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IDBC-TS-WPZZZ-XXXX
A
Rev
15 September 2014
Rev Date
Description
RHS
Prepared
Checked
Endorsed
Approved
BANYU URIP
PROJECT
IDBC-TS-WPZZZ-XXXX
5 September 2014
Section
All
Description
Issued for internal review
Rev A
Page 2 of 13
BANYU URIP
PROJECT
IDBC-TS-WPZZZ-XXXX
5 September 2014
Rev A
Page 3 of 13
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.
BANYU URIP
PROJECT
IDBC-TS-WPZZZ-XXXX
5 September 2014
Rev A
Page 4 of 13
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.
BANYU URIP
PROJECT
IDBC-TS-WPZZZ-XXXX
5 September 2014
Rev A
Page 5 of 13
V833500
V833530
V833560
V833600
V833630
V833660
Equipment/Line Number
SCH
3-OL-833-9922-A11A
3-OL-833-9902-A11A
-OL-833-9901-A11A
HFF833511
3-OL-833-9905-A11A
3-OL-833-9906-A11A
-OL-833-9904-A11A
HFF833541
3-OL-833-9909-A11A
3-OL-833-9910-A11A
-OL-833-9908-A11A
HFF833571
3-OL-833-9913-A11A
3-OL-833-9914-A11A
-OL-833-9912-A11A
HFF833611
3-OL-833-9916-A11A
3-OL-833-9917-A11A
-OL-833-9915-A11A
HFF833641
3-OL-833-9920-A11A
3-OL-833-9921-A11A
-OL-833-9919-A11A
HFF833671
10S
10S
40S
ISO VG32
(Turbine Oil)
10S
10S
40S
ISO VG32
(Turbine Oil)
10S
10S
40S
ISO VG32
(Turbine Oil)
10S
10S
40S
ISO VG32
(Turbine Oil)
10S
10S
40S
ISO VG32
(Turbine Oil)
10S
10S
40S
ISO VG32
(Turbine Oil)
Equipment/Line Number
SCH
Oil Type
4-OL-966-4123-B11A
4-OL-966-4124-B11A
4-OL-966-4125-B11A
4-OL-966-4126-B11A
HFF966514
4-OL-966-4127-B11A
4-OL-966-4128-B11A
4-OL-966-4129-B11A
4-OL-966-4130-B11A
HFF966614
10S
10S
10S
10S
Oil Type
Material
SS A312 GR. TP316L
SS A312 GR. TP316L
SS A312 GR. TP316L
SS
SS A312 GR. TP316L
SS A312 GR. TP316L
SS A312 GR. TP316L
SS
SS A312 GR. TP316L
SS A312 GR. TP316L
SS A312 GR. TP316L
SS
SS A312 GR. TP316L
SS A312 GR. TP316L
SS A312 GR. TP316L
SS
SS A312 GR. TP316L
SS A312 GR. TP316L
SS A312 GR. TP316L
SS
SS A312 GR. TP316L
SS A312 GR. TP316L
SS A312 GR. TP316L
SS
V966510
V966610
10S
10S
10S
10S
ISO VG68
(Synthetic Oil,
PAG) CPI: CP1507-68
ISO VG68
(Synthetic Oil,
PAG) CPI: CP1507-68
Material
SS A312 GR. TP316L
SS A312 GR. TP316L
SS A312 GR. TP316L
SS A312 GR. TP316L
SS A312 GR. TP316L
SS A312 GR. TP316L
SS A312 GR. TP316L
SS A312 GR. TP316L
BANYU URIP
PROJECT
IDBC-TS-WPZZZ-XXXX
5 September 2014
Rev A
Page 6 of 13
3. Gas Lift Compressors 1st Stage Packages A/B and 2nd Stage Packages A/B
Tag No
V654510
V654610
V654560
V654660
Equipment/Line Number
Spec
Oil Type
Material
3-OL-654-5017-A11A
3-OL-654-5018-A11A
-OL-654-5019-A11A
HFF654513
3-OL-654-6017-A11A
3-OL-654-6018-A11A
-OL-654-6019-A11A
HFF654613
3-OL-654-5040-A11A
3-OL-654-5041-A11A
-OL-654-5042-A11A
HFF654563
3-OL-654-6040-A11A
3-OL-654-6041-A11A
-OL-654-6042-A11A
HFF654663
10S
10S
40S
ISO VG46
(Turbine Oil)
10S
10S
40S
ISO VG46
(Turbine Oil)
10S
10S
40S
ISO VG46
(Turbine Oil)
10S
10S
40S
ISO VG46
(Turbine Oil)
Oil Type
Material
V656610
Equipment/Line Number
Spec
3-OL-656-5825-A11A
3-OL-656-5826-A11A
HFF656516
3-OL-656-5823-A11A
3-OL-656-5824-A11A
HFF656616
10S
10S
10S
10S
ISO VG32
(Turbine Oil)
ISO VG32
(Turbine Oil)
BANYU URIP
PROJECT
IDBC-TS-WPZZZ-XXXX
5 September 2014
Rev A
Page 7 of 13
5. Vapor Recovery Compressors 1st Stage Packages A/B and 2nd Stage Packages A/B
Tag No
Equipment/Line Number
Spec
V656540
3-OL-656-5895-A11A
3-OL-656-5896-A11A
10S
10S
HFF656547
V656640
3-OL-656-5752-A11A
3-OL-656-5753-A11A
10S
10S
HFF656647
V656570
V656670
3-OL-656-5917-A11A
3-OL-656-5918-A11A
HFF656577
3-OL-656-5901-A11A
3-OL-656-5902-A11A
HFF656677
10S
10S
10S
10S
Oil Type
ISO VG32
(Turbine Oil)
ISO VG32
(Turbine Oil)
ISO VG32
(Turbine Oil)
ISO VG32
(Turbine Oil)
Material
SS A312 GR. TP316L
SS A312 GR. TP316L
SS A312 GR. TP316L
SS A312 GR. TP316L
SS A312 GR. TP316L
SS A312 GR. TP316L
SS A312 GR. TP316L
SS A312 GR. TP316L
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).
BANYU URIP
PROJECT
6.
IDBC-TS-WPZZZ-XXXX
5 September 2014
Rev A
Page 8 of 13
FLUSHING FLOWRATE
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.
BANYU URIP
PROJECT
j)
IDBC-TS-WPZZZ-XXXX
5 September 2014
Rev A
Page 9 of 13
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
Confirm Air blowing of the external lube oil pipe line has been done.
BANYU URIP
PROJECT
IDBC-TS-WPZZZ-XXXX
5 September 2014
Rev A
Page 10 of 13
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.
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.
BANYU URIP
PROJECT
IDBC-TS-WPZZZ-XXXX
5 September 2014
Rev A
Page 11 of 13
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.
IDBC-TS-KPZZZ-.Rev A HOT OIL FLUSHING PROCEDURE FOR MECHANICAL PACKAGE
BANYU URIP
PROJECT
IDBC-TS-WPZZZ-XXXX
5 September 2014
Rev A
Page 12 of 13
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
IDBC-TS-WPZZZ-XXXX
BANYU URIP
PROJECT
5 September 2014
Rev A
Page 13 of 13
INSPECTION REPORT
HOT OIL FLUSHING
CUSTOMER
CERTIFICATE NO
OWNER
DATE
PROJECT
JOB NO
SYSTEM
SUPERVISOR
TEST PACK NO
PAGE
: 1 OF 1
OIL TYPE
START : DATE/TIME
STOP: DATE/TIME
DURATION (hours & minutes)
TEMPERATURE/VISCOSITY
FLOWRATE
SAMPLES TAKEN
DATE
REMARKS
/
/
O
C/
Cst
Litre / Min
CLEANLINESS LEVEL
TIME
REMARKS
ISO 4406
1
2
3
4
REMARKS:
THE ABOVE WORK HAS BEEN CARRIED OUT AND COMPLETED TO THE SATISFACTION OF
THE FOLLOWING REPRESENTATIVES.
ACCEPTANCE
CESCOS
TRIPATRA-SAMSUNG
MCL
VENDOR
NAME / SIGNATURE/DATE
NAME / SIGNATURE/DATE
NAME / SIGNATURE/DATE
NAME / SIGNATURE/DATE
NOTES :
: HOF PUMP
JUMPER LOOPING
: FILTER
: VALVE
: INLET
: OUTLET
: HOSE
NOTES :
: HOF PUMP
: FILTER
: VALVE
: INLET
: OUTLET
: HOSE
JUMPER LOOPING
JUMPER LOOPING
NOTES :
: HOF PUMP
: FILTER
: VALVE
: INLET
: OUTLET
JUMPER LOOPING
: HOSE
JUMPER LOOPING
NOTES :
: HOF PUMP
: MANIFOLD
JUMPER LOOPING
: VALVE
: INLET
: OUTLET
JUMPER LOOPING
: HOSE
NOTES:
: HOF PUMP
: FILTER
: HOSE
: INLET
: OUTLET
JUMPER LOOPING
: VALVE
NOTES :
: HOF PUMP
: FILTER
: HOSE
JUMPER LOOPING
: INLET
: OUTLET
: VALVE
NOTES:
: HOF PUMP
: FILTER
: VALVE
JUMPER LOOPING
: INLET
: OUTLET
: HOSE