Banyu Urip Project

HOT OIL FLUSHING PROCEDURE

FOR MECHANICAL PACKAGE

IDBC-TS-WPZZZ-XXXX

A
Rev

15 September 2014

Issued for Internal review

Rev Date

Description

RHS
Prepared

Checked

Endorsed

Approved

HOT OIL FLUSHING PROCEDURE

BANYU URIP
PROJECT

FOR MECHANICAL PACKAGE

IDBC-TS-WPZZZ-XXXX
5 September 2014

MPI: NOT CLASSIFIED

REVISION MODIFICATION LOG

Revision

Section

All

Description
Issued for internal review

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

Rev A
Page 2 of 13

HOT OIL FLUSHING PROCEDURE

BANYU URIP
PROJECT

FOR MECHANICAL PACKAGE

IDBC-TS-WPZZZ-XXXX
5 September 2014

MPI: NOT CLASSIFIED

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.

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

HOT OIL FLUSHING PROCEDURE

BANYU URIP
PROJECT

IDBC-TS-WPZZZ-XXXX

FOR MECHANICAL PACKAGE

5 September 2014

MPI: NOT CLASSIFIED

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.

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

HOT OIL FLUSHING PROCEDURE

BANYU URIP
PROJECT

FOR MECHANICAL PACKAGE

IDBC-TS-WPZZZ-XXXX
5 September 2014

Rev A

MPI: NOT CLASSIFIED

Page 5 of 13

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

Tag No

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

2. HP Fuel Compressor A/B

Tag No

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

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

HOT OIL FLUSHING PROCEDURE

BANYU URIP
PROJECT

FOR MECHANICAL PACKAGE

IDBC-TS-WPZZZ-XXXX
5 September 2014

Rev A

MPI: NOT CLASSIFIED

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)

SS A312 GR. TP316L

SS A312 GR. TP316L
SS A312 GR. TP316L

10S
10S
40S

ISO VG46
(Turbine Oil)

SS A312 GR. TP316L

SS A312 GR. TP316L
SS A312 GR. TP316L

10S
10S
40S

ISO VG46
(Turbine Oil)

SS A312 GR. TP316L

SS A312 GR. TP316L
SS A312 GR. TP316L

10S
10S
40S

ISO VG46
(Turbine Oil)

SS A312 GR. TP316L

SS A312 GR. TP316L
SS A312 GR. TP316L

Oil Type

Material

4. Atmospheric Vapor Recovery Compressors A/B

Tag No
V656510

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)

SS A312 GR. TP316L

SS A312 GR. TP316L
SS A312 GR. TP316L
SS A312 GR. TP316L

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

HOT OIL FLUSHING PROCEDURE

BANYU URIP
PROJECT

IDBC-TS-WPZZZ-XXXX
5 September 2014

FOR MECHANICAL PACKAGE

Rev A

MPI: NOT CLASSIFIED

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).

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

HOT OIL FLUSHING PROCEDURE

BANYU URIP
PROJECT
6.

IDBC-TS-WPZZZ-XXXX

FOR MECHANICAL PACKAGE

5 September 2014

MPI: NOT CLASSIFIED

Rev A
Page 8 of 13

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
D
7.

= flushing fluid viscosity - centistokes

= pipe/tube inside diameter - inches

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

HOT OIL FLUSHING PROCEDURE

BANYU URIP
PROJECT
j)

IDBC-TS-WPZZZ-XXXX

FOR MECHANICAL PACKAGE

5 September 2014

MPI: NOT CLASSIFIED

Rev A
Page 9 of 13

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.

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

HOT OIL FLUSHING PROCEDURE

BANYU URIP
PROJECT

FOR MECHANICAL PACKAGE

IDBC-TS-WPZZZ-XXXX
5 September 2014

MPI: NOT CLASSIFIED

Rev A
Page 10 of 13

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.

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

HOT OIL FLUSHING PROCEDURE

BANYU URIP
PROJECT

IDBC-TS-WPZZZ-XXXX

FOR MECHANICAL PACKAGE

5 September 2014

MPI: NOT CLASSIFIED

Rev A
Page 11 of 13

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

HOT OIL FLUSHING PROCEDURE

BANYU URIP
PROJECT

IDBC-TS-WPZZZ-XXXX

FOR MECHANICAL PACKAGE

5 September 2014

MPI: NOT CLASSIFIED

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

IDBC-TS-WPZZZ-XXXX

HOT OIL FLUSHING PROCEDURE

BANYU URIP
PROJECT

5 September 2014

FOR MECHANICAL PACKAGE

Rev A

MPI: NOT CLASSIFIED

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 FLUSHING DATA

1
2
3
4
5
6

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

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
TRIPATRA-SAMSUNG
MCL
VENDOR

NAME / SIGNATURE/DATE

NAME / SIGNATURE/DATE

NAME / SIGNATURE/DATE

NAME / SIGNATURE/DATE

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

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