OIL FLUSHING Procedure Form Ver.1 (POWER GT 8001 ABC)
OIL FLUSHING Procedure Form Ver.1 (POWER GT 8001 ABC)
OIL FLUSHING Procedure Form Ver.1 (POWER GT 8001 ABC)
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ECCN XXXX
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This document is made available subject to the condition that the recipient will neither use nor disclose the contents except as agreed in
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Neither the whole nor any part of this document may be reproduced or distributed in any form or by any means (electronic, mechanical,
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Shell U.K. Limited PRD-PT-GEN-00-E-BA-6178-00010
Penguins Redevelopment Project Date 20/07/2021
Project No. P3NG
This manual has been revised as indicated below and described in the revision record on the
following page. Please destroy all previous revisions.
Lead Engineer:
Commissioning
Manager:
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Oil Flushing Procedure
Ver.1
(POWER GENERATION 8001 A/B/C)
Revision History
HOLD History
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Oil Flushing Procedure
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TABLE OF CONTENTS
1. Introduction ........................................................................................................................6
2. Objective .............................................................................................................................6
3. Responsibilities ...................................................................................................................7
3.1 Cleaning Contractor Responsibilities ................................................................................................... 7
4. Pre-Requisites.......................................................................................................................... 8
4.1 System Requirements .............................................................................................................................. 8
6. Drawings ................................................................................................................................ 10
7. Procedure ............................................................................................................................... 10
7.1 System Setup.................................................................................................................................... 10
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1. Introduction
This procedure applies to PENGUINS Project: POWER GENERATON 8001 A/B/C
for Lube Oil Flushing. This procedure specifies requirements and gives recommendations for
performing shop and lube oil flushing on piping systems. In case of a conflict between this
procedure and the PEF documents the latter shall govern.
2. Objective
The goal of this procedure is to detail the method to perform high velocity oil flushing of all
required piping without any negative impact to personnel, equipment, or the environment.
This procedure outlines the plan for oil flushing the piping, which consists of providing all
the necessary temporary equipment (flushing skid, hoses, fittings, etc.), materials and
personnel required to complete the scope of work.
The oil will be heated between 140°F and 160°F to reduce the viscosity and increase the
efficiency of the flush. This will be performed using an external high velocity flushing skid
that contains a pump, heater, filters, holding tanks, and reverse flow manifold.
The system will be filled with flushing oil, circulated, and heated to begin the flush. During
the filling and initial circulation, all high points will be bled to ensure there are no air pockets
in the system which can reduce the effectiveness of the flush. During the flushing process,
the oil will be filtered with inline filters on the flushing skid to remove debris and particles in
the system.
Appropriate waste collection including drip trays, hoses and fittings, and collection tanks will
be design and supplied as required by the local site and environmental authorities.
After completion of the oil flushing, the temporary equipment shall be removed and cleaned,
and the system will be re-instated to the normal operation set-up. All removed items such as
orifices, control valves, check valve internals, etc. shall be re-installed if required.
3. Responsibilities
This procedure is a mandatory document and shall be implemented by all employees and
contractors when engaging in oil flushing for this project.
Cleaning Contractor
Piping layout sketch outlining connection points, temporary equipment, and flushing loops.
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Equipment and materials required to perform the lube oil flushing as outlined in this procedure
Disposal of any waste solids and fluids generated during the job execution.
Fluor
Emergency Services.
4. Pre-Requirements
4.1 System Requirements
Before the Oil Flushing can begin the following issues need to be addressed and
completed:
1. System is construction complete and all relevant pressure tests have been
performed and signed off.
Equipment Description
Contains pump, heater, mixing tank, pressure and
Flushing Skid temperature gauges, and filters.
Recommended capacity of 2000LPM
Oil transfer to fill the unit/oil reservoir and water and waste
Oil Transfer Pump transfer for post job cleaning.
Flow Meter/ interface To monitor the system flow rate
Particle Counter To monitor the system particles
Stainless Steel Manifolds As required for system connections and cycling of loops
As required for system connections, stainless steel construction
Hoses, Valves and Fittings
and specialty chemical hoses
5. Cleaning Verification
Cleaning contractor will provide onsite lab sampling to verify the cleanliness of samples
taken from the system during the cleaning operation. This will allow the onsite technical
supervisor to monitor the job progress and determine when the required specification has
been met.
The cleanliness specification for this work is API 614, ISO 4406 CODE 16/14/12. The
cleanliness of the system will be determined by inserting 100 mesh screen paddles at critical
points such as the oil supply connections on Equipment & Pipe and at other strategic points
mutually agreed upon by Fluor and the cleaning contractor. The screens shall have no more
particles than listed in API 614, ISO 4406 CODE 16/14/12.
Two consecutive filter patch results with 2 hours run on each filter patch meeting the
following.
a) Number of particles on each patch shall be no more than the maximum listed in API
614, ISO4406 CODE 16/14/12.
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6. Drawings
The following table depicts the drawings supplied by Fluor for the scope of this steam blow
procedure:
The following are the Flushing Layout and Loop Drawings for this flush:
LD-PG-LO-01
LD-PG-LO-02
LD-PG-LO-03
7. Procedure
The sections below detail the oil flushing procedure undertaken during this scope of work. It
is your responsibility to ensure that you understand this procedure before performing the
following tasks. Contact the document author if you have any questions about this
procedure.
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Ensure flushing equipment is in close This reduces heat losses and number of
1
proximity to the system. hoses
Place flushing equipment inside spill The use of a spill kit may be necessary
2
containment area. inside containment area.
Place oil drums/totes within containment
3 area (if possible) or as close to the Allows for easy transfer of fluid.
containment area as possible.
Place the Oil transfer pumps and air supply
4 Pumps to be grounded
near the oil drums/totes.
See Appendix 1:
U40-OL-80-01-TP002
U40-OL-80-01-TP003
U40-OL-80-03-TP007
Run hoses, manifolds and valves as required
U40-OL-80-03-TP008
by the flushing diagrams from the flushing
U40-OL-80-05-TP009
5 unit to the system to perform flushing
U40-OL-80-05-TP012
operations as per provided schematics and
P&ID’s.
Layout Drawings
PG-LO-01,
PG-LO-02,
PG-LO-03
All open connections on permanent
system piping will be immediately
blinded/bagged to prevent
During the rig up, special attention will be
contamination. All removed items such
6 paid to preserve and protect the client’s
as control valves, check valve internals,
equipment and instrumentation.
RO plates, etc. will be tagged and tied
to piping or placed in appropriate
storage location
Containment will be used under each Place drip trays under any potential
7 temporary connection to ensure that any sources for leaks such as system tie ins
leaking fluids are contained. and hose connections.
Temperatures at points in the system may
Signs will be posted to inform all personnel in reach temperatures as high as 70°C
8 the area that the piping in the system being (154°F) during the flushing operation.
flushed is hot. Barriers will be erected to keep personnel
away from this piping and hose.
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Once Loop 3 has been flushed for a The cleanliness specification for the mesh
minimum of 6 hours, the oil looks visibly screens is API 614 ISO4406 CODE
clean, and there is not significant 16/14/12.
16. plugging across then install 100 mesh
screens at the discharge points and See Appendix 1:
continue flushing for 2hours. If mesh is U40-OL-80-03-TP008
clean, install the Particle counter and U40-OL-80-05-TP009
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Any personnel working at height over 1.8 meters, will require fall protection, and possible
SRL (Self- retracting line)
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A pre-job safety meeting will be conducted before undertaking any operation. The flushing
operation presents some unique hazards and can affect a significant portion of the area. For
this reason, the audience for this toolbox talk must include all personnel involved in the
work.
Upon reaching the worksite, all cleaning contractor personnel will undergo the site safety
induction as required.
The work site Permit-to-Work (PTW) system will be strictly adhered to. No work will be
carried out unless the required PTW has been raised, authorized, and signed on. If the scope
of work changes during the duration of the Permit, the cleaning contractor supervisor will
ensure that any changes are discussed with the appropriate client representative and the
permit modified, if necessary, and re-issued.
Prior to operations commencing, a Pre-Job Safety Meeting will be held to ensure that all
parties involved in or affected by the work are aware of its nature and of the hazards
involved. The meeting will be held on site and recorded on the appropriate forms. Any
outstanding actions following the meeting will be closed out prior to operations
commencing.
The Toolbox Safety Talk will be conducted on site before each new job task or section of a
job procedure. The talk(s) will be logged in the Daily Operations Report.
8.4 Chemicals
The cleaning contractor will be responsible for ensuring that all chemicals are handled by
trained personnel, that proper handling techniques are employed, and that all personnel are
wearing the necessary PPE. MSDS sheets will be available on site for all chemicals used in
the flushing and post job cleaning operation. Copies of the MSDS will be provided to the
client and pipe-fitting supervisor prior to commencing flushing operations. If the piping
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foreman is interested in providing the MSDS information to the crews, the material will be
readily accessible.
The Risk Assessment Analysis sheet identifies the hazards and hazard effects and is used to
assess the Risk as follows:
• The Severity column describes the gravity of the injury, damage or loss (low,
moderate or high).
• An Initial Risk Factor will be obtained by assessing the severity and probability
(frequency) of the harm that might arise from the Hazard.
• Existing or proposed Hazard control measures will be entered against each identified
potential accident. These measures should reduce the risk to an acceptable level. If the
risk remains unchanged other remedial actions should be specified on the sheet until it
is reduced.
Refer to Appendix 3: Detailed Risk Assessment for this work scope
Appendix Description
1 System Marked Up P&IDs and Layout Drawings
2 Equipment and Consumables List
3 Detailed Risk Assessment
4 Oil Flushing Sign-off Sheet
5 MSDS
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Appendix 1: U40-OL-80-01-TP002
Appendix 1: U40-OL-80-01-TP003
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Appendix 1: U40-OL-80-03-TP007
Appendix 1: U40-OL-80-03-TP008
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Appendix 1: U40-OL-80-05-TP009
Appendix 1: U40-OL-80-05-TP012
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