Hot Oil Flushing Procedure for Mechanical Package

Banyu Urip Project

HOT OIL FLUSHING PROCEDURE

FOR MECHANICAL PACKAGE

IDBC-TS-WPZZZ-XXXX

A 15 September 2014 Issued for Internal review RHS

Rev Rev Date Description Prepared Checked Endorsed Approved

BANYU URIP PROJECT

HOT OIL FLUSHING PROCEDURE FOR MECHANICAL PACKAGE

IDBC-TS-WPZZZ-XXXX 5 September 2014

Rev A MPI: NOT CLASSIFIED Page 2 of 13

IDBC-TS-KPZZZ-.Rev A HOT OIL FLUSHING PROCEDURE FOR MECHANICAL PACKAGE

REVISION MODIFICATION LOG

Revision Section Description

A All Issued for internal review

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TABLE OF CONTENT

1. PURPOSE..................

2. CODE AND STANDARD

3. SCOPE.....

4. EQUIPMENTS REQUIRED..

5. ACCEPTANCE CRITERIA.

6. FLUSHING FLOWRATE

7. FLUSHING EXECUTION...

7.1 SAFETY REQUIREMENT

7.2 ORGANIZATION CHART

7.3 PRE-EXECUTION WORK...

7.4 EXECUTION WORK....

8. POST FLUSH

9. ATTACHMENTS.

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1. PURPOSE

The main objective of the hot oil pipe flushing for mechanical package is to ensure site fabrication piping and cooler for mechanical package is clean for the lube oil system. High velocity of oil flow will remove scale and dirts from the internal piping and through close loop circulation. The scale and dirt will be trapped at flushing strainer.

2. CODE AND STANDARD

The ISO 4406 Cleanliness code range numbers for 4, 6 and 14 micron levels are 16/14/12 or lower (particle counter calibration per ISO 11171).

3. SCOPE

The procedure covers the internal cleanliness of the pipeline and lube oil cooler by flushing loop. The designated pipeline number and lube oil cooler to be flushed is as below:

1. Gas Turbine Generator A/B/C/D/E/F with cooler 2. HP Fuel Compressor A/B with cooler 3. Gas Lift Compressors 1st Stage Packages A/B and 2nd Stage Packages A/B

with cooler 4. Atmospheric Vapor Recovery Compressors A/B with cooler 5. Vapor Recovery Compressors 1st Stage Packages A/B and 2nd Stage

Packages A/B with cooler

Flushing loop must be done by interconnection external piping first. After flushing result is acceptable than continue flushing loop with interconnection piping with cooler package.

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1. Gas Turbine Generator A/B/C/D/E/F

Tag No Equipment/Line Number SCH Oil Type Material

V833500

3-OL-833-9922-A11A 10S ISO VG32

(Turbine Oil)

SS A312 GR. TP316L 3-OL-833-9902-A11A 10S SS A312 GR. TP316L -OL-833-9901-A11A 40S SS A312 GR. TP316L

HFF833511 SS

V833530

3-OL-833-9905-A11A 10S ISO VG32

(Turbine Oil)


HFF833541 SS

V833560

3-OL-833-9909-A11A 10S ISO VG32

(Turbine Oil)


HFF833571 SS

V833600

3-OL-833-9913-A11A 10S ISO VG32

(Turbine Oil)


HFF833611 SS

V833630

3-OL-833-9916-A11A 10S ISO VG32

(Turbine Oil)


HFF833641 SS

V833660

3-OL-833-9920-A11A 10S ISO VG32

(Turbine Oil)


HFF833671 SS

2. HP Fuel Compressor A/B

Tag No Equipment/Line Number SCH Oil Type Material

V966510

4-OL-966-4123-B11A 10S ISO VG68

(Synthetic Oil, PAG) CPI: CP-

1507-68

SS A312 GR. TP316L 4-OL-966-4124-B11A 10S SS A312 GR. TP316L 4-OL-966-4125-B11A 10S SS A312 GR. TP316L 4-OL-966-4126-B11A 10S SS A312 GR. TP316L

HFF966514

V966610

4-OL-966-4127-B11A 10S ISO VG68

(Synthetic Oil, PAG) CPI: CP-

1507-68

SS A312 GR. TP316L 4-OL-966-4128-B11A 10S SS A312 GR. TP316L 4-OL-966-4129-B11A 10S SS A312 GR. TP316L 4-OL-966-4130-B11A 10S SS A312 GR. TP316L

HFF966614

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3. Gas Lift Compressors 1st Stage Packages A/B and 2nd Stage Packages A/B

Tag No Equipment/Line Number Spec Oil Type Material

V654510

3-OL-654-5017-A11A 10S ISO VG46

(Turbine Oil)


HFF654513

V654610

3-OL-654-6017-A11A 10S ISO VG46

(Turbine Oil)


HFF654613

V654560

3-OL-654-5040-A11A 10S ISO VG46

(Turbine Oil)


HFF654563

V654660

3-OL-654-6040-A11A 10S ISO VG46

(Turbine Oil)


HFF654663

4. Atmospheric Vapor Recovery Compressors A/B


V656510 3-OL-656-5825-A11A 10S ISO VG32

(Turbine Oil) SS A312 GR. TP316L

3-OL-656-5826-A11A 10S SS A312 GR. TP316L HFF656516

V656610 3-OL-656-5823-A11A 10S ISO VG32



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5. Vapor Recovery Compressors 1st Stage Packages A/B and 2nd Stage Packages A/B


V656540 3-OL-656-5895-A11A 10S ISO VG32 (Turbine Oil)

SS A312 GR. TP316L 3-OL-656-5896-A11A 10S SS A312 GR. TP316L

HFF656547

V656640 3-OL-656-5752-A11A 10S ISO VG32 (Turbine Oil)

SS A312 GR. TP316L 3-OL-656-5753-A11A 10S SS A312 GR. TP316L

HFF656647

V656570 3-OL-656-5917-A11A 10S ISO VG32



V656670 3-OL-656-5901-A11A 10S ISO VG32



The limitation of the flushing for each above pipe line refers to P&ID marked up drawings in attachment 1.

4. EQUIPMENT REQUIRED

Flushing activity requires below material, not limited to. All metal piping material shall be 316SS and all internal shall be cleaned after manufacturing. And all of fastening device (bolts/nuts and gasket) shall be provided together.

5. ACCEPTANCE CRITERIA

1. The ISO 4406 Cleanliness code range numbers for 4, 6 and 14 micron levels are 16/14/12 or lower (particle counter calibration per ISO 11171).

2. There are no visible particles on the 100 mesh screen or no more than 5 non-metallic particles no larger than 0.010 inch (0.254mm) in the 25 micron bag(s).

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6. FLUSHING FLOWRATE

The following flushing sequence is required to minimize the possibility of contamination of components and assemblies. It is to be followed at the manufacturing facilities and in the field. Adherence to this sequence as prescribed in Figure 1, will substantially minimize the effort and the time necessary to successfully complete the flushing operations. Each flow line, cooler, etc. shall be flushed at a flow rate and temperature so that a minimum Reynolds number of 4000 is achieved through each section, or 150% of design flow, whichever is applicable. The Reynolds number can be calculated by:

Nr = 3160.GPM CS.D

Where: GPM = flushing fluid flow rate - gallons per minute CS = flushing fluid viscosity - centistokes

D = pipe/tube inside diameter - inches

7. FLUSHING EXECUTION 7.1 SAFETY REQUIREMENT

a) Ensure Job Safety Analysis (JSA) has been prepared, reviewed and approved by the authorize persons.

b) Conduct safety toolbox meeting within the working crew in accordance with approved JSA.

c) Prepare necessary work permits as required d) Ensure the use of the minimum Personal Protective Equipment (rain gear, rubber

boots, rubber gloves, safety glasses and visor) for all personnel involved. e) Running water shall be made available at working area near the pump f) Only personnel with adequate training shall execute hot oil flushing operations. g) Personnel working within Pre/Commissioning Team must be fully aware of their

duties, responsibilities and potential hazards associated with the system to be commissioned or tested.

h) Material data sheet for the oil type is to be displayed in the secured area of the hot oil flushing unit. Personnel carrying out the work should be familiar with the information contained in the document.

i) Walkie-talkies for use by the Pre/Commissioning Team to be made available. Public announcement must be made when necessary.

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j) Provide safety barriers on the affected working areas, especially surrounding piping and lube oil cooler.

k) Appropriate lighting and fire-fighting equipment must be readily available at site. l) Necessary warning signs are also be required to provide at designated locations. m) A safety risk assessment will be conducted prior commencing the flushing work. n) All Schedule waste has to manage to comply with Waste Management System

7.2 ORGANIZATION CHART The organisation chart during flushing execution as shown in attachment-1:

a) Flushing leader is the responsible person for the successfully execution and coordinate overall preparation as per the approved plan.

b) One supervisor with the crew will be assigned at flushing area. He will be responsible for all require preparation and execution activities. He will be a signal controller when the flushing is ready.

c) One safetyman will be assigned at pig launcher area while one more other at pig receiver area. They will be responsible to secure the area boundary from unauthorized and relevant persons as well as advise the crews for any unsafe action and condition during the preparation and execution.

7.3 PRE-EXECUTION WORK The flushing will be executed after the completion of pneumatic test and air blowing of the pipe lines. A join inspection will be conducted between the Contractor and Client representative to ensure the reediness of pre-execution work are in placed with the agreed plan and safety requirement.

7.4 EXECUTION WORK - Confirm lube oil cooler fan motor has been de-energized. - Confirm lube oil cooler pipes are cleaned before installation. - Confirm Air blowing of the external lube oil pipe line has been done. - Confirm oil for flushing is same specification with oil machinery.

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A. Flushing Interconnecting External Piping STEP1: Preparation

a. Line-up flushing equipment, hoses and fittings as per attachment for every package. Barricade the area of flushing activities.

b. Filling temporary lube oil flushing tank up to 60% of the tank using oil filling. During filling lube oil flushing tank, filter shall be installed to prevent any contamination in original lube oil.

c. For first flushing, install mesh 50 at the outlet spool piping. d. Priming flushing pump with oil by open pump suction valve (V1) and bleed through

recycle valve (V2) back to tank. e. Open recycle valve (V2) to about 20% and bump start the pump with discharge valve

(V3) closed position. f. Restart flushing pump if there is no leak and slowly open more recycle valve (V2).

STEP2: Flushing loop with 50 mesh filter a. Line up V4, V5 & V6 and then slowly open V3 discharge valve and start filling L.O

flushing for loop. Caution: 1) Monitor oil tank level closely, top-up oil into the tank if necessary. 2) Check all joints for any leak. If there is major leak, immediately stop flushing pump and repair leak.

b. When flow of oil return back to the flushing oil tank established, slowly closed recirculation line V2 and continue flushing loop for 2 hours. Caution: 1) Keep on monitor tank level and pump discharge pressure. 2) If pump discharge pressure increase more than 4 barg, stop flushing and prepare to clean or change filter basket.

c. Check wire mesh filter every 1 hour. Stop flushing when no dirt collected at 50 mesh filter.

STEP3: Flushing loop with 100 mesh filter a. Stop flushing pump and change strainer filter to 100 mesh and line-up through loop. b. Line up V4, V5 & V6 and then slowly open V3 discharge valve and start filling L.O

flushing for loop. Caution: 1) Monitor oil tank level closely, top-up oil into the tank if necessary. 2) Check all joints for any leak. If there is major leak, immediately stop flushing pump and repair leak

c. When flow of oil return back to the flushing oil tank established, slowly closed recirculation line V2 and continue flushing loop for 2 hours.

d. Inspect wire mesh filter every 1 hours and cleanness of the flushing oil/strainer. Stop flushing when no dirt collected at 100 mesh filter.

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Figure 1. Typical PID for flushing equipment B. Flushing Interconnecting External Piping with Cooler

STEP1: Preparation a. After the external pipe flushing result acceptable, connect external pipe with cooler

package. b. For flushing, still using 100 mesh filter basket into the outlet spool. c. Priming flushing pump with oil by open pump suction valve (V1) and bleed through

recirculation valve V2 back to tank. d. Open recirculation valve V2 minimum recycle line to about 20% and bump start the

pump. Restart flushing pump if there is no leak and slowly open more recycle valve (V2). 1) Monitor oil tank level closely, top-up oil into the tank if necessary. 2) Check all joints for any leak. If there is major leak, immediately stop flushing pump and repair leak

e. Line up V4, V5 & V6 and then slowly open V3 discharge valve and start filling L.O flushing for loop. Caution: 1) Monitor oil tank level closely, top-up oil into the tank if necessary. 2) Check all joints for any leak. If there is major leak, immediately stop flushing pump and repair leak

f. When flow of oil return back to the flushing oil tank established, slowly closed recirculation line V2 and continue flushing loop for 2 hours.

g. Inspect wire mesh filter every 1 hours for cleanness of the flushing oil. Stop flushing when no dirt collected at 100 mesh filter.

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8. POST FLUSH After completion of the hot oil flushing, secure temporary equipment for flushing and pipe ends are to be sealed or reinstall to the system to prevent contamination from entering the piping system.

9. ATTACHMENTS

Attachment 1. Inspection Report Attachment 2. Gas Turbine Loop Flushing Attachment 3. HP Fuel Compressor Loop Flushing Attachment 4. Gas Lift Compressors Loop Flushing Attachment 5. Atmospheric Vapor Recovery Compressors Loop Flushing Attachment 6. Vapor Recovery Compressors Loop Flushing

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INSPECTION REPORT HOT OIL FLUSHING

CUSTOMER : CERTIFICATE NO : OWNER : DATE :

PROJECT : JOB NO :

SYSTEM : SUPERVISOR :

TEST PACK NO : PAGE : 1 OF 1

OIL FLUSHING DATA REMARKS 1 OIL TYPE 2 START : DATE/TIME / 3 STOP: DATE/TIME / 4 DURATION (hours & minutes) 5 TEMPERATURE/VISCOSITY OC/ Cst 6 FLOWRATE Litre / Min

SAMPLES TAKEN CLEANLINESS LEVEL REMARKS DATE TIME ISO 4406

1

2

3

4

Line Number / Equipment Number / Description (if applicable)

REMARKS:

THE ABOVE WORK HAS BEEN CARRIED OUT AND COMPLETED TO THE SATISFACTION OF THE FOLLOWING REPRESENTATIVES.

ACCEPTANCE CESCOS

NAME / SIGNATURE/DATE

TRIPATRA-SAMSUNG


MCL


VENDOR


JUMPER LOOPING

NOTES :

: HOF PUMP

: FILTER

: VALVE

: INLET

: OUTLET

: HOSE

: HOF PUMP

: FILTER

: VALVE

: INLET

: OUTLET

: HOSE

NOTES :

JUMPER LOOPING JUMPER LOOPING

JUMPER LOOPING

JUMPER LOOPING

NOTES :

: HOF PUMP

: FILTER

: VALVE

: INLET

: OUTLET

: HOSE

JUMPER LOOPING

: HOF PUMP

: MANIFOLD

: VALVE

: INLET

NOTES :

JUMPER LOOPING

: OUTLET

: HOSE

: HOF PUMP

: FILTER

: HOSE

NOTES:

JUMPER LOOPING

: INLET

: OUTLET

: VALVE

JUMPER LOOPING

NOTES :

: HOF PUMP

: FILTER

: HOSE

: INLET

: OUTLET

: VALVE

JUMPER LOOPING

NOTES:

: HOF PUMP

: FILTER

: VALVE

: INLET

: OUTLET

: HOSE

Hot Oil Flushing Procedure for Mechanical Package

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