazards associated with CO2 and have been trained to use
extinguishers.

SIMOPS 
 During Lube Oil Flushing no other activities except those being directed by
Vendor will be allowed within the vicinity of the GTG.
 Loop Testing will be in progress during Lube Oil Flushing. Care must be taken to
ensure that Lube Oil Flushing is not interrupted.
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Spare Parts 
 It is Rotating Equipment Specialist responsibility to ensure that adequate spare
parts are available (obviously not every contingency can be planned for however
Vendor will determine what is considered necessary for the task at hand).

6. PROCEDURE
6.1. Specific pre-start activities and considerations

1. Blowing with clean, dry and oil free air will be executed in the following systems as
advised by Vendor;

a. Lube Oil Flushing Circuit

b. Oil Vapour Separator Circuit
c. Hydraulic Oil Flushing Circuit
 

2. Lube Oil Tank must be inspected for Cleanliness prior Lube Oil Flushing.
3. Three random samples of Lube Oil must be taken from drums to be used as baseline
reading for cleanliness prior to Lube Oil Filling.
4. All orifice plates required must be removed prior to air blowing and Lube Oil Flushing
and stored in a safe location until final reinstatement after the completion of Lube Oil
Flushing.
5. All instruments except those designated by Vendor must be removed and stored in a
safe location. (Such as gauges, transmitters and switches).
6. All instrument root valves in Lube Oil Circuits must be tagged and closed prior to Air
Blowing and Lube Oil Flushing.
7. Prefabricated temporary spools may be required at control valve locations (utilise hoses
may not be practicable where space is an issue).
8. All removed valves must be taped to ensure that internals remain clean and stored in a
safe location.
9. To avoid contamination of the on skid Lube Oil System, the off-skid Lube Oil Cooler will
have a dedicated basket strainer installed prior to return of oil to the Lube Oil Tank. The
100 Mesh basket strainer must have isolation valve so that frequent cleaning can be
carried with minimal loss of oil.
10. Control valve bypasses must be flushed during Lube Oil Flushing.
11. Install all designated temporary hoses, permanent filters and temporary mesh screens
prior to leak testing.
12. Temporary mesh screens must be installed so that any debris will be easily removable
during inspections.
13. All temporary restriction orifices should be Stainless Steel, while temporary blinds and
spades can be carbon steel.
14. Leak testing with dry, clean and oil free air is the last activity prior to filling the circuit with
Flushing Oil.
15. Ensure that Aux. Lube Oil Pump PL-2 and Lube Oil Heater 23QT-1/2/3/4 are available
utilising temporary power prior to start the Lube Oil Flushing activities.

Warning: Lube Oil Heaters 23QT-1/2/3/4 must be switched off when Aux. Lube Oil Pump
PL-2 is not running.

Note: All instrument tags indicated in this procedure are related to Gas Turbine Generator
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51-MJ01-A. For 51-MJ01-B increase all instrument tag numbers of 500, for 51-MJ01-C
increase all instrument tag numbers of 1000 and for 51-MJ01-D increase all instrument tag
Step Description Qty Comments
100 Mesh basket strainer on 10”
4 1 Require isolation valve for cleaning.
manhole of Lube Oil Tank
5 Rated Hose and Clamp 1 To connect TP-120 to basket strainer.
7 Pressure Gauge PG-5158 1 Ensure calibration is current.
numbers of 1500.

Step 1: Lube oil short circulation bypassing Lube Oil Cooler

Procedure 

1. Remove the TCV-5184, installing a proper three ways piping spool.

2. Remove the restriction orifice RO-5240.
3. Turn in close position the spectacle blind on TP-121 and relocate the spectacle blinds on
three ways spool so as to close the supply line from the cooler.
4. Install 100 Mesh basket strainer on Lube Oil Tank.
5. Install by-pass hose from TP-120 to the 100 Mesh basket strainer, with isolation valve
before it in order to control the oil flow and to allow basket strainer cleaning.
6. Isolate the PT-5183 and LT-5175.
7. Start the Aux. Lube Oil Pump PL-2 for the first time just run for 1 minute and monitor
pump discharge pressure with PG-5158. Start flushing the circuit and verify the
cleanliness of the 100 Mesh basket strainer.
8. Energize the Lube Oil Tank Heaters 23QT-1/2/3/4 and monitor the oil temperature with
TG-5181.
9. Continue the flushing until acceptance criteria for particulate at basket strainer is
satisfied and then proceed to Step 2.

Material Requirements 

 
Step 2: Lube oil short circulation including Lube Oil Cooler

Procedure 

1. Relocate the spectacle blinds on three way spool so as to isolate the lube oil cooler by-
pass line and turn in closed position the spectacle blind on TP-121.
2. Install 100 Mesh strainer on TP-121 at inlet of Lube Oil Cooler.
3. Install 100 Mesh strainer on TP-120 at inlet of the temporary hose.
4. Start the Aux. Lube Oil Pump PL-2 and monitor pump discharge pressure with PG-5158.
5. Energize the Lube Oil Tank Heaters 23QT-1/2/3/4 and monitor the oil temperature with
TG-5181.
6. Continue flushing cycle until acceptance criteria for particulate at TP-120, TP-121 and
basket strainer is satisfied and then proceed to Step 3.
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Material Requirements 

Step Description Qty Comments

2 100 Mesh Screen 6” 1 At TP-120.
3 100 Mesh Screen 6” 1 At TP-121.

Step 3: Lube oil long circulation on main circuit

Procedure 

1. Remove 100 Mesh at TP-120 and make up joint with final gasket
2. Confirm that cartridge filter is installed at FL-1A and FL-1B and put in service only one.
3. Turn in closed position the spectacle blinds on TP-121 (removing the 1000 Mesh screen)
and relocate the spectacle blinds on three ways spool so as to close the supply line from
the cooler (same configuration of Step 1).
4. Isolate the PDT-5157.
5. Disconnect the impulse line on PCV-5164.
6. Remove RO-5165.
7. Disconnect and plug tubing to IGV System located upstream of TG-5167.
8. Install blind gasket on accessory gear box supply line.
9. Disconnect the supply line for turbine bearing 1 and install a 100 Mesh screen on the
bypass line to the Lube Oil Tank.
10. Disconnect the supply line for turbine bearing 2 and install a 100 Mesh screen on the
bypass line to the Drain Box-3.
11. Disconnect the supply line for the load gear bearings and install a 100 Mesh screen on
the bypass line to the connection point BL-162.
12. Disconnect the supply lines for the generator bearings and install two 100 Mesh screens
on the bypass lines to the related return line.
13. Install 12” blind gasket on load gear return line.
14. Locked close the 1 ½” valve on common suction line of Jacking Oil Pumps PJ-1A/1B and
PJ-2A/2B.
15. Remove suction and return line on mist oil separator for air blown and mechanical brush
for cleanliness and inspection.
16. Inspect the oil mist separator filter.
17. Fill the Drain Box.
18. Start Mineral Oil Vapour Extractor Fan 88-QV-1.
19. Start the Aux. Lube Oil Pump PL-2 and monitor pump discharge pressure with PG-5158.
20. Energize the Lube Oil Tank Heaters 23QT-1/2/3/4 and monitor the oil temperature with
TG-5181.
21. Start oil flushing cycle until acceptance criteria for particulate is satisfied and then
proceed to Step 4.

 
Material Requirements 

 
Step Description Qty Comments
2 Cartridge Filter 2 At FL-1A and FL-1B.
7 ½” Plug for Tubing 1 To isolate tubing to IGV.
8 2” blind gasket 1 To isolate accessory gear.
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9 2” 150 lb flange for hose bypass 1 To bypass turbine bearing 1.

9 2” 100 Mesh Screen 1 On bypass turbine bearing 1.
To connect turbine bearing 1 supply
9 2” Rated Hose and Clamps 1
line to Lube Oil Tank.
10 1” 150 lb flange for hose bypass 1 To bypass turbine bearing 2.
10 1”100 Mesh Screen 1 On bypass turbine bearing 2.
To connect turbine bearing 2 supply
10 1” Rated Hose and Clamps 1
line to Drain Box-3.
11 4” 150 lb flange for hose bypass 1 To bypass load gear bearing.
11 4” 100 Mesh Screen 1 On bypass load gear bearing.
To connect load gear bearing supply
11 4” Rated Hose and Clamps 1
line to BL-162
12 ¾” 150 lb flange for hose bypass 2 To bypass generator bearings.
12 ¾” 100 Mesh Screen 2 On bypass generator bearings.
To connect generator bearing supply
12 ¾” Rated Hose and Clamps 2
lines to the return lines.
13 12” blind gasket 1 To isolate load gear return line.

 
 

Step 4: Hydraulic oil circuit

Procedure  

1. After lube oil flushing completion, connect the Hydraulic Oil Auxiliary Pump PH2-1 with
protection panel (rotation test to be done in advance).
2. Verify Hydraulic Oil Filter cartridge at FH2-1 and FH2-2.
3. Line up one Hydraulic Oil Filter Cartridge, FH2-1 or FH2-2.
4. Install blind gasket on IGV Control System supply line.
5. Disconnect the supply line for DLN skid installing a bypass line to the Drain Box-2.
6. Start Hydraulic Oil Auxiliary Pump PH2-1 and run for 5 min.
7. Stop the Hydraulic Oil Auxiliary Pump PH2-1.
8. Reconnect supply line for DLN skid.
9. Install tubing bypasses around ZCV-5010, XV-5009 and XEV-5024.
10. Install tubing bypasses around ZCV-5013, XV-5012 and XEV-5025.
11. Install tubing bypasses around ZCV-5020, XV-5021 and XEV-5026.
12. Install tubing bypasses around ZCV-5021, XV-5022 and XEV-5027.
13. Start Hydraulic Oil Auxiliary Pump PH2-1 and run for 5 min.
14. Stop the Hydraulic Oil Auxiliary Pump PH2-1.

Material Requirements 

Step Description Qty Comments

4 ¾” blind gasket 1 To isolate IGV Control System.
5 1” 150 lb flange for hose bypass 1 To bypass DNL skid.
To connect supply line for DLN to Drain
5 1” Rated Hose and Clamps 1
Box-2.
9, 10, ½” Tubing 3m To bypass ZCV-5010, XV-5009, XEV-
11, Fitting OD ½” M/F 24 5024 ZCV-5013, XV-5012, XEV-5025
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12 Union fitting OD ½”
½ F/F 12 ZCV-5
5020, XV-50221, XEV-502
26 ZCV-
5021, XV-5022, XE
EV-5027.

 
   
   
  8.Atttechmen
nts:
 
   
8.1.T
TYPICAL IN
NLINE FLUS
SHING SCR
REEN ISOL
LATION CO
ONFIGURA
ATION

8.2. Attchment
A 2: Typical Inline Flus
shing Screen
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