Assembly Instruction Handbook

Only for internal use

Timelkam 003845 DM
OES800 MAV

Kraftwerk/Power Plant Block/Unit KW-Nr./Plant CoUA Inhaltskennzeichen/Contents CodeZähl-Nr./Reg. No.

System/Komponente: Lube Oil Module L2 with 2x100% lube oil cooler

System/Component

Anweisungstitel: TE2 Erection and Commissioning Manual

Instruction Title

Scope of Assembly

1 Safety Requirements for Erection & Commissioning

2 Production Description

3 Erection Manual

4 Supporting Technical Specifications

5 On-Site Quality Assurance Plan

6 Time Schedule

7 Erection Drawings

8 Commissioning Manual

9 Annex

Seitenzahl: 40 Anlagen: 15
No. of Pages Appendices

*) Erstellt Geprüft/Freigeg.*) Geprüft/Freigeg.*) Geprüft/Freigeg.*) Freigegeben.

Nichtzutreffen
des streichen Prepared by Verified /Released by Verified /Released by Verified /Released by Released by
Delete if
inappropriate
Dienststelle Flenco, D Flenco, It
Department
Name Neumann
Name
Datum
Date
Unterschrift
Signature
 Safety requirements

1.0 General Notes

For your safety and the safety of the others, operation and maintenance of this equipment should be
done only by qualified persons that completely understand the equipment!

The present operating manual is part of the delivery of this oil unit. The manual should always be
available closed to the oil unit. A good knowledge of this operating manual is required for a failure-
free operation of this oil unit.
For this reason it should be in the interest of the operator that this manual should be read and
understood very well from all the workers which are responsible for transport, assembling and
operation.

Attention:
Flenco Spa. will not be responsible for any damage or operating breakdown which is resulting in
non-observance of the operating manual.
The Shuaibah lube oil module which is described in that manual was developed for stationary
application on a concrete platform. The described oil unit corresponds to the latest state-of-the-art.
It is not allowed to duplicate this operating manual without any allowance of Flenco Spa.
If you have any technical questions regarding the system, please contact Flenco Spa.

1.1. Health Hazard

Several warning signs are attached in a vital area of the lube oil module manufactured by Flenco.
All warning labels of the unit must be read, understood and strictly adhered at all times. Do not
remove, damage or cover any warning labels, identification nameplates or switch panel nameplates,
on the units or its components. The labels or the nameplates have to be replaced in case of any
damage.
Flenco Spa. recommends to carefully follow all instruction and to work around this area with the
maximum attention to the various indication.

1.2. Noise Hazard

Lube oil module manufactured by Flenco hasn’t the enclosure protection, for this reason the
various equipment may generate noise that is above a safe level. For this reason we
recommend to use ear protection when working near the module area.

1.3. Fire Hazard

The used fluids in this equipment can be flammable! For this reason all fire precautions must
be observed.
A very violent effect can occurred in case of fire disintegrating or melting some components
due to excessive heat. In these circumstances, certain components may decompose and release
potentially dangerous gases and liquids.
During normal operating conditions, the system is designed to work without any kind of risk.
Some equipment are used in order to assure a constant vacuum pressure inside the tank and to
guarantee therefore any potential leakage of dangerous fluid to outside.

-2-
 Safety requirements

1.4 Storage

The lube oil unit is designed for indoor use only and for this reason the system should be stored
indoor. Whenever possible with protection from extreme over temperature, shock and dust, and
free of corrosive or chemical damaging fumes.
During storage of the system, pumps should be cranked at least once a month verifying the
proper amount of lubrication exists. During this process, parts such as the shaft and bearings
should change their position.
Electric motor bearing lubricants should be renewed. The bearings should also be inspected,
and renewed, if necessary.
Electric motor insulation should be checked, during and after storage, according to
recommendations of the motor manufacturer. If the motors are equipped with heaters, the
heaters should be used during long term storage (more than 3 months) per the motor
manufacture’s recommendations.

Uncouple the motors and energize them for at least one hour each month, otherwise, remove
the motors and store them in a controlled environment.
Check all painted and galvanized surfaces for oxidation or eventually sign of rust every six
months. All rusted area must be cleaned and “touched up” immediately.

1.5 Handling

Fluid (lubricants, hydraulic oil, and rust preventatives) used in the lube oil module
manufactured by Flenco Spa are corrosive and irritating to skin and therefore require
appropriate personal protective equipment during handling.
In case of skin accidental contact with these fluids during skid operation, it is necessary to
remove and to clean very well all the parts, also because these products are really fire hazard
if left on the skin during operation.
For this reason, a high standard of personal hygiene should be maintained.
In case of contact with eyes, flush with large amount of clean water. In case of ingestion, do
not induce vomiting and seek for medical attention immediately.
Under no circumstances may this unit be operated by an operator who is under the influence
of any type of intoxicant.

In any case, the operators have to follow all instructions and recommendations in accordance
with local environmental regulations.

1.6 Transport

No hazardous material at the time of shipment were present, when the lube oil module left the
FLENCO shop, therefore the unit is not classified as dangerous for all normal used transport
tooling’s.

1.7 Packaging

Attention must be paid to the figurative markings on the packing.

-3-
 Safety requirements

The lube oil module will have sea worth package.

Local environmental regulations will be applied for all packaging material.

Note: The system shall be immediately inspected on receipt for possible transport damage.
Any defects shall be brought to our notice in writing and without delay, however, no later
than 14 calendar days after the defect has been detected. We shall be given a chance of
checking the claim at site. The Buyer shall be committed to receive and accept the goods even
if he makes a claim in respect of a defect.
Defect or the lack of assured properties shall be warranted by us exclusively in such a way
that by taking measures at our option, we shall either repair or replace the goods free of
charge. Defect of part of the lot supplied shall not result in rejection of the entire lot.

1.8 General Disclaimer

The operational safety of the system supplied is only ensured, when it is used for the
expressed purpose for which it is intended. The unit shall be not operated under other
operating conditions without the manufacturer permission.
Flenco doesn’t have the control about the handling, storage and use of the equipment, for this
reason will not be responsible for any damage due to an unforeseen use of the system.
Many information available in this document are obtained from reliable component suppliers.
Nevertheless, Flenco is not responsible about the accuracy and correctness relating to its
suppliers.

Exclusion of liability
We made every endeavour to ensure the accuracy of the contents of this document. However,
errors cannot be ruled out. Consequently, we accept no liability for such errors as may exist
nor for any damage or loss whatsoever which may arise as result of such errors. The content
of the manual is checked regularly. Any corrections required will be incorporated in
subsequent editions. We welcome any suggestions for improvements. All details are subject to
technical modifications.

-4-
 Product Description

2.0 Short Functional Description

The lube oil module consists of a:

• welded oil tank
• 2 main lube oil pumps
• 2 lifting oil pumps
• 1 emergency pump
• 1 double tube heat exchanger (shell and tube type)
• 1 oil mist purifier
• 1 CSM 1000 Contamination Sensor

and several regulation and control devices.

The described lube oil unit serves for oil cooling and lubrication of bearings. The unit was taken of a
detailed inspection and was examined according to the order data.

The oil supply is assured by three groups of pumps. The lifting and main lube oil pumps require an
AC power supply, the emergency oil pump motor needs a DC power supply. All pumps are fed with
lube oil from the oil tank via separate suction lines. The installed lube oil system works as a vacuum
system.
The pumps suck the oil in a suction line. In the circular flow is a filter installed to clean the
circulating oil. A heat exchange system is installed, which, if required, the oil temperature cools
down. The gear pump from the CSM1000 unit sucks the oil to be analyzed and conveys it to the
Contamination Sensor, in which the particulate contamination is captured by an optical sensor and
analyzed according to particle size classifications and counted.
A temperature valve controls the flow and temperature of the supplied oil flow. The oil will be
transported to the terminal equipment over a discharge – line.
All the above mentioned components are installed on top of the oil system. The cooler is installed on
a separate base plate and is connected with pipes to the oil system.

The oil supply unit is exclusively designed for use of the oil supply at steam turbines. Any other use
of the unit is not in accordance with Flenco Spa. terms. Flenco Spa. shall not be liable for damage
arising as a result of the unit being used for purposes than originally intended. In such a case, the risk
lies solely with the user.

Before site delivery, the module has been completed with all components, instruments, pipes and
wiring and various components (lifting pumps, lube oil pumps, emergency pump, cooler without
water, instruments) has been pre-tested according to original product order.

2.1 Main technical data

The Timelkam OES800 lube oil module is produced by Flenco Spa drawing n° 07.080.00 and it is in
accordance with below shown specification:

- Specification 11618-981505/003

and all other documents relevant to piping & instrumentation diagrams, outlines, specification
mentioned in the contractual BOM.

-5-
 Product Description

• Module type: L2
• Pumped liquid: ISO VG46
• Lube oil flow rate: 59 l/s
• Lifting oil flow rate: 3,77 l/s
• Required excess pressure for lifting: 155 bar
• Operating Voltage: 400V / 50 Hz / 3 DS
• Ambient temperature: from +5° to + 43° C
• Max. relative humidity at max. ambient temperature: 85%
• Seismic, design layout: Zone 2A, UBC
• Type of arrangement: Concrete platform

-6-
 Product Description

2.2 Table of System Components

Flenco Main Part list Revision: 0

Date: 17.03.2008
Timelkam OES800
Page 1
Item Description Technical data KKS
Lube oil package Flenco SpA
Ambient conditions +5° to +43°C, 85% humidity
Installation Indoor
Medium ISO VG 46
Operating voltage 400V / 50 Hz / 3 DS
Control voltage 24V DC
0100 Oil tank Flenco,size 30000/45000 0MAV10 BB001
0010 Vane pump with AC-motor Operation pressure: 155 bar 0MAV31AP001
(lifting oil pump) Rate of revolutions: 1470 rpm 0MAV32AP001
Required electrical power:
93,2 kW
Thermal motor protection: 6
PTC thermistors
0030 Centrifugal pump with AC-motor Pump size L2, 100-250/01 0MAV21AP021
(main lube oil pump) Type of construction: V1 0MAV21AP022
Discharge flange: DN 200
0040 Centrifugal pump with DC-motor Pump type: 100-200/01 0MAV24AA201
(emergency oil pump) Type of construction: V1 0MAV24AA401
Discharge flange: DN 200 0MAV24AP001

0070 Double plate heat exchanger Max. cooling water inlet 0MAV41AC001
temperature: 35,9°C 0MAV41AC002
Cleanness factor: 90%
Quality of cooling water:
Demineralized water
0080 Oil temperature control valve AMOT Type 8BRDC 0MAV41AA151
0090 Double change-over filter with ball valve HP HDD.601.25G.HR.E.P 0MAV35CP016
stainless stell wire mesh, 0MAV35AA271
25 µm, 0MAV35AA272
clogging indicator: visual- / 0MAV35AT001
electrical 0MAV35AT002

0120 Oil mist separator FF2-366.30020 0MAV82 AN001,

100 mbar / 440 m³/h 0MAV82 AN002,
0MAV82 CP501,
0MAV82 CP502
Check valve:
0MAV82 AA201,
0MAV82 AA202
0240 External de-watering and filtration unit FAM 70-M-2-T, Fluid Aqua 0MAV91AT001
Mobil
0539 Contamination Sensor CSM1000

-7-
 Product Description

2.3 Scope of supply

The scope of supply includes:

• The lube-oil-unit
• Heat exchanger
• Pipes for flushing
• Filter cartridges for high and for low pressure system
• Starting resistor
• Oil mist separator
• CSM1000 Oil purifier
• The technical documentation

The system shall be immediately inspected on receipt for completeness and possible transport
damages.
Any defects shall be brought to our notice in writing and without delay, however, no later
than 14 calendar days after the defect has been detected. We shall be given a chance of
checking the claim at site. The buyer shall be committed to receive and accept the goods even
if he makes a claim in respect of a defect.
Defects or the lack of assured properties shall be warranted by us exclusively in such a way
that by taking measures at our option, we shall either repair or replace the goods free of
charge. Defects of parts of the lot supplied shall not result in rejection of the entire lot.

Picture 1: Timelkam lube oil unit with separate heat exchanger.

-8-
 Erection Manual

3.0 Erection Manual

Handling of all equipment should be conducted by skilled personnel and be consistent with
safe handling practice. Refer to the FLENCO Accessory Module General Arrangement
drawing, contained within this operation for details of lifting points. Verify the lift capacity
and operating condition of handling equipment. Maintain handling equipment to avoid serious
personal injury.
Lube oil units, heat exchanger, the oil vapour system, flushing system pipes are shipped
separated and have to be lifted with adequate lifting beam. Check if all material is complete
with provided material list in the corresponding package.
Mount the Franke Filter on the lube oil system tank on the therefore destined position. For
assembling the filter use only the provided screws and bolts.
Attention: For all assembled parts of the lube oil unit, use the torque data sheet and bolting-up
procedure sheet in the annex.
Heat exchanger skid has to be lifted only with provided lifting beams, shackles and slings. In
order to avoid damage the use of the spreader bar is suggested. Also, do not attach slings to
projecting shafts, levers, handles or pipes. Take care not to scratch the system during lifting
phase.
Partial or disassembled units require special handling. All parts should be handled in a fashion
which protects the coatings and other parts from damage. Components should be handled in a
way that forces are not concentrated and bending or distorsion cannot occur.

3.1 Scope of Erection

The scope of erection consists of the following working steps:

• Move the lube oil unit and lube oil cooler package on site. Use therefore available lifting
beam.
• Mount the foot construction on the lube oil package and the cooler.
• Align the lube oil unit with the cooler vertically and horizontally.
• Connect the lube oil unit with the cooler. Both units are constructed that the connection
points aligned together. In any cases of stress or unfitting screw couplings, you have to
realign the lube oil unit and the cooler.
• Connect the electric connections according available wiring diagram (see annex).
• Final check if erection was according to the Field Quality Plan (FQP).

-9-
 Erection Manual

3.2 Ressourcen

The following workers and material are needed for the erection of the lube oil unit and the cooler
unit:

• Crane with a lifting capacity of 12 tons for the lifting of the cooler system
• Crane with a lifting capacity of 25 tons for the lifting of the lube oil unit
• Lifting Beam
• 5 metal workers, 3 electrician
• Different common screw spanner and screw driver, torque wrench
• Foots for the lube oil system, and shim plates for heat exchanger skid.

3.3 Precondition to Erection

For the precondition of erection the following parts must be considered:

• Site regulations: The mounting area has to be cleaned and dry. The foundation of the lube oil
package has to be done according to the foundation plans.
• Storage requirements: The oil unit has to be stored on a solid concrete horizontal foundation
in the original packing of the company Flenco Spa. If the storage of the oil unit on a solid
concrete and horizontal foundation in its original packing is not possible, the unit can be
stored in a closed up warehouse, after a Flenco Spa employee confirmed.

The above mentioned storage requirements have to be followed. If not the warranty obligations will
become invalid immediately. For detailed information about the warranty obligations, please read
the TE2 manual chapter 1 “Safety requirements”.

- 10 -
 Erection Manual

3.4 Description of Erection

The oil unit supplied by Flenco is not completely assembled due to some components were
shipped or supplied separately or in pieces. The constructor has the responsibility to assemble
these parts (see also chapter 3.0) following this manual instructions concerning proper
handling.
Flenco will be not responsible for system malfunction due to not correct installed equipment.
All surfaces must be clean, sound and free from dust, ice, oil, grease and other surface
contaminants such as curing membranes and form release agents.
Bolt holes and fixing pockets should be free of dirt and debris by air blasting. For maximum
bond, surface should be abraded or roughened, preferably by mechanical means such as needle
gun, grit blasting, grinding etc.
Before installing the module, remove all shrink wrapping, yellow paint covers and plugs, and
the protective coating on machines surfaces using a suitable solvent. Protective clothing should
be worn when using solvents.
All customer piping connections should be fitted, bolted or welded and care must be taken not
to stress the piping connections.

The erection manual contains the following working steps:

1. Place the lube oil unit horizontal on site, using suitable lifting equipment.
2. Fix securely in place the module with relevant foundation bolts.
3. Align the unit with the connected pipe work. Shim the module required so that undue strain
exists when secured.
4. If applicable, fix the foundation bolts using suitable cement, ensuring that there are no voids.
5. Tight the foundation bolts and re-check the alignment.
6. Ground skid to plant ground and align it to all directions.
7. Connect skid terminal point to piping site using appropriate gaskets and fastenings.
8. Align the cooler unit with the lube oil unit and fix it.
9. Connect all pipes and tubes from the cooler to the lube oil unit. Use therefore the supplied
screws and screw nuts and use the appropriate turning moment (see annex). Check all flange
connections and make a professional pressure test on the tubes, pipes and flanges.
10. Be always careful at work and connect all pipes correct according to Flenco / Siemens
instructions.
11. Fill up the lube oil tank according to the Siemens specifications with oil:

Filling of lube oil tank:

Filling of the lube oil tank shall be performed via the manhole opening (plate). This
plate must be removed and the inside of the tank checked for cleanness and absence of
foreign materials before initial filling of the tank is performed. The overview drawing
for the lube oil tank specifies the initial fill quantity for the lube oil tank. For tank
filling, besides the oil delivery contractor staff an additional person must also be
present to monitor oil level on the level indicator. After the tank has been filled with the
initial fill, the pumps must be operated to fill the lube oil lines and the bearings. It must
then be checked that the operating level matches the level settings specified in the
overview drawing for the base module and the limit switches adjusted to the settings
given in this drawing. When topping up the tank using a pump under automatic control
(say on a tank truck), an additional person must always be stationed at the level
indicator to monitor this and instruct the oil delivery contract staff to terminate oil
filling at the appropriate moment.

- 11 -
 Erection Manual

12. Fill up the lifting oil pump with oil before first commissioning via connection „F“ (see label
on the unit). (MAV30AA251 has to be open during operation)

13. Oil mist separator:

- Open external air fitting
- Start vacuum pump
- Close external air fitting slowly until the necessary underpressure has been created
in the tank.
Note: The filter has reached its operating status as soon as the filter tubes are saturated with
oil. Check underpressure during the first 4 weeks. Adjust if necessary.

14. The AMOT valve needs no user settings for first run up. For long life AMOT valves should
not be operated continuously at temperatures in excess of their maximum continuous rating.
For mixing and oil circuits the temperature may be 1 to 2°C higher due to flow, viscosity and
other system parameters.
BR type valves are fitted with a variable manual override which allows a progressive opening
of port A to C. In automatic mode the valve will control the temperature automatically, but
turning the adjusting nut on top of the operator clockwise will cause the element to move
toward its hot (extended) position, regardless of temperature. There is a position indicator on
each manual override which shows the element position during manual operation. Each
element assembly has its own Manual Override.
Note: Manual Override should only be used in case of an emergency or element failure.

15. CSM1000
Once the CSM is hydraulically connected to the overall system via the IN and OUT lines and
electrical installation has been completed, settings have to be made to the unit.

Turn the throttle valve [A] in a clockwise direction until it is

completely closed.

Attach the pressure gauge to test point 1.

- 12 -
 Erection Manual

Slightly tighten the adapter using the open-jaw wrench, size 22.

Start up the unit. The pressure gauge now shows the pressure present at the inlet of the
Contamination Sensor (CS) (max. 60 bars).

Remove the cap nut from the pressure relief valve [B].

Loosen the counter nut.

Set the pressure relief valve [B] using an Allen wrench, size 4.

Set the pressure at maximum viscosity of the hydraulic medium to ca. 40 bars.

Screw the counter nut tight. Make sure that the setting of the
pressure relief valve [B] is not changed in the process.

Close the cap nut.

- 13 -
 Erection Manual

Remove the pressure gauge from test point 1 and connect it to test point 2 [C].
Now open the throttle valve [A] very slightly until a pressure drop is shown on the pressure
gauge. Pressure ca. 0,5 bars lower as compared to when the throttle valve is closed
completely.
Switch the CSM off.
Remove the pressure gauge and the measurement hose from test point 2 [C].
Close both test points 1 and 2 using the connected dust cap.
The CSM is now ready for operation.

16. Proof every step you have made according the Field Quality Plan (FQP).
17. Connect the grounding cables from the cooler and also the grounding cables from the lube oil
unit to the ground.
18. Connect the electrical connections with the available junction boxes and check all electrical
insulation resistances.

Attention: For the flushing procedure please take care that you have fixed all connections
professional again after flushing.

Connect power supply to main lube oil pumps motors, emergency motors and lifting pump
motors. Before starting, check the continuity for all motor connections. Power supply
connection is not included in Flenco scope of supply.
Check the overall system for possible under voltage and for efficiency of all switching controls;
check the three-phase equipments for unbalanced line currents and voltage and check the
equipment for under loading.
Pressurize each system and check all external connections and module internal piping
connections for leakage.
Customer shall connect signal to skid junction boxes, as specified on the applicable contractual
interconnecting wiring diagrams.

- 14 -
 Erection Manual

Erection – Clearance - Certificate ECC - SIEMENS FORMBLATT

- 15 -
 Supporting Technical Specifications

4.0 Supporting Technical Specifications

4.1 Overview of the Lube Oil System

Picture 2: Lube oil unit Timelkam

In this chapter we provide you some 3D-model pictures to help you to understand how to build up
the lube oil system.
The pictures 3, 4 and 5 on the next pages are 3D-models which show you the unit from all sites.

- 16 -
 Supporting Technical Specifications

Picture 3: 3D-Model of the unit, left side

Attention: The pipes of the unit have a slope. Please check available P&ID. The computer designed
pictures are low distorted.

Picture 3: 3D-Model of the unit, right side

- 17 -
 Supporting Technical Specifications

Picture 4: 3D-Model of the unit, top side

Picture 4: 3D-Model of the unit, back side

- 18 -
 Supporting Technical Specifications

Description of the ground feet of the Lube Oil Unit

- 19 -
 Supporting Technical Specifications

4.2 Wiring Diagram

- 20 -
Supporting Technical Specifications

- 21 -
Supporting Technical Specifications

- 22 -
 Quality Assurence Plan

5.0 Quality Assurance Plan

On the next pages you can find the Fiel Quality Plan (FQP).

- 23 -
 Document No.: OES800-
SIEMENS
Technical Contract Condition project-specific Index / Date: 2008-03-30
Page: 4 of 4

Handling:
Field Quality Plan For internal use only

Timelkam OES800 MAV

Power Plant Unit Plant Code UA Contents Code Reg. No.

System/Component: Lube Oil Module L2 and Cooler

Belonging to Assembly Instruction: Erection Manual

Erection Company: Appendices

Checks by *) Results /Reports Date/Signature *)

EC AV S C EC AV S C

Pre Erection
1 Complete material delivery, refer to +
drawings Nr 0708000_REV02_635,
636, 637 (Annex of EMM) and
delivered material lists.

2 Material free from damage +

3 Remove all transportation saftety +

devices

4 Check if dedicated lifting beam is +

needed

5 Check if additional level pads for +

vertical alignment are required
Erection
6 Alignment of:
lube oil tank and heat exchanger + H
and oil purifier
according to drawings Nr
0708000_REV02_635, 636, 637
(Annex of EMM) and erection
manual.

7 Installation in accordance with +

erection manual.

8 Check if contamination sensor +

CSM is assembled correct and
ready for use (see chapter 3.4)

- 24 -
 Document No.: OES800-
SIEMENS
Technical Contract Condition project-specific Index / Date: 2008-03-30
Page: 4 of 4

9 Tightening torque for all pipes and + H Wx

flange connections

10 Check if cable tray and tubing are + H

adequately supported
+
11 Check if all motor rotations are
correct

12 Inspect masonry and + Wx

steelwork fixings of tray supports

13 Rectify prime coating prior to top +

coating application

14 Check groundings and all electrical +

connections with relevant wiring
diagram

15 Check all instrument settings and +

position of manual valves as per
P&ID

Post Erection
16 Final Inspection + H Wx

17 Check if lifting pumps are filled + H

correct prior to first start up

18 Check if oil return line of purifier +

immerse in the oil level according
to drawing in ANNEX

19 Check the vacuum of the unit, +

when oil mist separator is in
operation

20 Check level pressure of each line +

21 Check for exceptional vibrations +

during the first startings

22 Review of correctness and + H H

completeness of documentation
package

*) legend of abbreviations at the end of the table

- 25 -
 Document No.: OES800-
SIEMENS
Technical Contract Condition project-specific Index / Date: 2008-03-30
Page: 4 of 4

Power Plant: Field Quality Plan

Timelkam

Assembly Instruction No.1 Item

Remarks:

Legende:
H = Haltepunkt. Anwesenheit ist vorgeschrieben. Freigabe für
weitere Montageschritte erst nach Beendigung des
Prüfschritts.
+ = Montageschritt durchführen und Ergebnisse protokollieren.
I = Informationpunkt. Beteiligte werden von EC vor der Prüfung
informiert. Montage kann ohne Anwesenheit der Beteiligten
fortgeführt werden.
Wx = Meldepunkt: Die Durchführung der Prüfung ist ohne
Anwesenheit von S/AV/C nicht zulässig, es sei denn
S/AV/C hat schriftlich auf eine Teilnahme verzichtet.
x = prozentualer Anteil des Prüfumfanges
LEGEND :
H = hold point. Attendance at check is obligatory. Release of
further erection steps after finishing the check step.
+ = carrying out the step and record the results.
I = information point. Parties have to be notified prior to check
by EC. The erection continues whether the parties are there
or not.
Wx = witness point: The test may be carried out under the
presence of S/AV/C unless S/AV/C has formally renounced
to the participation.
x= percentage of the inspection scope

Preparation of FQP
Prepared by Verified by Verified by Released by Released by
Supplier Supplier Ordering Department Project Team.

Name

Date

Signature

Verification of completeness
Erection Company Advisor/Supervisor Customer Site Owner/Client
(EC) (AV) Management (S) (C)

Name

Date

Signature

Ausfüllanleitung für FQP Data Entry Instruction of FQP

Spalte EC „Montagekontraktor“
• Kennzeichen: +
EC führt den Schritt aus, zeichnet den Prüfschritt ab und
dokumentiert die Ergebnisse wie vorgegeben. Die Fortführung
der nächsten Schritte ist freigegeben, wenn nicht in gleicher
Zeile weitere „H“ und/oder “Wx“ angegeben sind. (Mit der
abschließenden Unterschrift Site Management des Bestellers (S)
wird der FQP geprüft).
Column EC “Erection contractor”
• + marking:
The EC must carry out and sign the step and the results will be
documented as provided, if not in the same row additional “H”
and/or “Wx” marked. (with the final signature, at the bottom,
Customer's Site management (S) reviews the field quality plan).

Spalten S “Baustellenleitung des Bestellers**”, AV Columns S “Customer's Site management”, AV

“Advisor/Supervisor/TFA” (Advisor/Supervisor/TFA des ”advisor/supervisor/TFA” (supervisors/advisors/TFA of the
Komponentenherstellers) und C “Bauherr“ Contractor) and C “Owner”

- 26 -

SIEMENS
Technical Contract Condition project-specific
• Kennzeichen: Keine
EC muss vor der Durchführung des Schrittes niemanden
(S/AV/C) informieren.
• Kennzeichen: H
EC informiert die Teilnehmer (S/AV/C). EC führt den Schritt aus.
Teilnahme der Partei(en) (S/AV/C) ist vorgeschrieben. Die
Partei(en) zeichnen den Prüfschritt ab und bestätigen damit die
korrekte Durchführung. Erst dann ist die Fortführung der
nächsten Schritte freigegeben.
• Kennzeichen: I
Beteiligte werden von EC vor der Prüfung informiert. Montage
kann ohne Anwesenheit der Beteiligten fortgeführt
werden.
• Kennzeichen: Wx
Fertigmeldung für Prüfung/Abnahme. Die Durchführung der
Prüfung ist ohne Anwesenheit von S/AV/C nicht zulässig, es sei
denn S/AV/C hat schriftlich auf eine Teilnahme verzichtet. In
diesem Fall kann die Prüfung unabhängig von der Teilnahme
durch S/AV/C durchgeführt werden. Bei Teilnehme: Die
Partei(en) (S/AV/C) zeichnen den Prüfschritt ab und bestätigen
damit die korrekte Durchführung.
x = Angabe des prozentualen Anteil des Prüfumfanges
Beispiel: W50 = Teilnahme an 50 % der vorgesehenen
Prüfungen
** soweit anwendbar
- 27 -
Document No.: OES800-
Index / Date: 2008-03-30
Page: 4 of 4
• no marking:
The EC does not have to inform the relevant parties (S/AV/C)
before carrying out this quality step.
• H-marking
Notification of readiness for inspection/ testing by the EC. The
EC must carry out and sign the step The test must be carried out
under the presence of the dictated parties (S/AV/C).All relevant
parties sign the step as correct fulfilled. After signing the
construction work can be continued.
• I-marking
Notification of readiness for inspection/ testing by the EC. The
construction work can by continued without witnessing of the
informed parties.
• Wx-marking
Notification of readiness for inspection/ testing. The test must be
carried out under the presence of S/AV/C unless S/AV/C has
formally renounced to the participation. In this case the test may
be carried out independently of the presence of S/AV/C. If
presence of S/AV/C: .All present parties sign the step as correct
fulfilled.
x = percentage of the inspection scope
Example: W50 = participation in 50 % of the planned inspections
** if applicable
 Time Schedule

6.0 Time schedule

The build up of a the Flenco Spa lube oil system takes approximately about one week, as shown with
the main items in the schedule below. The development and preparation of the basement is not in
scope of Flenco Spa supply.

- 28 -
 Erection Drawing

7.0 Assembly / erection drawings

7.1 List of drawings

• 0708000_REV02_635.pdf, GA skid
• 0708000_REV02_636.pdf, GA skid
• 0708000_REV02_637.pdf, GA skid
• 0708009.pdf lifting cooler

- 29 -
 Erection Drawing

- 30 -
 Erection Drawing

- 31 -
 Erection Drawing

- 32 -
 Erection Drawing

- 33 -
 Commissioning manual

8.0 Commissioning Manual

8.1 Testing

The lube oil system has been tested by the manufacturer (pressure and functionally tested), if its
written in the contract order. Then the module is delivered in a clean condition with all pipes
already flushed. It is needed to repeat this type of activities, if the module has been stored in
dirty ambient conditions or for a long time period (more than 3 months).

The Timelkam lube oil system was sent to site without flushing or functional tests according to
the contract order.

A comparison for piping, tubing, gauges, switches, etc, respect to Accessory Piping Diagram
has been carried out for each system.
Full electrical checks included the continuity and the terminal point positions and connection in
the junction boxes are required before beginning of common operation. LO filters should be
tested with the cartridges supplied with the module. Flenco suggest to use these cartridges for
site system flushing and to use the supplied spares cartridge prior to equipment start-up.

During functional test, check vibration in every direction for all pumps. For more detailed info
about used test procedure, please refer to supplied contractual Quality documents.

8.2 Commissioning

Fill the tank with specified mineral lube oil according chapter 3.4.

Vent air as needed. The oil tank shall have a normal operating level.
In order to prevent a dry running of the lifting oil pumps for the first start up or after a long
shutdown period, the pumps have to be filled with oil before first commissioning.

Verify the presence of all covers in the right place before to starting to operate the module and
the correctness of all electrical connections and that the cable and motor insulation and earth
continuity readings are satisfactory.

Verify the insulation of each electrical equipment from its power supply before to operate with
them.

Oil testing is performed to verify the quality of oil delivered to the users. In service testing is
performed to determine the condition of the oil, and the test results are used to determine the
level of oil maintenance required, conditioning, additive addition, partial replacement, or full
replacement. It is also important to use the same test procedure. Maintaining accurate records of
test is important.

- 34 -
 Commissioning manual

Inspect lube oil system, in detail:

Check the presence of leaking pipe joints and/or corrosion;

Verify the correct positioning gland and tighten if necessary of manual valve as per
applicable P&ID and inspect packing gland and tighten if necessary;

Check for manual valve leaking seals;

Check the level of oil inside the tank as per previous para.

Check the correctness of instrument set and if needed, vent and bleed all pressure
switches and pressure gauges.
Check the functionality of the CSM.

Operate the unit carefully following all instructions shown on this manual and work
around this area with the maximum attention to various indications.
Verify the presence of cartridge installed in the LO filter system.

Verify setting and calibration limits for instrument pressure, differential pressure, and
temperature switches and compare to applicable P&ID.
Check the proper rotation of the pumps (using the arrow indication on the casing of
each pump). If the direction of rotation is wrong, then change the wiring of the motors
in accordance with the electrical wiring diagram.
Check oil pressure regulator control functions properly.

Check all instrument valves for open position.

Check the position of the manual valves as per applicable flow diagram.

If all the points mentioned above and the FQP plan are fulfilled , the lube oil unit and the cooler unit
are ready for the initial start-up procedure.
If there are any problems, please do not hesitate to contact the supervisor of the Siemens AG on the
plant. If necessary, he will pass the problem to the manufacturer of the unit.

8.3 Initial start-up procedures

If the Flenco Spa is not involved in the start up process of the lube oil unit by manpower all
instructions which are written in the plant manual have to be followed. In this chapter are the
operating instructions for the lube oil system written.

This chapter is for your assistance to perform the first start up without any problems. Before the start
up please be sure that all points mentioned in chapter 8.2 Commissioning are worked out.

- 35 -
 Commissioning manual

Before the first operation and after finishing the erection, it is required to flush the complete lube oil
system with turbine oil. The flushing instructions for the system will be released by Siemens AG.
After the flushing the lube oil unit is ready for operation.

The oil mist separator should work during the whole operating time of the unit to achieve a
good removal of oil mist produced during the operation.

Attention: In order to prevent a dry running of the lifting oil pumps for the first start up or
after a long shutdown period, the pumps have to be filled with oil before first commissioning.

The temperature control valve operates autonomous. During the flushing sequence of the
system, this valve is removed. Be sure that the valve is reinstalled properly and the screws
are fastened tight.

The lube oil unit is delivered with filter elements. Check the optical advice at the back of the
filter after the flushing and during the first start up operation. Duplex filter are provided with
transfer valve in order to have the possibility to isolate one pressure vessel and the change
relevant cartridge without to stop the completely unit. A low point drain is supplied with
filter to allow drainage prior to removal of filter elements. Unbolt the top plate and swing the
plate to the side and replace the dirty cartridge (verifying the correctness of the used cartridge
characteristic). After this type of activities, a new complete set of gaskets has to be used in
order to avoid potential leakage from the filter cover. Reassemble the cover and close the
drain valve again.

For the adjustment of the throttle valves in the lifting oil control block please refer to the
relevant manual. The handle of these throttles are equipped with a key which is delivered
with the unit and fixed to the control block.

- 36 -
 Commissioning manual

8.4 Troubleshooting

ISSUE CAUSE WHAT TO DO

Lube oil low pressure alarm: Insufficient oil delivery due to: 1. increase opening of
MAV21CP001 1. insufficient opening of MAV21AA051 main oil
MAV42CP012 MAV21AA051 main oil throttle
MAV42CP019 throttle 2. verify all lube oil piping
MAV42CP016 2. piping break 3. verify MAV10BB001 tank
MAV42CP017 3. insufficient oil in the oil tank oil level
MAV42CP018 4. dirty cartridges of 4. verify MAV42AT001-002
MAV42AT001-002 duplex duplex filter cartridges
filter 5. dismantle the pump
5. damages to pump (MAV21AP021 or
(MAV21AP021 or MAV21AP022 or
MAV21AP022 or MAV24AP001, whichever
MAV24AP001, whichever in operation), inspect and
in operation) service
6. instrument malfunction 6. verify instruments and
electrical wiring
Lifting oil low pressure Insufficient oil delivery due to: 7. verify all lifting oil piping
alarm: 7. piping break 8. verify MAV10BB001 tank
MAV31CP001 8. insufficient oil in the oil tank oil level
MAV32CP001 9. dirty cartridges of 9. verify MAV35AT001-002
MAV35CP001 MAV35AT001-002 duplex duplex filter cartridges
filter 10.dismantle the pump
10.damages to pump (MAV31AP001 or
(MAV31AP001 or MAV32AP001, whichever
MAV32AP001, whichever in operation), inspect and
in operation) service
11.instrument malfunction 11.verify instruments and
electrical wiring
Lube oil MAV42CP013 12. dirty MAV42AT001-002 12.replace MAV42AT001-002
differential pressure switch duplex filters cartridges duplex filter cartridges
alarm on MAV42AT001-002 13. foreign material on lube oil 13.check pipes and remove
filters pipes foreign material
14. instrument malfunction 14.verify instruments and
electrical wiring

- 37 -

ISSUE
Lifting oil MAV35CP016
differential pressure switch
alarm on MAV35AT001-002
filters
Lube oil pump / lifting oil
pump high vibration
Lube oil pump / lifting oil
pump fail to start
LO temperature alarm
(MAV42CT001)
Lifting oil temperature alarm
(MAV35CT001)
low and low-low level switch
alarms (MAV10CL021-022-
023)
Oil(mist) at the clean
exhaust
Oil does not drain off
For any component or instrument malfunction, please always refer also to relevant O&M manual.
Commissioning manual
CAUSE WHAT TO DO
15. dirty MAV35AT001-002 15.replace MAV35AT001-002
duplex filters cartridges duplex filter cartridges
16. foreign material on lube oil 16.check pipes and remove
pipes foreign material
17. instrument malfunction 17.verify instruments and
electrical wiring
18.misaligned pump shaft line 18. dismantle pump and verify
19.worn bearing 19. dismantle pump and verify
20. electrical circuit open or 20. dismantle the motor and
damaged verify wire connections
21. foreign material in rotating 21. dismantle pump and verify
parts
22. MAV41AA151 TCV 22. verify MAV41AA151 TCV
improper operation operation and its installation
23. foreign material on lube oil 23. check pipes and remove
pipes or MAV41AC001-002 foreign material
cooler 24. verify cooling water valves
24. insufficient cooling water opening
flow 25. verify instruments and
25. instrument malfunction electrical wiring
26. MAV10BB001 main oil 26. Check main oil tank
tank temperature too high temperature
(excessive temperature of (MAV10CT001)
return oil from turbogenerator) 27. verify instruments and
27. instrument malfunction electrical wiring
28. insufficient oil quantity in 28. .a) verify that
tank MAV10AA251-252
29. instrument malfunction drain valves are closed
b) verify MAV10BB001
main oil tank and all lube
and lifting oil piping
c) cross check with level
indicator MAV10CL521
29. verify instruments and
electrical wiring
Oil mist purifier
air - Bypass via oil return Make sure that oil return line is
- Filtered oil cannot drain off immersed in the oil level
- Leakage at the oil return
- Filter tube broken - Switch off vacuum pump
- open maintenance cover
according to Franke mainte-
nance, check filter tubes
Maximum pressure reached Replace filtertubes
- Oil return choked - Check oil return lines
- Helicline oil return line - Oil return line must have
incline
- 38 -
 Commissioning manual

8.5 Spare parts

It is recommended to have a store with the most important wear and tear parts of the unit available.
These parts are for example gaskets, screws and bolds and also the filter cartridges.
Flenco Spa can only give the warranty for the spare parts, which are supplied by Flenco Spa.

NOTE:
Please notice that supplied spare parts which are not delivered by Flenco Spa are not approved for
usage.
The use and installation of these spare parts can change the default characteristics and jeopardise the
security of the lube oil system.
Flenco Spa will not give any guarantee to any damage which is caused by the use of those spare
parts.

- 39 -
 Annex

9.0 Annex

• Bolting-up procedure
• Torque required to produce bolt stress
• Erection Clearance Certificate
• Assembly Instruction
• Oil-Flushing
• P&ID LOS
• P&ID Lifting oil
• Franke Filter

- 40 -
 Annex
Bolting
To achieve an effective seal all over the
• flange to flange connections
• flange to component connection
it is required to apply an even compressive force.

The effective seal is a strict requirement that shall be validated through the inspection method stated
below, but finally by flushing operation. or leakage test.

To achieve this, a very definitive bolt-up procedure must be followed when tightening a flange
using torque methods.

This tightening procedure is detailed as follows:

• install the gasket on the flange seating surface and bring the mating flange in contact with
the gasket
• install all bolts (or rod + 1 nut each, with washer as necessary), making sure they are free of
dirt and grit, and well lubricated
• run-up all nuts snug tight without compressing gasket seating surface
• develop the required bolt stress (see table A) in a minimum of four steps, following a
tightening-up procedure as detailed below

• it is important to make certain, that no more than 30% of required bolt stress (table A) is
achieved on the initial set. Should this occur, serious damage can be done on the gasket and
subsequent tightening can not off set the damage.
• After following this sequence, a final tightening should be performed in a c1ockwise bolt-to-
bolt sequence to ensure that all bolts have been evenly stressed.
• The utilisation of impact wrenches is recommended all over the installation whereas allowed
by c1earance. The utilisation of impact wrenches is strictly required on connection in
between flange and valve body.
• Should the Quality Control Plan or Quality provisions require, at this stage the utilisation of a
dark coloured pen to mark the checked bolts is required.

- 41 -
 Annex
Torque
Torque Required To Produce Bolt Stress

The torque or turning effort required to produce a certain stress in bolting is dependent upon a
number of conditions, some of which are:
1. Diameter of bolt
2. Type and number of threads on bolt
3. Material of bolt
4. Condition of nut bearing surfaces
5. Lubrication of bolt threads and nut bearing surfaces.

Table A: Torque data:

Stress

Diameter at Area at 30,000 psi 45,000 psi 60,000 psi

Nominal Number of Root of Root of Torque Load Torque Load Torque Load
Diameter of Threads Thread Thread Ft/Lbs Lbs Ft/Lbs Lbs Ft/Lbs Lbs
Bolt (Inches) (Per Inch) (Inches) Sq.Inch
1/4 20 .185 ,027 4 810 6 1215 8 1620
5/16 18 ,240 ,045 8 1350 12 2025 16 2700
3/8 16 ,294 .068 12 2040 18 3060 24 4080
7/16 14 .345 ,093 20 2790 30 4185 40 5580
1/2 13 .400 .126 30 3780 45 5670 60 7560

9/16 12 .454 ,162 45 4860 68 7290 90 9720

5/8 11 .507 ,202 60 6060 90 9090 120 12120
3/4 10 ,620 ,302 100 9060 150 13590 200 18120
7/8 9 ,731 ,419 160 12570 240 18855 320 25140
1 8 .838 .551 245 /. 16530 368 24795 490 33060

1-1/8 8 .963 .728 355 21840 533 32760 710 43680

1-1/4 8 1.088 .929 500 27870 750 41805 1000 55740
1-3/8 8 1.213 1.155 680 34650 1020 51975 1360 69300
1-1/2 8 1.338 1.405 800 42150 1200 63225 1600 84300
1·5/8 8 1.463 1.680 1100 50400 1650 75600 2200 100800

1-3/4 8 1.588 1.980 1500 59400 2250 89100 3000 118800

1-7/8 8 1.713 2.304 2000 69120 3000 103680 4000 138240
2 8 1.838 2,652 2200 79560 3300 119340 4400 159120
2-1/4 8 2.088 3.423 3180 102690 4770 154035 6360 205380
2·1/2 8 2.338 4.292 4400 128760 6600 193140 8800 257520

2-3/4 8 2.588 5.259 5920 157770 8880 236655 11840 315540

3 8 2.838 6.324 7720 189720 11580 284580 15440 379440
3-1/4 8 3.088 7.490 10000 224700 15000 337050 20000 449400
3-1/2 8 3.338 8.750 12500 262500 18750 393750 25000 525000

- 42 -
 Document No.: ZEN000-DD04-0143/0144-000001

Appendix 2
Technical Contract Condition non-project-specific Index / Date: d / 2006-03-30
Page: 1 of 3

Handhabung/Handling

(Firma/company) Montage-Abschlussprotokoll Nur für internen Gebrauc

Erection Clearance Certificate For internal use only
Protokoll-Nr./Certificate
No.:
(ECC)

Q
Kraftwerk/Power Plant Block/Unit KW-Nr./Plant CoUA Inhaltskennzeichen/Contents CodeZähl-Nr./Reg. No

Bauwerk/Abschnitt:
Ausgabedatum/Date of Issue:
Building/Structure
System/Komponente:
System/Component

Anlagen/
Appendices
Die Verantwortlichen für die Montage und The parties responsible for installation and
Inbetriebsetzung bescheinigen, daß das/der commissioning confirm that the system/
beschriebene System/Anlagenteil sich in part of plant detailed is in a sufficiently
einem ausreichend fortgeschrittenem advanced stage of installation to carry out
Montagezustand befindet, um die commissioning.
Inbetriebsetzung durchführen zu können.

Beschreibung System/Anlagenteil:
Description of system/part of plant:
Systemschaltplan Nr.:
System diagram no.:
Zugehörige Unterlagen:
Associated documents:
Keine offenen Punkte
No outstanding items
Liste der offenen Punkte Ref. Nr.:
List of outstanding items
Liste der Tests und Abnahmen Ref. Nr.:
List of tests and inspections
Bemerkungen/Remarks:

Montage/Installation Ibs/Commissioning
Firma/Dienststelle
Company/
Department

- 43 -
 Document No.: ZEN000-DD04-0143/0144-000001

Appendix 2
Technical Contract Condition non-project-specific Index / Date: d / 2006-03-30
Page: 1 of 3

Name
Name
Datum
Date
Unterschrift
Signature

Verteiler/Copy to: Original in Baustellendokumentation /Original to be filed in

site documentation

- 44 -
 Document No.: ZEN000-DD04-0143/0144-000001

Appendix 1
Technical Contract Condition non-project-specific Index / Date: d / 2006-03-30
Page: 1 of 1

(Firma/company) Montage-Anweisung Handhabung/Handling:

Assembly Instruction Nur für internen Gebrauch/
For internal use only
Seite 1 von 2

(1) (2) DM (3) (11)

Kraftwerk/Power Plant Block/Unit KW-Nr./Plan UA Inhaltskennzeichen/Content Zähl-Nr./Reg.

System/Komponente: (4)
System/Component

Anweisungstitel: (5)
Instruction Title

Seitenzahl: Anlagen:
No. of Pages Appendices
1 Montageumfang
Scope of Assembly

Ausfüllanweisung/ Data entry instruction

(1) Anlagennamen Project name

(2) Kraftwerksnummer Project identification
(3) Inhaltskennzeichen Contents code
(4) System/Komponente System/ Component ID
(5) Anweisungstitel Instruction title
(6) Erstellt: Unterschriftenfeld für den Prepared by editor of the instruction
Ersteller der Anweisung (Komponenten- Contractor
Hersteller/Lieferant)
(7) Geprüft: Prüfung der MAW durch den Verified by Contractor
Komponenten- Hersteller oder
Lieferanten
(8) Geprüft: Prüfung der MAW durch die Verified by ordering department
bestellende Abteilung
(9) Geprüft: Prüfung der MAW durch den Verified by the responsible lead engineer
zuständigen Teamleiter Errichtung construction
(10) Freigabe: Freigabe der MAW durch Released by the Customer’s Project
Projektleitung) management
(11) Zählnummer: Laufende MAW- Nummer Registration number of the assembly
instruction
Die Angaben für (1) - (4) und (11) werden The input for (1) - (4) and (11) will be
vom Besteller vorgegeben. given by the Customer

Transmittal, reproduction, dissemination and/or editing of this document as well as utilization of its contents and
Siemens communication thereof to others without express authorization are prohibited. Offenders will be held liable for payment
of damages. All rights created by patent grant or registration of a utility model or design patent are reserved.

Timelkam_TE2_Manuale_rev0.doc
 Document No.: ZEN000-DD04-0143/0144-000001

Appendix 1
Technical Contract Condition non-project-specific Index / Date: d / 2006-03-30
Page: 1 of 1

*) Nichtzutreffendes Erstellt Geprüft/Freigeg.*) Geprüft/Freigeg.*) Geprüft/Freigeg.*) Freigegeben.

streichen
Delete if Prepared by Verified /Released by Verified /Released by Verified /Released by Released by
inappropriate
Dienststelle (6) (7) (8) (9) (10)
Department
Name
Name
Datum
Date
Unterschrift
Signature

Transmittal, reproduction, dissemination and/or editing of this document as well as utilization of its contents and
Siemens communication thereof to others without express authorization are prohibited. Offenders will be held liable for payment
of damages. All rights created by patent grant or registration of a utility model or design patent are reserved.

Timelkam_TE2_Manuale_rev0.doc
 Annex
Oil-Flushing

- 47 -
 Annex
P&ID - LOS

- 48 -
 Annex
P&ID - LOS

- 49 -
 Annex
P&ID - LOS

- 50 -
 Annex
P&ID - LOS

- 51 -
 Annex
P&ID – Lifting oil

- 52 -
 Annex
P&ID – Lifting oil

- 53 -
 Annex
Franke Filter

- 54 -
 Annex
Franke Filter

- 55 -