BANUWATI-K GAS COMPRESSOR PLATFORM

CONTRACT NO. 332003115

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81 27-12-2013 ISSUED FOR REVIEW PRAWOTO B.HARI W RUSAEFUL
REV. DATE DESCRIPTION BY CHECK. REVIEW. EXAM. APPRO.
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CERTIFI. NO.
DOCUMENT NO.
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LUBE OIL LINE CLEANING
A112002816
AND FLUSHING PROCEDURE
3115-BWK-PRQ-F0-001 021.5





CONTENTS


1.0 INTRODUCTION ........................................................................................................................ 3
2.0 PROJECT OVERVIEW ............................................................................................................... 3
3.0 SCOPE ....................................................................................................................................... 4
4.0 REFERENCES ........................................................................................................................... 5
5.0 PREPARATION FOR FLUSHING .............................................................................................. 6
6.0 PROCEDURE ............................................................................................................................. 7
7.0 ACCEPTANCE CRITERIA ......................................................................................................... 8
8.0 POT FLUSH PROCEDURE ........................................................................................................ 8
9.0 LUBE OIL COOLERS ............................................................................................................... 9

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1.0 INTRODUCTION

Currently the existing Banuwati-A, which started up in 2007, is the main gas production
platform in Central Area, whose gas is delivered to Widuri P platform in North Area for
power generation and to a gas plant in Pabelokan island for further gas conditioning.
Gradually the well pressure from Banuwati-A is expected to be deplete over years, so a
new Banuwati Gas Compressor Platform (Banuwati-K) will be installed alongside
Banuwati-A for Boosting pressure to increase operating pressure of Banuwati-A to
normal level to ensure gas flow to Pabelokan gas plant and Widuri platform. In addition
to Banuwati-A gas, the gas from Asti-A and Mila-A will also be compressed by booster
compressors on Banuwati-K.
This new Banuwati Gas Compressor Platform (Banuwati-K) shall accommodate all
equipment such as gas compressors, etc. for gas pressure boost and it will be bridge
connected to Banuwati-A platform so the operators from Banuwati-A can access and
operate it.

2.0 PROJECT OVERVIEW

Table 1.1. below briefly shows the basic scope of the project.

No. Item Description
1. Field or Site General
Location
Banuwati Facility is located at 120-160 km off
the north coast of West J ava. The new booster
compressor platform, BWK, will be bridge
connected to Banuwati-A.
2. Description of Banuwati-K
Gas Compression Platform.
- Design flow to BWK is 100 MMscfd wet gas
(ref.2)
- 2 x 50% sets of Gas Turbine driven booster
compressors will be accommodated on
BWK for processing 100 MMscfd wet gas.
Each compressor has it own dedicated
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suction and discharge scrubber and after
cooler.
3. Condensate stabilization Condensate that will be produced needs to be
stabilized (by flashing) prior to sending into the
6 Kartini pipeline. Condensate stabilization will
be executed in the existing closed drain
vessel, V-370 on BWA and in new closed drain
vessel, V-500 on BWK.
4. Utilities Several utilities will be installed on BWK.
Diesel will be taken from BWA. Supply boat
landing facility is also provided diesel.
5. Cooling and separation
process
Since the operating pressure will be reduced
from 620 psig (normal) to 175 psig, an
adequate check on the existing production
cooler, E-200A/B and the existing production
separator, V-210 has been executed. As a
result of feed study an additional production
cooler e-900A/B will be installed on BWK.

3.0 SCOPE

This specification covers the preparation and acceptance criteria for the cleaning
and flushing of components and piping used in lube, seal and hydraulic systems on
Solar packages. Proper cleaning and flushing will remove the contamination built
into components and systems before operation so that sensitive components do
not fail prematurely. Components to be cleaned and flushed include, but may not
be limited to the following:
o Lube oil supply and drain lines
o Seal oil supply and drain lines
o Servo system supply and drain lines
o Hydraulic start system supply and drain lines
o Power take off system supply and drain lines
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o Lube oil reservoir level control (auto fill) system Seal oil interconnect lines
o Lube oil coolers
o Lube oil interconnect lines

Reservoirs, tanks, and tank vent piping require mechanical cleaning only, per
Appendix A.

Note: this specification covers the flushing requirements for components (such as
the turbine package, the lube oil cooler assembly and interconnect piping) both, at
the manufacturing plant and in the field. The procedures described herein have a
universal application.

The turbine package is normally flushed prior to delivery and only the external
cooler interconnect lines and the coolers need to be flushed in the field if the
turbine package integrity is maintained and if the fill oil meets the cleanliness
requirements of Section 7.0 of this specification. Any residual debris on the turbine
package that is generated during shipment should be easily and immediately
removed with the package filter.

The lube oil coolers are pre-flushed, to the cleanliness levels of this specification,
at the suppliers facility, but a field flushing of the oil cooler is recommended as a
result of external factors related to transportation and storage prior to the lube oil
cooler installation.

Any interconnect piping that is used to connect the cooler to the package shall be
cleaned to the Acceptance Criteria of this specification, as shown in section 7.0.

4.0 REFERENCES

Solar Specifications

ES2184 Cleaning and flushing of Hydraulic System / Components
ES 9-224 Specification For Lubricating Oils For Use In Solar Gas Turbines
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ES 9-248 Corrosion Preventive Oil For Long Term Preservation

Other

ISO 4406 ISO Cleanliness Code
ISO 11171 Calibration of Automatic Particle Counters

ASTM D6439 -05 Standard Guide for Cleaning, Flushing, and Purification of Steam,
Gas, and
Hydroelectric Turbine Lubrication Systems


5.0 PREPARATION FOR FLUSHING

Rust, scale, machining chips, grit blast, weld slag, etc. shall be thoroughly removed
from all tanks, vessels, pipes, etc. prior to flushing.

Tank internal surfaces, tank vent pipi ng and vessels shall be cleaned per Appendix
A. Pickling and passivation of carbon steel pipe work and equipment shall be
treated, prior to being flushed, as per
Appendix B. Stainless steel piping is recommended, as it does not need to be
pickled. Interconnect piping needs to be designed in a fashion that facilitates
proper cleaning, as referred by ASTM D6439 -05. Sensitive components (bearings,
seals, valve, etc) shall be removed or bypassed during the cleaning and flushing
to avoid contamination.

Equipment required: (See Figure 1 for typical flushing system)

1. Flushing pump of sufficient capacity.
2. Flushing fluid heater.
3. Flushing fluid filter rated at 5 micron with an efficiency of 99.5% or
better (Beta ratio, 25=200 or better) to remove contamination from flushing
loop.
4. Flushing fluid strainer(s) (100 mesh or finer) or filter bag(s) (25 micron or
finer) at end of each pipe run or component being flushed for cleanliness
verification.
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5. Particle Counter (per ISO 11171) to determine fluid cleanliness (ISO 4406)
or optical filter patch kit.
6. Flow measurement device for each piping leg or component.
7. Thermometer (s).
8. Dead blow hammers or pneumatic vibrators.
9. Flushing fluid that is compatible with the mineral based oils in Solar ES 9-
224.
10. Flushing oil reservoir. The reservoir is normally contained in a flushing rig
external to the package. However, if the package lube from the lube oil
tank is used to flush, then an extra flush loop filter should be installed
where the flushing oil re -enters the tank (see Fig.1, Note 4).

6.0 PROCEDURE

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.

Required Flushing Sequence
a) Pre-filter the package fill oil or flushing oil to ISO 16/14/12 cleanliness level.
b) Loop flush/filter the flushing rig, and any associated piping, that is
considered part of the flushing system, at the maximum capacity of the
rig/ flushing system to ISO 16/14/12 and no 100 -mesh screen captured
particles. (Note: Steps a & b can be done together if the flushing rig has
its own oil reservoir).
c) (This step does not appl y for cooler manufacturers.) Do not flush
package oil lines through the bearings of the engine, driven equipment, and
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3115-BWK-PRQ-021.5
gearboxes. Disconnect package oil lines from bearing inlet ports, and loop
these lines back to the flushing reservoir. Then flush/filter to ISO 16/14/12
and no 100 mesh screen captured particles.
d) (Thi s step does not appl y for cool er manufacturers.) Add the off-skid
cooler interconnect piping to the flush loop (without package or cooler
connection) and flush/filter to ISO 16/14/12 and no 100 mesh screen
captured particles. Other means of cleaning the cooler interconnect
piping may be used, however, the same ISO 16/14/12 cleanliness
requirements shall be met.


7.0 ACCEPTANCE CRITERIA

The following flushing acceptance criteria shall be met for the
following conditions.
A. Flushing of components at the manufacturing facility: such as turbine
package and lube oil cooler assembly shall meet Section 7.1 and 7.2.
B. Field flushing of: the oil fill, flushing rig, cooler lines and cooler assembly
shall meet Section 7.1 at a minimum.
7.1 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).
7.2 There are no visible particles on the 100 mesh screen, or no more than 5
non-metallic particles no larger than 0.010 inch (0.254 mm) in the 25
micron ba g(s).

8.0 POT FLUSH PROCEDURE

After flushing, the piping, system, and components shall be sealed with metal blind
flanges or metal plugs to prevent recontamination. If the piping or component will
be in storage for any length of time it shall be completely drained and flushed with
preservative oil per Solar ES 9-248 or partially filled with a vaporizing preservative
oil that is compatible with the mineral based oils in Solar ES 9-224. Preservative
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3115-BWK-PRQ-021.5
oils shall be filtered to meet the cleanliness requirements of this specification.
Tanks and vessels shall be preserved per Appendix B.

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

Table 1 shows the minimum required flow rates for several pipe and tube sizes.
Reynolds numbers in excess of 4000 will increase the effectiveness of the flush
and will decrease the flushing time required to achieve the required cleanliness.
Proper cleaning of individual details before assembly as well as clean assembly
processes will also reduce flush times and reduce contamination hideout.


9.0 LUBE OIL COOLERS

Air/Oil Coolers
Air to oil coolers are to be flushed per the procedure shown in section 4.0 and
shall meet the cleanliness acceptance criteria of section 5.0 of this specification.

Water to Oil Coolers
1. Plate and Frame Water to Oil Coolers
Since the plate and frame type water to oil coolers can be inherently clean
with clean assembly procedures and controls and since a Reynolds number
of 4000 may not be achievable, these coolers should only need to be flushed
to the following conditions.
a. Flow: 1.5 times the design flow
b. Temperature: 150 F
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c. Duration: At least 1-hour before a fluid sample can be taken and the
strainers or filter bags at the outlet of the flushing rig can be inspected.
d. Direction: The direction of the oil flow shall be both in the forward and
reverse, starting with the reverse direction of flow first.
e. Cleanliness Acceptance Criteria: These coolers must meet the
acceptance criteria of section 7.0 of this specification.

2. Shell and Tube Water to Oil Coolers
On a shell and tube cooler the oil flows through the baffles and not the tubes.
The pressure created inside the cooler when trying to achieve a turbulent flow
that is equivalent to a 4000 Reynolds number, may surpass the vessels
design pressure. Based on the above reasons, it is recommended that the
shell and tube type water to oil coolers be flushed to the following conditions:
a. Flow: 1.5 times the design flow
b. Temperature: 150 F
c. Duration: At least 1-hour before a fluid sample can be taken and the
strainers or filter bags at the outlet of the flushing rig can be inspected
d. Direction: The direction of the oil flow shall be both in the forward and
reverse, starting with the reverse direction of flow first.
e. Cleanliness Acceptance Criteria: These coolers must meet the
acceptance criteria of section 8.0 of this specification.

3. Dual coolers with transfer valves assemblies
Every precaution shall be taken to ensure and maximize the cleanliness of
the internal sections of the transfer valve and interconnect piping assembly
prior to assembly. Doing this will reduce the total flushing time required to
achieve the Cleanliness Acceptance Criteria. The complete dual water to
oil cooler and transfer valve assembly shall meet the same cleanliness
acceptance criteria of section 7.0 of this specification prior to shipment.






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FM1 - Flow Meter
FS1 - Strainer, Flush Pump Suction
FS2 - Filter, Flush Loop
FS3 - Inspection Screen or Filter Bag
FS4 - Strainer, Fill Pump Suction
FS5 - Filter, Fill System
FS6 - Filter, Flush Loop
H1 - Heater (may
be in tank) P1 -
Pump, Flush
Loop
P2 - Pump, Fill System
TI1 - Temperature Indicator
VH1 - Valve, Sample

Figure 1. Typical Flushing System
FS1 P1 H1 FS2
TI1
FM1
FS6 FS3
VH1
FS4 FS5 P2
SECTION OR
COMPONENT BEING
FLUSHED
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3115-BWK-PRQ-021.5
NOTES
1. Delta P indicators across filters are required.
2. Pump relief valves are required if positive displacement pumps are used.
3. Flow control valves, bypassing for positive displacement pumps, throttling for
centrifugal pumps are required.
4. If the required flushing sequence on page 2 isnt followed or if the package lube oil
tank is used instead of a separate fill system, then FS6 should be installed to
prevent contamination of the package lube oil tank.


TABLE 1
FLOW RATES FOR REYNOLDS NUMBER (NR) = 4000



PIPE/TUBE SIZE
GPM REQUIRED FOR
NR = 4000 W/C32 OIL
80F OIL
48 CS
120F Oi l
21 CS
150F Oil
12.5 CS
0.375 X 0.049 tube 16.8 7.4 4.4
0.50 X 0.049 tube 24.4 10.7 6.4
0.75 X 0.049 tube 39.6 17.3 10.3
1.0 X 0.049 tube 54.8 24.0 14.3
1.25 X 0.049 tube 70.0 30.6 18.2
0.75 Sch 80 pipe 45.1 19.7 11.7
1.0 Sch 80 pipe 58.1 25.4 15.1
1.5 Sch 80 pipe 91.1 39.9 23.7
2.0 Sch 40 pipe 117.4 51.5 30.7
3.0 Sch 40 pipe 186.4 81.6 48.5
4.0 Sch 40 pipe 244.5 107.0 63.7
6.0 Sch 40 pipe 368.5 161.2 96.0


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APPENDIX A
CLEANING OF OIL TANK INTERNAL SURFACES
AND TANK VENT PIPING


1.0 Surface Preparation
A. Abrasive blast to produce a grayish metallic near white surface with 1 mil
minimum profile depth.

B. Steel plugs shall be used for thread protection during the blast and paint
process. These plugs shall be removed from all threaded openings and the
grit removed by using shop air or vacuuming. Brayco 785 shall be applied
to the threads and plastic plugs insert ed into the ports.
C. All flange gasket surfaces must be protected during the blast and paint
process. Brayco 785 shall be applied to the flange gasket surfaces and
shipping covers shall be installed to protect the flange surface and avoid
contamination of the lube oil tank.
D. All pipe assemblies that will become part of the base assembly must be
blasted internally and swabbed clean before being installed.
E. Lube oil tank covers are to be painted to Solar system E unless otherwise
specified by engineering drawing
F. Manifolds which are welded into oil tank covers shall be unpainted on the
section that is internal to the tank.
G. Tank associated vent piping is to be mechanically cleaned per section 2.0.


2.0 All residual grit, scale, flakes, or other foreign matter shall be thoroughly removed
from the tank or piping internal surfaces before the application of Brayco 785 or
other approved preservative fluid.

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Pipe and manifold sections which are part of the tank assembly as well as the
tank vent piping shall be thoroughly cleaned with shop air and have a clean swab
or pig drawn through them until the swab or pig is clean of any detectable grit or
debris.

No residual grit is permitted. No flaky rust or mill scale is permitted. The
assembly shall be considered clean when foreign material such as scale, rust,
metal shavings, and sand are not visible to the eye and grittiness is not
detectable to the touch.

Cleaned and preserved piping shall be installed in the system and thoroughly
sealed against subsequent external source contamination as soon as practical.

3.0 Application of Brayco 785 or Other Approved Preservative Fluid - Brayco 785 can
be applied to a surface showing slight discoloration or oxidation provided that
the surface does not have flaky rust or mill scale. Brayco 785 may be applied
by spray, roller, or other means as required for coverage of all unpainted
surfaces. Other approved preservative fluids shall be applied per the
manufacturers instructions.
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APPENDIX B
PICKLING AND PASSIVATION OF
PIPEWORK AND EQUIPMENT

1.0 All carbon steel piping shall be pickled to the following minimum requirements:

A. Ensure that all statutory and safety precautions are taken for carrying out
the work and as determined by site conditions.

B. Piping to be cleaned shall be isolated from all equipment, machined
surfaces, and non- ferrous components to avoid damage.

C. Piping shall be dismantled in suitable sections to ensure sufficient flow
of fluids in each section.

D. Each section shall be degreased. Degreasing shall be performed by use
of heavy duty alkaline or detergent solutions maintained at 175 to 195F
for a duration sufficient to remove oils or greases in the piping. After
degreasing the piping shall be thoroughly flushed with potable water to
remove all traces of degreasing solution.

E. Acid cleaning or pickling shall be carried out by use of 10% solution of hot
(not exceeding 150F) inhibited hydrochloric acid. The piping shall be
flushed with acid solution repeatedly until cleanliness is achieved. Pickling
shall continue until all loose rust, mill scale, or other foreign materials are
not visible in the piping. The strength of the acid shall be monitored to
maintain the required concentration and the solution shall be replaced if
ferric content exceeds 0.6% by weight.

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3115-BWK-PRQ-021.5
F. The piping shall be thoroughly rinsed and flushed with potable water
as rapidly as possible after the acid cleaning to remove all traces of acid
and iron salts to prevent rust. The rinsing/flushing shall continue for 10
minutes after the pH of the effluent water equals the pH of the in going
water.

G. Passivation of piping surfaces shall be performed after the pickling and
flushing. This will be done by circulating a 3% phosphoric acid solution at
160 to 175F for an adequate duration.

H. The piping shall be thoroughly rinsed after passivation with potable
water. After rinsing the piping shall be drained of water and air dried
with hot, dry, filtered air at 150 to 170F.

I. Piping that will not be immediately flushed with oil and put into service
shall be internally coated or flushed with a preservative oil per Solar ES 9-
248, and capped with metal blind flanges or threaded plugs.








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