BANUWATI-K GAS COMPRESSOR PLATFORM

CONTRACT NO. 332003115

PIPING

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REV. DATE DESCRIPTION BY CHECK. REVIEW. EXAM. APPRO.

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CERTIFI. NO. DOCUMENT NO. .

LUBE OIL LINE CLEANING

A112002816 AND FLUSHING PROCEDURE 3115-BWK-PRQ-F0-001

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 

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 Java. 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

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

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 supplier’s 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

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

b etter (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.

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 apply for cooler manufacturers.) Do not flush

package oil lines through the bearings of the engine, driven equipment, and

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) (This step does not apply for cooler 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

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

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 vessel’s

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.

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 FS5P2

SECTION OR COMPONENT BEING FLUSHED

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 isn’t 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

80°F OIL48 CS

120°F Oil 21 CS

150°F Oil 12.5 CS

0.375 X 0.049 tube 16.8 7.4 4.40.50 X 0.049 tube 24.4 10.7 6.40.75 X 0.049 tube 39.6 17.3 10.31.0 X 0.049 tube 54.8 24.0 14.31.25 X 0.049 tube 70.0 30.6 18.20.75 Sch 80 pipe 45.1 19.7 11.71.0 Sch 80 pipe 58.1 25.4 15.11.5 Sch 80 pipe 91.1 39.9 23.72.0 Sch 40 pipe 117.4 51.5 30.73.0 Sch 40 pipe 186.4 81.6 48.54.0 Sch 40 pipe 244.5 107.0 63.76.0 Sch 40 pipe 368.5 161.2 96.0

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.

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

manufacturer’s instructions.

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 195°F

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 150°F) 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.

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 175°F 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 170°F.

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.