You are on page 1of 48

Status: Approved

Confidential

Installation Manual

Document id: DBAC063079 - Page 1 (48)

INSTRUCTIONS

16 Cleaning and flushing of external piping
Document ID

WDAAA116767i

Date of issue

21.09.2011

Status

Approved

Classification

Confidential

Status: Approved

Confidential

Document id: DBAC063079 - Page 2 (48)

Status: Approved

Confidential

Document id: DBAC063079 - Page 3 (48)

Installation Manual

Table of Contents
16. Cleaning and flushing of external piping................................................................................................ 16-1
16.1. Cleaning procedure............................................................................................................................. 16-1
16.1.1. Steel pipes.................................................................................................................................... 16-1
16.1.2. Stainless steel pipes..................................................................................................................... 16-2
16.2. Pickling of steel pipes.......................................................................................................................... 16-2
16.2.1. Preparation for pickling................................................................................................................. 16-2
16.2.2. Various types of pickling methods................................................................................................ 16-3
16.2.3. Pickling bath.................................................................................................................................. 16-3
16.2.4. Pickling procedures...................................................................................................................... 16-3
16.2.4.1. Citric acid method.................................................................................................................. 16-4
16.2.4.2. Hydrochloric acid method...................................................................................................... 16-5
16.2.4.3. Phosphoric acid method........................................................................................................ 16-6
16.2.5. Neutralizing/rinsing of piping after pickling................................................................................... 16-6
16.3. Pickling of stainless steel pipes........................................................................................................... 16-7
16.3.1. Stainless is not always stainless................................................................................................... 16-7
16.3.2. Chemical surface treatment.......................................................................................................... 16-8
16.3.3. Mechanical surface treatment....................................................................................................... 16-8
16.4. Sandblasting........................................................................................................................................ 16-8
16.5. Flushing of pipes................................................................................................................................. 16-8
16.5.1. Preparation for flushing................................................................................................................. 16-9
16.5.2. Flushing system setup.................................................................................................................. 16-9
16.5.3. Specifying the flushing equipment.............................................................................................. 16-11
16.5.4. Flushing temperature.................................................................................................................. 16-12
16.5.5. Flushing procedure..................................................................................................................... 16-13
16.5.6. After flushing............................................................................................................................... 16-14
16.6. Flushing of external LO piping systems............................................................................................. 16-14
16.6.1. Pipe module final flushing check, W38 & W46 engine................................................................ 16-14
16.6.2. Pipe module final flushing check, W32 engine........................................................................... 16-17
16.6.3. Lube oil filling and emptying pipes.............................................................................................. 16-17
16.7. Flushing of external LFO unloading system...................................................................................... 16-17
16.7.1. Flushing unloading piping with diesel oil.................................................................................... 16-17
16.7.2. Flushing of piping from storage tank to feeder unit and return.................................................. 16-18
16.7.3. Flushing of piping from LFO tank to pipe racks and return........................................................ 16-20
16.7.4. Flushing of fuel piping inside the power house........................................................................... 16-21
16.7.5. Final flushing check of the LFO system...................................................................................... 16-23
16.7.5.1. Part 1 (and 3)........................................................................................................................ 16-23
16.7.5.2. Part 2 (and 4)........................................................................................................................ 16-24
16.8. Flushing of external HFO piping system............................................................................................ 16-26
16.8.1. Hand cleaning of piping between buffer tank, day tank and separator unit............................... 16-26
16.8.2. Flushing of piping between the buffer tank and the separator unit............................................ 16-27
16.8.3. Cleaning of the pipeline from the HFO separator to the HFO day tank...................................... 16-28
16.8.4. Diesel oil flushing of piping from HFO day tank to HFO feeder and return................................ 16-28
16.8.5. Flushing of HFO piping from the day tank up to the pipe racks and return from the pipe racks 16-30
16.8.6. Flushing of the HFO pipeline in the pipe rack and booster connection(s) inside the power
house....................................................................................................................................................... 16-31
16.8.6.1. Flushing the HFO pipes in the pipe rack (step 1)................................................................. 16-32
16.8.6.2. Flushing the booster connections (step 2)........................................................................... 16-32
16.9. Cleaning and flushing of gas systems of SG and DF engines........................................................... 16-33
16.9.1. Cleaning TIG welded carbon steel piping................................................................................... 16-33
16.9.2. Cleaning TIG welded stainless steel piping................................................................................ 16-33
16.9.3. Storing and cleaning of stainless steel pipes.............................................................................. 16-34
16.10. Flushing of compressed air systems............................................................................................... 16-35
16.11. Flushing of cooling water system.................................................................................................... 16-35
16.11.1. Flushing the expansion pipes................................................................................................... 16-36

WDAAA116767i

Confidential

i

Status: Approved

Confidential

Document id: DBAC063079 - Page 4 (48)

Installation Manual

16.11.2. Flushing the pipes between pipe module and radiators........................................................... 16-36
16.11.3. Flushing the whole cooling radiator system.............................................................................. 16-36
16.11.4. Flushing the pipes between pipe module and cooling tower................................................... 16-36
16.11.5. Flushing the whole cooling tower system................................................................................. 16-37
16.12. Cleaning of steam boilers, steam drums, feed water tanks and related water spaces................... 16-37
16.12.1. Alkaline boiling-out.................................................................................................................... 16-38
16.12.2. Acid boiling-out......................................................................................................................... 16-38
16.12.3. Neutralization boil-out............................................................................................................... 16-39
16.12.4. Passivation................................................................................................................................ 16-39
16.12.5. Inspection, flushing and precautions........................................................................................ 16-39
16.12.6. Boil-out of an oil-fired boiler..................................................................................................... 16-40
16.13. Cleaning of steam pipes and feed water pipes............................................................................... 16-40
16.13.1. Cleaning the pipes between auxiliary boiler, steam header and exhaust gas boilers.............. 16-40
16.13.2. Cleaning the steam pipes between header, pipe rack, consumers inside the power house and
blow-down tank...................................................................................................................................... 16-41
16.13.3. Cleaning the steam pipes between header, consumers outside the power house and blowdown tank............................................................................................................................................... 16-41

ii

Confidential

WDAAA116767i

tanks. EN 10216-2 X X X X Nozzle temp.5) H = Flushing with water D and E are alternative cleaning methods. rust and scaling with tools (steel brush. heat recovery units. A = Washing with alkaline solution in hot water at 80 °C for degreasing (to be done only if pipes are greased) B = Removing of slag. to EN 10217-1 X X X Natural gas Pipes acc.4) F = Flushing with lube oil (refer to section 16.1 Steel pipes Properly clean all pipelines between the engine and its auxiliary units. The various cleaning procedures for pipelines in different systems are shown in Table 16-1. EN 10216-2 X X X [1] Lube oil Pipes acc. All pipes (dimensions) are according to EN 10220.) and grinding welding seams inside the pipe C = Blowing with compressed air D = Pickling (refer to section 16. to EN 10305-1. EN 10216-2 X X Exhaust gas All pipes X X Charge air All pipes X X Sludge Pipes acc. Cleaning and flushing of external piping 16. control Pipes acc. Cleanliness is an utmost prerequisite for the troublefree operation of the power plant. to EN 10216-2 X X [1] A X E F G H X X X X For details.5) G = Flushing with LFO (refer to section 16. to EN 10305-1. etc. EN 10216-2 X X X Steam Pipes acc. EN 10216-2 X X X District heating Pipes acc. to EN 10305-1. to EN 10305-1. etc. to EN 10305-1. but only use sandblasting or shot blasting if it is possible to visually check the cleaning result.1 Cleaning procedure 16. EN 10216-2 X X X Cooling water Pipes acc. see WDAAA180387. WDAAA116767i Confidential 16-1 . Table 16-1 Various cleaning methods System Pipelines Fuel oil B C D Pipes acc. EN 10216-2 X X X X Compressed air Pipes acc. to EN 10305-1. to EN 10305-1. Cleaning and flushing of external piping 16.1.Page 5 (48) Installation Manual 16.2) E = Sandblasting or shot blasting (refer to section 16. hammer. prior to the startup of the plant.Status: Approved Confidential Document id: DBAC063079 .

bolts and nuts. Cleaning and flushing of external piping 16.). heaters.1. coarse slag. in order to get a general understanding on why. ● Design documents like flow diagrams. 16. The chlorine ions can initiate crevice. sealings. ● The environmental protection has to be agreed (neutralization and discharge).2. have to be identified. pools. 16. ensure that the sand is truly clean (not recycled). ● Passivation and protection must be done before re-installation. lists. mechanically remove all weld spatter.2 Pickling of steel pipes Pickling removes rust. tightening torque. Do not use steel shot blasting. etc. etc. from the pipes. etc. the following procedures have to be agreed between Wärtsilä and the pickling Contractor: ● The chemicals used for pickling have to be approved by Wärtsilä. ● Personnel safety equipment has to be reviewed and accepted. how and for how long time the flushing shall be done. ● The way of working has to be discussed in detail. After completing the pickling. This must be done to avoid leaving residue of chlorine ions. etc. ● Final tightening and re-installation (sealings. use a non-chlorinated solvent to remove the grease. if they are to be stored for a long period. ● The method to be used has to be explained and agreed. ● The mixing properties have to be agreed and a pre-test must be done.Page 6 (48) 16.2.1 Preparation for pickling Before the pickling work starts. weld spatter. Avoid grinding or polishing with grinding wheels or belt sanders.2). Do not use blasting methods that could roughen the surface. The following documents shall be established at the site: ● Flushing order and time schedule ● Logbook defining the status and progress of work (signed by the Contractor and the Wärtsilä representative) 16-2 Confidential WDAAA116767i . no further welding is allowed. etc. pitting and stress corrosion. Before starting pickling of a pipeline construction. pickle the pipe again. as they tend to overheat the surface to the point where corrosion resistance cannot be restored even with pickling. if additional welding of a pickled pipe is required. Cleaning Do not clean stainless steel pipes with any type of metallic wire brush other than stainless steel. bolts and nuts. ● The pickling method must be verified (see section 16. as described in Table 16-1.) must be planned. (if accessible).2 Installation Manual Stainless steel pipes Storing Place stainless steel pipes in a dry and ventilated location.Status: Approved Confidential Document id: DBAC063079 . Another method is glass ball blasting. slag. ● The equipment to be used has to be verified (pumps. If a very heavily contaminated stainless steel surface is to be cleaned by sandblasting. Check the cleaning results visually. However. If the pipes are greased.

2 Pickling at site pipe by pipe: Disassemble all pipes and fill them one by one with chemicals according to the pickling procedure. Put blind flanges in one end of the pipes and lift up the other end of the pipes on some kind of support. For methods 2–4. Cleaning and flushing of external piping ● Inspection report ○ The report has to be approved by Wärtsilä.Page 7 (48) Installation Manual 16. since a lot of toxic fumes are coming from the solutions (affecting both humans and equipment). class AISI 316.2 Various types of pickling methods The following methods can be used for pickling: 1 Sending the pipes to a shipyard or factory for pickling. 16.2. 16. NOTE Remove all air from the pipes in order to ensure a good pickling result. 4 Pickling at site using a pump for filling the pipes: ● Alternative 1: Take the pipes outside of the building and connect them together into a loop. 3 Pickling at site: Pickling baths of adequate size. ● Alternative 2: Do the pickling inside the building. The report will be part of the commissioning report later on. The authorized persons shall have the knowledge to decide on what to look for and to decide when the systems are acceptably clean. ● Organisation and responsibilities ○ The Contractor and Wärtsilä representative shall each name a person who will have the authority to sign the reports for each system. Heaters for the hot water pool and the neutralizing pool should be installed. are manufactured at site. 16.3 Pickling bath Pickling baths should be made of PVC. WDAAA116767i Confidential 16-3 .Status: Approved Confidential Document id: DBAC063079 . system by system.2. wood or stainless steel.4 Pickling procedures Three different pickling methods are presented: Citric acid. polyethylene. The size of the baths must be large enough to fully cover the pipes sunk into the baths for treatment with pickling chemicals. NOTE The pickling should be done outside the powerhouse.2. into which the pipes are put for pickling. the following equipment is needed: ● Pools for the chemicals and for hot water ● Heaters for heating of water and for the neutralization solutions ● Compressed air for blowing of the pipes ● Oil for protecting the inside of the pipes (after a Wärtsilä supervisor has accepted the pickling result). Hydrochloric acid and Phosphoric acid.

Confidential WDAAA116767i . ● Using heated (the hotter the better) water (60–80 °C) speeds the process. Long breaks between the steps might affect the pickling result.Status: Approved Confidential Document id: DBAC063079 . It is possible to cut a test piece of the same pipe material and put it in a plastic bucket that contains the same citric acid solution. By monitoring the test piece. ● The key is to adjust the concentration to the task – light concentration for lightly rusted items. Product information: ● Name: Citric acid monohydrate. When pickling at site and using a pump to circulate the solution. 16-4 2 Blow the lines with compressed air to remove all pickling solution. a mask should be used to prevent inhalation of toxic fumes. not the other way around. it is possible to determine the proper processing time. heavy concentration for encrusted items. Fill the pipes or immerse them in an acid solution of 6–8% citric acid (C6H8O7). Always use proper protection (rubber gloves and boots. 3 Rinse the pickled pipe properly with a sufficient amount of hot water and blow with dry compressed air immediately after the rinse. NOTE Remove any paint from inside pipes or pipe components. NOTE Remember that you are working with an acid. ● Remember to put the powder into the water. the pump pressure and flow depend on the pipe system to which the pump is connected. ● The acid is working when you notice bubbles rising.Page 8 (48) 16. If the ventilation is poor. Complete all steps from 1 to 5 without any interruptions. Add a bit of alcohol (methylated spirits) to break down the surface tension. De-rusting can take 2-4 hours depending on the condition of the pipe and the concentration/ temperature of the solution. Cleaning and flushing of external piping Installation Manual Wärtsilä recommends the use of Citric acid as the first choice in site conditions.2.V. Procedure 1 Pickle the pipes with an acid solution. 16.1 Citric acid method Prerequisites NOTE Wash greased pipes with a hot alkaline solution before starting the pickling procedure. or if working for long times close to the acid. and a squirt or two of detergent to help with any degreasing. Citric acid is irritating to eyes and may cause skin irritation.4. The main idea is that the pickled pipes are full of solution and the solution circulates. protective glasses). E330 ● Importer: Algol Chemicals Oy ● Foreign producer: Jungbunzlauer B.

2. or if working for long times close to the acid.4. Always use proper protection (rubber gloves and boots. The use of dirty water might affect the pickling result. After the pickling result is approved by Wärtsilä.Status: Approved Confidential Document id: DBAC063079 . Postrequisites NOTE To avoid corrosion of the pipes. Make sure that the water is clean. ● A Wärtsilä supervisor must check the result. discuss with the local sewerage station how to handle the solution.Page 9 (48) Installation Manual 4 16. 2 Blow the lines with compressed air to remove all pickling solution. unless local rules prohibit this. Fill the pipes or immerse them in an acid solution of 10% hydrochloric acid (HCl) and 10% formalin inhibitor (HCHO) for 4–5 hours. If the ventilation is poor. a mask should be used to prevent inhalation of toxic fumes. start the flushing immediately after the pickling procedure. Cleaning and flushing of external piping Check the result. 3 Rinse the pipes with hot water at 70 °C. Procedure 1 Pickle the pipes with an acid solution. 5 Plug the pipes when they are dry at the inside surface. protective glasses). Disposal considerations: ● Crystal or flour can be disposed of as a solid waste or burned in a suitable installation subject to the Environmental Protection (Duty of Care) Regulations 1991. fill the pipes with protection oil. If the result is not good. WDAAA116767i Confidential 16-5 . Examples of brands: ● Armohib 28 ● Rhodine 213 ● Metacorr AC1100. Long breaks between the steps might affect the pickling result.2 Prerequisites NOTE Wash greased pipes with a hot alkaline solution before starting the pickling procedure. ● For large amount. Hydrochloric acid method 16. Complete all steps from 1 to 8 without any interruptions. CAUTION Remember that you are working with an acid. 4 Perform the neutralization. repeat the pickling procedure. ● Small amounts of citric acid solution can be flushed down a sink with a large quantity of water (the pH value must be between 6 and 11).

If the result is not good. If the ventilation is poor or if you are working long times close to the solution.5 Neutralizing/rinsing of piping after pickling Rinse the pickled pipe properly with a sufficient amount of hot water and corrosion inhibitor at 60 °C. If the pipes are stored for a long time (days) in a corrosive environment without protection. start the flushing immediately after the pickling procedure. corrosion will take place and the pickling has to be repeated. CAUTION Remember that you are working with an alkaline. The use of dirty water might affect the pickling result. aluminium and zinc. WARNING Always remember that you are working with an acid. Make sure that your skin is covered and you are using protective glasses. the supplier's recommendation has to be followed. Steam can also be used to rinse the pipes from pickling solution.3 Phosphoric acid method When using the phosphoric acid method.4. This chemical is suitable to use for steel. Plug the pipes when they are dry on the inside surface. repeat the pickling procedure. The temperature of the neutralizing solution should be 40–50 °C. Do not use this method on site. protection glasses).Status: Approved Confidential Document id: DBAC063079 . Postrequisites NOTE To avoid corrosion of the pipes.2. 16. ● A Wärtsilä supervisor must check the result.2. wear a mask to prevent inhalation of toxic fumes. 6 Rinse with hot water at 70 °C. 16-6 Confidential WDAAA116767i . Pickle the pipes in 15–72% phosphoric acid for a time of 20 minutes to four hours. It is important to remove the pickling solution completely from the pipe in all bends and possible pockets inside the pipe.Page 10 (48) 16. 16. and blow with dry compressed air immediately after the rinse. Keep the pipes in the solution for 20 minutes. After the pickling result is approved by Wärtsilä. 5 Blow the lines with compressed air. 8 Put protection covers on the pipe ends. Cleaning and flushing of external piping Installation Manual Fill the pipes or immerse them in a neutralizing solution of 10% caustic soda (NaOH) and 50 g Na3PO4 (sodiumtriphosphate) per litre. Generally. Check the concentration of the pickling solution regularly and add acid if the check shows a low concentration. fill the pipes with protective oil. Make sure that the hot water is clean. The recommended pickling temperature is 45 °C. Example of brand: ● Antox Supra. 7 Check the pickling result. the pipes are immersed in a pickling bath. Always use proper protection (rubber gloves and boots.

The comparisons show that pickling is the best method for achieving optimum corrosion resistance. The corrosion resistance of the stainless steel will then be restored. The pickling agent should. the underlying chromium depleted layer. 16. The fact that stainless does not rust in many situations does not mean that the metal itself is noble. in acids or in water containing chlorides. Common stainless steel will not usually rust when exposed to normal atmospheric conditions. in that the splash danger is minimized. Different pickling products are available on the market: pickling paste. abrasive blasting or brushing.g. Chromium depletion often happens during exposure to high temperatures.Page 11 (48) 16. ● A "neutralising agent" for treating the resulting wash water after pickling. e. and pickling solution.3. consisting mainly of chromium oxide. Chemical treatment means that the damaged oxide layer is dissolved. The wash water is acidic.3 Document id: DBAC063079 . and neither runs nor falls off.1 Stainless is not always stainless The concept of "stainless" or "rust-free" steel must be qualified. which results in the formation of a thin protective layer that prevents corrosion. The oxide layer. The corrosion resistance is due to the steel surface reacting to oxygen. Additionally. Pickling is the superior method Research has been carried out to evaluate which method produces the best corrosion resistance. There are two main methods: pickling and electrolytic polishing. usually with acid solutions. disturbed. The agent should remove all heat tint. give a clean surface after about an hour. as well as residual slag. Cleaning and flushing of external piping Pickling of stainless steel pipes Use these instructions for guidance and information only. Requirements for successful pickling The pickling agent needs to adhere well to the surface. Mechanical treatment means that the surface layer is removed by grinding. which facilitates spray-pickling through its colour and at the same time reduces the formation of hazardous nitric fumes. is called a passive layer. and contains heavy metals dissolved from the stainless steel. under normal conditions (15–22 °C). for example during welding. There are two ways to do this: ● Chemical surface treatment ● Mechanical surface treatment. Always obtain valid instructions from the supplier of the pickling chemicals for each specific project. but in other surroundings. Pickling paste is often preferred because it adheres best to the stainless surface. ● An indicator. The following accessories are necessary when pickling: ● A suitable acid burn ointment for treating small areas of the skin that may have come in contact with pickling acid. paste is more worker friendly. WDAAA116767i Confidential 16-7 . protective oxide layer is damaged. pickling gel. the risk for corrosion increases.Status: Approved Confidential Installation Manual 16. The need for postweld treatment of stainless steel welds A protective oxide layer can be rebuilt if both the weld heat tint and the underlying chromium depleted layer are removed in the proper manner. Corrosion of the stainless steel may occur when this thin. or depleted in chromium. and the process of building the layer is called passivation.

If this method is correctly done. through chemical action. a mechanical polishing followed by a chemical cleaning or passivation. but it is not an alternative for pickling. especially for iron contamination. and must be handled with care.g. pipes and hoses are not included in the Wärtsilä supply. but not always the underlying chromium depleted layer. and thus the welded object achieves an optimal (for the alloy) corrosion resistance. Shot blasting or peening is the process where glass beads. the metal oxides are dissolved by the combination of hydrofluoric and nitric acids. It needs to be done at a sufficiently oblique angle to prevent blasting particles into the surface. High demands are also made on the cleanliness of the blast media. e.3. filters. Portable units do exist. which can be difficult for large fabrications. and stress corrosion cracking.g.Page 12 (48) 16. from the pipelines. 16. Done properly. It requires that the object be immersed in a bath. Depending on the abrasive particle size. it may leave a too rough surface. Heat tint and weld spatter are efficiently removed. pump. especially pitting. However.5 Flushing of pipes The purpose of the flushing is to remove all debris and foreign material.3 Mechanical surface treatment Grinding can be done with a rotating abrasive disc. When sandblasting. Cleaning and flushing of external piping 16. blasting is a quick and effective way of removing heat tint. 16. Also remember the limitation of sandblasting: use it only if it is possible to visually check the cleaning result. e. but they are generally limited to the cleaning of relatively smooth surfaces (80–400 grit). This method is technically superior for the surface treatment of stainless steel since it removes. NOTE The flushing tank. This means that a further treatment after grinding should be done. which could cause damage to the engine or to auxiliary equipment. The disadvantage is that pickling acids are corrosive and poisonous. Electrolytic polishing is an electrochemical pickling method which requires costly equipment.Status: Approved Confidential Document id: DBAC063079 . the resultant rough grinding marks (more than 120 grit roughness) are areas where localized corrosion may start.3.2 Installation Manual Chemical surface treatment When pickling. 16. 16-8 Confidential WDAAA116767i . Brushing with a stainless steel wire brush can be used when surface quality requirements are lower. The clean surface is then re-passivated rapidly by the oxygen in the air. ensure that no harmful particles are left inside the pipelines.4 Sandblasting Sandblasting is used in the cleaning of pipelines when pickling is not enough. or with coarse abrasive coated papers. crevice corrosion. on the outside of pipes and equipment. it gives good results. heater. any areas of inferior corrosion resistance on the surface. These acids dissolve the heat tint and the underlying chromium depleted zone. or abrasive particles such as corundum or olivine sand of varying size are sprayed with high pressure against the surface.

● The pipe routing and looping must be identified and agreed. check points and checking intervals). ● The equipment to be used has to be verified (pumps. 16. See Fig 16-2.2 Flushing system setup To perform the flushing at the site. Install flushing filters horizontally to the return line just before the flushing oil tank. The report will be part of the commissioning report later on. pools. lube oil. bolts and nuts. ● The way of working has to be discussed in detail. water.). ● Organisation and responsibilities.5. WDAAA116767i Confidential 16-9 .) must be planned. Cleaning and flushing of external piping Preparation for flushing Before the flushing work starts. The authorized persons shall have the knowledge to decide on what to look for and to decide when the systems are acceptably clean. NOTE Drain the flushing tank regularly to remove condensed water from the tank. tightening torque.5. the following procedures have to be agreed between Wärtsilä and the flushing (pickling) subcontractor: ● The flushing media has to be decided (LFO. The following documents shall be established at site: ● Flushing order and time schedule ● Logbook defining the status and progress of the work (signed by the Contractor and Wärtsilä representative) ● Inspection report ○ The report has to be approved by Wärtsilä.Status: Approved Confidential Document id: DBAC063079 . in order to get a general understanding on why. ● Personnel safety equipment has to be reviewed and accepted. ● Final tightening and re-installation (sealings. etc. ● Passivation and protection must be done before re-installation. lists. sealings.Page 13 (48) Installation Manual 16. depending on the line to be cleaned). ● The method to be used has to be explained and agreed (mesh sizes. ● Design documents like flow diagrams. etc. etc. how and for how long time the flushing shall be done. The flushing system set up is shown in Fig 16-1. ● The working areas and environmental protection must be agreed (neutralization and discharge of the flushing media). have to be identified.1 16. ○ The Contractor and Wärtsilä representative shall each name a person who will have the authority to sign the reports for each system. bolts and nuts. build a movable flushing system. heaters.

Cleaning and flushing of external piping Fig 16-1 Installation Manual Flushing unit for external piping GUID-E6EB7112-6643-46CA-9F42-923CD8C0798D v1 Table 16-2 Flushing system equipment 16-10 Item No Pieces 1 1 Flushing oil tank (normal steel or stainless steel) 2 1 Heater with temperature controller (electric or steam) 3 1 Ventilation filter 4 1 Manhole 5 1 Temperature indicator 6 1 Closing valve 7 1 Strainer (safety filter for flushing pump) 8 1 Pump with electric motor (screw pump or impeller pump) 9 8 Closing valve 10 2 Flexible rubber hoses (industrial type for pipe connections) 11 2 Pressure indicator 12 2 Flushing filter (see Fig 16-2) Part Confidential WDAAA116767i .Page 14 (48) 16.Status: Approved Confidential Document id: DBAC063079 .

Status: Approved Confidential Installation Manual Fig 16-2 16. heater capacity and filter size. The capacity of the flushing pump should be dimensioned so that the Reynolds number (Re) exceeds 25000. tank. The cleaning efficiency increases with the Reynolds number.5. Cleaning and flushing of external piping Flushing filter GUID-5079C561-9AE0-45EE-ABB6-AA1BB0ECC52F v1 Specifying the flushing equipment When choosing the flushing pump. Where: ∂ = Viscosity [cSt] d = Pipe inside diameter [mm] Q = Flow [l/min] Re = Reynolds number Example: Flushing oil Shell Tellus TX 32 ∂ = 10 cSt at 80 °C d = 150 mm Q = 1770 l/min or WDAAA116767i Confidential 16-11 . The heater capacity has to be calculated (the flushing temperature must be at least be the same as the temperature during normal operation). For the inner pipe diameter.3 Document id: DBAC063079 . A Reynolds number of 25000 is considered the lower limit for efficient cleaning.Page 15 (48) 16. determine the following values for the different systems: ● Flow rate in each system ● Operating temperature of the liquids ● Liquid volume in the system plus the tank and piping. A higher oil temperature decreases the viscosity and consequently increases the Reynolds number. The flushing pump capacity is directly related to the flushing time and also to the flushing result. the largest pipe size in the system shall be used.

5. Cleaning and flushing of external piping Installation Manual Table 16-3 Minimum flow capacity for different pipe diameters Fig 16-3 16. 16-12 Confidential WDAAA116767i . Re = 25000 25 336 32 442 40 508 50 643 65 829 80 973 100 1263 125 1545 150 1879 200 2445 Flushing flow rate for different pipe size GUID-F0F44DB0-3D76-4938-A506-4F54939B7793 v1 Flushing temperature The temperature of the flushing oil is very important to achieve optimal flushing results. The flushing temperature must be at least the same as the temperature during normal operation.4 DN Flow (l/min) for Shell Tellus at 80 °C. The diagrams are based on the flow rate in Table 16-3.Page 16 (48) 16.Status: Approved Confidential Document id: DBAC063079 . The relationship between the Reynolds number and the oil temperature and viscosity is shown in Fig 16-4 and Fig 16-5.

5. The systems that should be flushed with these meshes are: ● lubricating oil piping ● LFO piping ● HFO piping ● nozzle heating piping.Page 17 (48) Installation Manual 16. Perform the flushing systematically according to the flow diagrams.5 mm ● 60 mesh ≈ 0. If the pipes are very clean. First flush the lubricating oil system. inspect the filters regularly and clean them when necessary.15 mm. according to the flushing procedure. Complete the flushing for one engine at a time and only one step at a time. the 100 mesh can be used directly. Start the flushing with the 30 mesh.5 v1 Flushing procedure During the flushing. NOTE For more detailed information concerning screens and mesh. WDAAA116767i Confidential 16-13 .25 mm ● 100 mesh ≈ 0. then the LFO system and finally the HFO system. refer to chapter 1. Cleaning and flushing of external piping Fig 16-4 Reynolds number variation depending on temperature (Shell Tellus TX 32) GUID-78F1B807-956A-4914-B59C-23AF7FF847AD v1 Fig 16-5 Reynolds number variation depending on viscosity GUID-36C42928-06C1-448A-8D7D-1510F1AE7BD6 16.Status: Approved Confidential Document id: DBAC063079 . Use the following flushing filters: ● 30 mesh ≈ 0. continue with the 60 mesh and finally use the 100 mesh.

Remove the plugs at the last moment before the remounting of the pipework. 5 If the engine oil sump was used as flushing tank. the required hoses and accessories must be purchased locally and a team must be assigned to carry out the flushing. Hold the pipes vertically by hand above the paper sheet. 16. Place a piece of paper or cloth on the floor.Status: Approved Confidential Document id: DBAC063079 . Also check any hidden spaces inside the piping by means of a swivelled mirror. Sweep the sump bottom with a magnetic pick-up to verify an acceptable result. Perform the final flushing check after the pipe and cooler module assembly has been completed. If debris is found on the paper. NOTE The flushing of the pipe module must be supervised.Page 18 (48) 16. 6 As soon as the sump has been cleaned from all flushing oil. W38 & W46 engine See the flow diagram WDAAA167409. Cleaning and flushing of external piping 16. disconnect and drain them one by one to ensure that no flushing oil is left in them. In general. shut the crankcase covers and seal them. Note that a flushing unit is not available even by request from the product factories nor network offices.5.6. be prepared to reserve time well enough in advance to comply with the erection schedule. 16-14 Confidential WDAAA116767i . give a couple of blows with a hammer on the pipe and check that no debris comes out. fill up the sump right after completing the flushing. clean the whole pipe system again. 4 Plug all pipelines and ensure that no dirt can enter the system.6 Installation Manual After flushing Procedure 1 Drain the entire system of flushing oil. See drawing WDAAA167687.1 Pipe module final flushing check. 2 Dismount some pipes and check visually that the pipes are clean. hose connections and flushing filters. drain the sump and clean it properly from flushing oil. Carry out a pickling cleaning on all steel equipment. such as thermostatic valves. CAUTION Reuse of flushing oil as engine or system oil is forbidden! Flushing of external LO piping systems 16. 3 If the piping system includes valves.6 Since the arrangement to flush a large system requires planning and material procurement locally. Procedure 1 Fabricate all needed equipment: flushing tank. If possible.

See drawing WDAAA180309. open number 213 and 214 as well. to avoid harmful cavitation. Stop the heating when the temperature of the oil reaches 60 °C. Close the valve. 7 Install the flushing mesh to the filters on top of the flushing tank. ● Open the automatic filter bypass valve. 4 Install all hoses. install it in the flushing tank.Page 19 (48) Installation Manual 2 16. pipes and the position of the valves leading from the separator. Visually inspect the inside of the piping and clean it if it is dirty. If a lube oil separator is used for heating the flushing oil. 10 Fill the pump and the motor bearings with grease according to the service manual. ● Open the valve from the hose coupling number 204. close them all. Cover the flushing tank with a tarpaulin. Start with mesh 60. When using the LO separator for oil circulation. check the hoses. When the flushing oil pressure has increased by 2 bar from the starting pressure. Do the same with the filter tightening nuts. check the condition of the cover’s O-ring gasket and reinstall the covers on the filter.Status: Approved Confidential Document id: DBAC063079 . couplings and flushing filters. ● Close the drain valve from the hose coupling number 201. ● Open the lube oil safety filter top covers (two). If an electrical heater is used for heating the flushing oil. monitor the flushing oil pressure and temperature. turn the change-over valve’s position from the safety filter to both filters. Check that all flange connections are tight and that they have gaskets. 5 Visually inspect the pipe and cooler module. 6 Follow the pipe/cooler module lube oil pipe flow diagram and do the following: ● Check the position of the non-return valve and open the closing valve after the prelubrication pump. cover and store them in a dry place. ● If a lube oil separator is used for heating the flushing oil. ● Close the drain valves at the bottom of the lube oil safety filter and if the piping has several drain valves. ● In order to fill the system with flushing oil. ● Close the inlet and outlet valves of the automatic filter. NOTE Check the cable connection of the heater. 8 Fill the flushing tank with clean oil (fill through a fine filter). ● Open the inlet and outlet valves of the lube oil cooler. ● Take out the filters from the safety filter. stop the flushing and clean the mesh. WDAAA116767i Confidential 16-15 . Cleaning and flushing of external piping Install the flushing tank slightly higher than the pre-lubrication pump. Check that there are no leaks. 3 Open the pipe module lube oil connections number 201. Continuously check the oil temperature. Carefully tighten the connections and make sure that there are no loose parts or any dirt inside the pipes or hoses. ● Inspect visually the cleanness of the inside of the safety filter. located on the engine side. 9 Start heating the oil. 204 and 205.

14 Disassemble the flushing arrangement.Page 20 (48) 16. Check the level in flushing oil tank. When the system is drained. Inspect the piping. ● Check the temperatures of the casing and bearings. c Connect the mobile pump to the hose coupling 2/201 drain valve and empty the piping system. d If the LO separator was used for heating. Inspect the piping. disconnect the power supply to the pre-lubricating pump.) ● When no more particles are trapped in mesh 100 after 4 hours running. The job is ready when after 4 hours of flushing no particles can be found in the mesh 100. Record the starting pressure and use it as reference pressure for deciding when the mesh has to be cleaned. Close the valves when oil starts to come out. piping and separator. 15 Install the filter cartridges in the safety filter. a Open the top covers. stop the oil heating and circulation. Cleaning and flushing of external piping Installation Manual Check the direction of rotation for the pre-lube oil pump. (Note: minimum flushing time is 4 hours. drain the hoses. Run the pump for a few seconds only and top up the tank when required until the system is filled up. Start the pre-lubricating oil pump a few seconds also in order to empty the suction side. 12 When the flushing oil tank is full and oil is circulating from the flushing tank to the pipe module and returning back to the tank via the flushing filter. ● Change the valve position of the safety filter to “change-over valve”. 13 During the flushing. Cover connections 213 and 214 with temporary plastic caps. ● Check that pump does not cavitate. 16-16 Confidential WDAAA116767i . b Empty the flushing tank to clean barrels. no more dirt is trapped in mesh 60. ● Check the filters every 4 hours. ● Check the oil level in the tank and the temperature of the oil. observe the following important things: ● Open or close the valve from connection 204 every 3 or 4 hours. Use the mobile LO transfer pump. Open the venting valves at the LO cooler and the safety filter during the filling. a Disconnect the power supply. Do not let oil drip on the floor. e Drain thoroughly and disconnect all flushing devices. Disconnect the hoses and couplings. after 4 hours of flushing. Turn the safety filter change-over valve to the one-filter position. NOTE The flushing result has to be inspected and approved by personnel authorized by Wärtsilä. ● Change to mesh 100 when. Check the cleanness of the separator inlet strainer. Turn the pump pressure adjusting screw a few rounds anticlockwise in order to decrease the pressure. Check that there are no leaks. 11 Start filling the system. Open the venting valves of the LO cooler and the safety filter. adjust the oil pressure to 1 bar. ● Let the oil temperature drop to 40 °C and start the flushing again. Drain the remaining oil from the pipes with the mobile pump.Status: Approved Confidential Document id: DBAC063079 .

NOTE Never leave the flushing process unsupervised. The pipe module is now ready for the start of the commissioning. Keep an eye on the pump bearing temperatures. Check that all draining and venting valves are closed.3 See the flow diagram. document number WDAAA175712 and WDAAA175775. a piece of some other suitable pipeline can be used for the return.7 Flushing of external LFO unloading system 16.2 See final flushing for W32 module. Cleaning and flushing of external piping b Pump out the oil from the chambers. see this instruction. For external systems. 16 Start the bellow assembly from the middle of the pipe module/engine. e Check the cleanness of covers and the condition of O-rings. equip the unit suction strainers (4) with a flushing mesh. 2 Connect the flushing or unloading hose (2) from the flushing tank to the unloading pump unit. Procedure 1 Install the flushing tank slightly higher than the unloading pump unit. and inspect and clean the filter chambers.7. Make sure that the pipeline used has been cleaned with pickling solution first.6. WDAAA116767i Confidential 16-17 . Begin with mesh size 30 and end with size 100. clean all the temporary steel piping materials (used for flushing) with a pickling solution. W32 engine 16. document number WDAAA182786. g Close the drain and venting valves. extra pipes and flushing filter are not included in the Wärtsilä scope of supply. Connect the flushing hose (2) from the end of the piping (11) to the flushing filter at the top of the flushing tank (1). f Install the covers to the filters. Pipe module final flushing check. See the installation instructions. 4 Turn the vertical part of the filling pipe leading to the LFO storage tank down towards the ground. The hose has to be a reinforced rubber hose of the same diameter as the suction piping. 16. Do not let the pump run dry.Status: Approved Confidential Document id: DBAC063079 . or larger. Before flushing.6.1 Flushing unloading piping with diesel oil See the flow diagram WDAAA168202.Page 21 (48) Installation Manual 16. 3 If the suction piping before the unloading pump unit is long. c Open the drain valves. If the distance between the LFO storage tank and the unloading pump unit is long. Lube oil filling and emptying pipes 16. d Take new filters from the store (inspect cleanness before installation). The hose has to be of the same size as the piping or at least 3" in diameter. For flushing with diesel oil. in order to make the flushing easier and faster.

16. clean it and fill it with clean flushing oil. drain the whole system. 14 If the unloading system will be out of use for a longer period of time. 7 If needed. 9 Start by slowly filling the pipes with flushing oil. Cleaning and flushing of external piping 5 Installation Manual If the unloading system has been equipped with a flow meter. 16-18 Confidential WDAAA116767i . fill the system with clean diesel oil. Inspect the flushing tank. or the flushing diesel oil begins to foam excessively. bypass the meter to begin with. Mix the flushing oil with 25–50% engine oil and circulate it in the piping for a few hours to give protection. or the pumps are cavitating.2 Flushing of piping from storage tank to feeder unit and return See the flow diagram WDAAA168212. Check the flushing oil level in the flushing tank and check for leaks. stop one of the pumps for a while. gently hammer the welding seams. Use oil barrels or similar for storing the flushing oil. Only run the pump for short periods of time. 16 Open a flange connection and inspect the cleaning. 15 When the flushing has been approved.Page 22 (48) 16. To avoid water in the oil. dirt or other harmful particles. continue with mesh size 60. Cover the flushing tank openings during the flushing. metal. 11 Start the other pump and check the pressures. When the mesh stays almost clean. 17 Reassemble the unloading system. Let the flushing pass through the meter only during the last few hours of the process. close draining and venting devices and cover the suction hose inlet. If the pressures are too high. During the flushing. and finally size 100. 10 Begin by running one pump. NOTE Do not let the oil leak onto the ground. 12 Begin flushing using a mesh of size 30.Status: Approved Confidential Document id: DBAC063079 . drain the flushing tank regularly. Carefully vent the air and make a note of the suction pressure and the pressure after the pumps. Check that the inlet and outlet valves are open and that the pump rotates in the correct direction.7. Rising pressures indicate that the flushing mesh is dirty and that the pumps must be stopped for cleaning of the mesh. 13 The flushing is ready when after three hours of continuous circulation mesh 100 is free of any sand. 6 Double-check all connections and venting devices. install a mesh of size 30 inside the flushing filter as well as in the unloading pump unit suction strainer. Check that there are no leaks. 8 Grease the pump bearings in accordance with the pump manual before the pumps are started.

Never leave the flushing process unsupervised. install the flushing filter in the manhole at the top of the storage tank or the flushing tank and connect it to the return pipe with a hose or pipe of the same diameter as the pipeline. Keep an eye on the temperatures of pump bearings and electric motors. Alternatively. 8 Loosen the tension adjusting screw in the feeder’s pressure control valve or replace the valve with a pipe spool. Use a filter when filling the tank. Cover the valve and store it in a dry place. If the pressures are not too high and the pumps are not cavitating. Open the inlet valve of the feeder unit and check that the pump rotates properly. clean all the temporary steel piping materials (used for flushing) with a pickling solution. Do not allow the pump to run dry. start the second pump as well. WDAAA116767i Confidential 16-19 . separate the piping from the LFO storage tank by closing the valve and installing a blind flange on the valve for safety reasons. or it has already been filled with clean fuel. Carefully vent the air from all pipes. 3 Install the flushing tank slightly higher than the LFO feeder unit and in a suitable place near the LFO storage tank. Procedure 1 If the LFO tank is larger than 150 cubic metres. use a separate flushing tank (400 l or larger). 14 Slowly start to fill the piping with flushing oil. The hose has to be a reinforced rubber hose of good quality and of the same diameter as the piping. for safety reasons. Mount the hose as straight as possible. 13 Grease the pump bearings in accordance with the pump manual. or the tank is not completely ready. install a blind plate between the flanges in the outlet of the feeder as well as in the piping between the feeder and the pipe rack/booster. 11 Install a mesh of size 30 inside the flushing filter. use both pumps for flushing. 7 Close the feeder outlet valve and. Increasing pressure during flushing indicates that the flushing mesh is dirty.Page 23 (48) Installation Manual 16. 15 Run the pump and make a note of the suction pressure and the pressure after the pump. Stop the pumps and clean the mesh. 9 Check the return piping from the LFO feeder to the LFO storage tank. Check the oil level in the flushing tank and check for leaks. 16 If the unit has two feeder pumps for LFO. 4 Connect a hose or steel pipe between the flushing tank (1) and the pipeline leading from the storage tank to the feeder. 5 Check the piping leading from the storage or flushing tank to the LFO feeder as well as the venting and drain devices and flange connections. 10 Install and connect the flushing filter in a suitable place at the end of the return piping between the storage tank and the pipe flange connection. Only run the pump for short periods of time. If the oil starts to foam excessively. stop one of the pumps for a while. 6 Check the condition of the LFO feeder unit and install a flushing mesh of size 30 in the suction strainers (11). 2 If a separate flushing tank has to be used. Check the pressures. Check that there are no leaks. 12 Inspect the tank to make sure it is clean and fill the tank with clean flushing oil. Also check venting/draining devices and flange connections. Cleaning and flushing of external piping NOTE Before flushing. or larger.Status: Approved Confidential Document id: DBAC063079 .

change to mesh 60 and finally to mesh 100. Gently hammer the welding seams during the flushing. Cleaning and flushing of external piping Installation Manual 17 Begin flushing using mesh size 30. Confidential WDAAA116767i . If the valve was removed. 16-20 5 Lock the return line valve(s) position to the LFO storage tank position. metal. Do not allow the pump to run dry. Check the flange connections. check the pressure regulating valve adjusting screw. Postrequisites Do not remove the flushing arrangement if some of it is needed later on. separate the pipe from the main pipeline and install a blind plate or flange at the nearest place. 4 Check the return piping from the bypass up to the LFO storage tank. Disconnect the suction pipe from the storage tank as well as the pipeline from the safety valve and install the flushing hoses number 16 and 17. All steel parts must be cleaned with pickling solution. 7 Install a mesh of size 30 inside the flushing filter and a mesh of size 60 inside the suction strainer in the LFO feeder. when after three hours of continuous circulation using mesh 100).3 See the flow diagram WDAAA168365. and open the valves in the feeder and the pipe to check for leaks. When the mesh is clean. Remove the blind plate or flange and connect the outlet piping to the feeder.Page 24 (48) 16. Fabricate and install a bypass with a flushing filter. drain the flushing tank at regular intervals. turn the valves to the bypass position.Status: Approved Confidential Document id: DBAC063079 . 3 Separate the LFO inlet pipe and the return fuel pipe from the pipe racks. NOTE Before flushing. Keep an eye on the temperatures of pump bearings and electric motors. (This is needed for the following part of the flushing). If the pipeline has the option of a flow meter. 2 Check the piping leading from the feeder up to the pipe racks inside the power house. Never leave the flushing process unsupervised. Install a mesh of size 30 inside the filter. If the pipeline has an external connection to other LFO consumers.. adjust the feeder line pressure back to 4 bar. and venting and draining devices. 8 Check the oil level in the flushing tank. Flush the pipe for other LFO consumers together with other smaller piping. Only let the flushing oil pass through the meter for the last few hours of the process. dirt or other harmful particles. 18 The flushing is complete. Do not let oil leak onto the floor. If it has loosened. Procedure 1 Check that the LFO feeder outlet valve is closed. 19 Before ending the flushing. To avoid water in the oil. Flushing of piping from LFO tank to pipe racks and return 16. clean all the temporary steel piping materials with a pickling solution. reinstall it and test the working pressure. the mesh is free of any sand. Cover the flushing tank openings during the flushing. Also check flange connections. the venting and draining devices and the position of the valves. 6 Connect the flushing hose between the pipeline (after the three-way valve) and the flushing filter arrangement. 20 Drain the piping slightly and open a flange connection in order to check if the pipes are clean.7.

fill them with LFO. 14 In order for the flushing to be approved. start running the pumps continuously. The person responsible for the flushing must approve the piping cleanness before the flushing is terminated.4 See the flow diagram WDAAA169857. ● Check that there is no cavitation noise from the pumps and check the casing temperatures. perform the following important checks and actions: ● Gently hammer the welding seams with a hammer or a piece of pipe. 3 Disassemble all pipes and transport them to the testing and cleaning area outside the power house.Status: Approved Confidential Document id: DBAC063079 . 4 Connect the pipes in a way that is suitable for the flushing. mark all pipes on location and in their correct positions. draining and venting devices. Example: If the plan is to start with DG1 or DG2 (both using the same booster unit). 2 After the piping assembly has been approved. change to mesh 60 and finally to mesh 100. WDAAA204630.7. 12 Begin the flushing process using a mesh 30. Rising pressures during the flushing indicate that the mesh is dirty. Cleaning and flushing of external piping Start filling the piping with flushing oil. Parts of DG3 and DG4 need to be flushed together with the first pipes in order to avoid any extra isolation valves. Make a note of the suction and line pressures. the mesh is free of sand. flush the piping marked with dashed flow lines first and the piping marked with divided flow lines next. 15 Remove all flushing equipment and install the piping permanently. Run the pumps only for short periods of time and vent the pipes at the same time. drain the piping and open a few flange connections to inspect the cleanness of the piping. mix the flushing oil with engine oil to give protection to the pipes. ● Check that there are no leaks. The flushing is ready when after 3–4 hours of continuous flushing with mesh 100. ● Check the flushing oil level in the tank. Stop the pumps and clean the filter. 13 If the pipes will be out of use for a longer period of time. 11 During the flushing. During the last hours of the flushing procedure. Close all valves. metal. Flushing of fuel piping inside the power house 16. WDAAA116767i Confidential 16-21 .Page 25 (48) Installation Manual 9 16. 10 When the whole system has been filled with oil and the air has been vented. NOTE Never leave the flushing process unsupervised. In order to avoid air pockets. Procedure 1 Finish the pipe installation and check that all pipes have the needed equipment. install temporary venting plugs. Remove the flushing mesh from the suction strainers. When the mesh is clean. dirt or any other harmful particles.

gently hammer the welding seams. 400 l or larger ● Heavy-duty suction filter and isolation valves ● Flushing pump with large flow capacity. repeat the pickling process.Status: Approved Confidential Document id: DBAC063079 . 12 Slowly start to fill the piping with flushing oil. Cover the flushing tank during the flushing procedure. Cleaning and flushing of external piping Installation Manual Plan the flushing flow in such a direction that it first passes through the pipes of larger diameter and passes last through the pipes of the smallest diameter in the end of the flushing loop.Page 26 (48) 16. Check that there are no leaks. 13 After filling the pipes. Do not install any valves or instruments because the pickling solution will damage them. If the pipes are still rusty. Use oil barrels or similar for storing the flushing oil. dirt or other harmful particles. 5 Carry out a pressure test with water and carefully vent the air. the mesh is free of any sand. run the flushing pump and carefully vent the air. 15 The flushing is ready when. 9 Assemble the flushing equipment according to drawing WDAAA169857. 6 Do the pickling by circulating the acid in the piping loop. inspect the cleanness of the flushing tank and fill it with clean diesel oil for flushing. Use a suitable acid-proof pump and equipment. metal. after 3–4 hours of continuous circulation with mesh 100. change to mesh 60 and finally to mesh 100. 60 and 100 ● Pressure gauge 0–6 bar ● Clean diesel oil. 5–10 cm in diameter ● Heavy-duty hose couplings ● Flushing filter with large filter mesh surface and mesh sizes 30. drain the system. Flushing equipment needed: ● Flushing tank. NOTE Do not spill oil on the ground. Only run the pump for short periods of time. 17 Open a flange connection and inspect the cleaning. because a pressure increase during the flushing can indicate that the mesh is dirty and needs to be cleaned. Do the final flushing of the fuel system with all units connected together. 16 After the flushing. When the mesh is clean. Vent the air carefully. 8 Start the flushing as soon as possible after the pickling. 7 Open a few flanges after neutralizing and check the result of the cleaning. 14 Begin flushing the pipes with mesh 30. 11 Install a mesh of size 30 inside the flushing filter. 18 Move all pipes inside the power house and do the final installation in the correct place. Protect the pipes with engine oil and carefully cover all pipe ends with plastic caps or similar. Make a note of the flushing pressure. During the flushing. 10 Double-check all connections. more than 30 cubic metres/hour – preferably a pump that has a pressure regulating valve ● Reinforced hoses of good quality. Check the oil level in the tank. 16-22 Confidential WDAAA116767i . A pressure test can also be done for separate pipes.

16. if needed.Status: Approved Confidential Installation Manual Document id: DBAC063079 . Start the feeder pump and make a note of the outlet pressure. Vent the air and check for leaks. Check that the pump suction strainer is clean. See drawings WDAAA193579 (W38 & W46). the fuel oil units. Procedure 1 After the final tank inspection. Use at least enough oil to fill and circulate the LFO system. open the bypass valve and lock the return line valve(s) in LFO storage tank position. the pipe rack modules and the piping between the pipe rack modules and the fuel oil units. 7 The final check of the pipeline for LFO to other consumers can be done by placing a flushing mesh of size 100 in the last flange connection before the consumer tank. Check for leaks along the return pipeline to the LFO storage tank. 5 Start the feeder and slowly open the outlet valve. Fill the pipeline.Page 27 (48) 16. 8 Fabricate a bypass flushing filter for the fuel oil hose connection before the tank. Confidential 16-23 . ● If the return piping from the pipe rack modules to the LFO storage tank has a flow meter. 4 Do the following checks: ● Check the piping from the LFO feeder to the pipe rack modules.5 Final flushing check of the LFO system See the flow diagram WDAAA169870.7. Clean all steel parts with pickling solution. 2 Check the piping leading from the tank to the LFO feeder as well as the return piping. ● Check that the three-way valve in the booster unit is positioned so that the return fuel from the fuel oil units runs to the LFO storage tank – not to the booster mixing tank.5. ● Check that all fuel oil unit inlet and outlet valves are closed. Cleaning and flushing of external piping The pickling can be performed in different ways: by filling each pipe with acid separately or by using a pickling bath. but do not remove it. the boosters and the pipe rack modules. 6 Remove the filter inserts from all fuel oil units and store them in a dry place. Check flanges and venting/ draining devices. Fill the tank and check the cleanness of the mesh. Fill the piping from the tank to the feeder and carefully vent the air and check for leaks. WDAAA215229 (W32) and WDAAA193580. adjust the pressure. Tighten the bolts of the blind flanges at the end of the pipe rack. Part 1 (and 3) 16. Procedure 1 WDAAA116767i Install the bypass flushing filter in the pipeline of the last DG set.7. fill the LFO storage tank with clean diesel fuel. ● Check the interconnections of the pipe rack modules and all the fuel piping between the engines. Now the feeder can be run non-stop. 3 Keep the feeder outlet valve closed.1 See the flow diagrams WDAAA169905 and WDAAA171033.

● Check the pump casing temperatures (bearing). 4 Open the fuel oil unit fuel return valve (HFO) manually. the mesh is free of sand.7.5. when the pressure rises above one bar (14. Check that there are no leaks in the return piping from the fuel oil units to the pipe racks. 9 When cleaning the LFO feeder unit suction strainer.Status: Approved Confidential Document id: DBAC063079 . make a note of the pressure from the flushing filter manometer. the booster and up to the LFO storage tank. 16.5 psi). Fill the unit and the flushing filter with fuel and vent the air from the fine fuel filter. the flushing is ready. 6 Start the fuel oil feeder pump. 2 Install a mesh of size 60 inside the bypass flushing filter. the flushing filter valves must be closed and the mesh cleaned.Page 28 (48) 16. 13 Start part two of the flushing process. 5 Check that the fuel oil feeder pump inlet valve from the fuel oil unit is open. Make a note of the pressure in the flushing filter and listen for cavitation noise. change to mesh 100. install the filter to the DG set when the commissioning is planned to start. stop the fuel oil unit feeder pump as well as the LFO feeder unit pump and close the LFO feeder inlet/outlet valves. 10 When after four hours of continuous circulation with mesh 60 the mesh is almost clean. Cleaning and flushing of external piping Installation Manual If the time schedule for the commissioning is tight. 3 Open the fuel oil unit LFO inlet valve manually. Inspect the cleanness of the flushing filter and install it between the engine and the pipe module or the fuel oil unit. do the following checks: ● Check that there are no leaks. 7 During the flushing. As the fuel oil is circulated by the feeder pump. after four hours of continuous circulation using mesh 100. ● Check the mesh every six hours (at least). ● Check the pressures in the LFO feeder and flushing filter. 8 In order to clean the bypass flushing filter mesh. metal. ● Check the fuel level in the LFO tank. 16-24 Confidential WDAAA116767i . 11 During the flushing. dirt or other harmful particles. See also the following drawings: WDAAA170675: Final flushing check. stop the feeder pump in the fuel oil unit and close the valves in the flushing filter. Perform grease filling on the pump bearings and check the pump’s rotation and seal guard devices.2 Part 2 (and 4) See the flow diagrams WDAAA169913 and WDAAA171076. ● Check for cavitation noise (this is very harmful to the pump). Booster unit WDAAA171023: Booster service filter insert WDAAA171079: Flushing filter device between engine and pipe module WDAAA193579: Flushing filter assembly W38 & W46 WDAAA215229: Flushing filter assembly W32 WDAAA193580: Flushing filter frame. 12 When. Check that there are no leaks.

Cleaning and flushing of external piping Procedure 1 Follow the booster unit flow diagram and start preparing the booster for flushing. Vent the air and open the mixing tank’s air vent. 4 Slowly open the booster outlet valve and check that there are no leaks in the piping to the pipe racks/fuel oil units. j Open all manometer valves. The mesh prevents dirt from entering the insert. f Open the inlet and outlet valves of one of the heaters. b Open the service filter and place a flushing mesh of size 100 around the filter insert. a Turn the three-way valve to the LFO position. If not. 9 Check and record the pressures in the LFO feeder. 5 Carry out a first grease filling on the pump bearings and check the booster pump’s rotation. The pressure in the flushing filter should be lower than 6 bar. switch over every few hours. the booster unit and the flushing filter. Only let the flushing oil pass through the meter during the last few hours of the process. k Check the booster unit inlet and outlet piping. Check the pressure in the flushing filter. correct the pressure by means of the pressure regulating valve from the pipe rack. e Open the booster pump inlet and outlet valves. l Connect to the main power supply. so that all the return fuel flows to the fuel tank(s) and not to the mixing tank. Increased pressures indicate that the meshes and filters should be cleaned. WDAAA116767i Confidential 16-25 .Page 29 (48) 16. 8 Start the fuel oil unit feeder pump. 3 Change the flushing filter mesh to size 60. h Close the final booster outlet valve. Close the venting valve. g Bypass the viscosity meter/sensor. Check that there are no leaks. d Set the three-way valve on the fuel return pipe from the engine(s) to the booster in the correct position. Keep the valves of the other heater closed. The pressure should be around 6 bar (when all fuel oil unit valves are closed). i Check that all venting and draining devices are closed. Reinstall the insert with the mesh back into the service filter and turn the position of the valve in the service filter. Wait until the indication light “low level in mixing tank” switches off. 7 Manually open the HFO inlet and fuel return valves from the fuel oil unit as well as the valves from the flushing filter. 6 Start one of the booster pumps and keep an eye on the outlet pressure.Status: Approved Confidential Installation Manual Document id: DBAC063079 . 2 Start filling the booster unit by slowly opening the valve from the pipe racks. c Bypass the flow meter.

16-26 Confidential WDAAA116767i . ● Monitor the pressures – suction and outlet. 16 The flushing process is ready when. Close the feeder inlet/outlet valves. The cleanness of the mesh in the booster service filter is not critical. switch booster operating pumps. stop the booster pump and finally the LFO feeder pump. equip the piping with several flange connections to enable cleaning by hand.8 Flushing of external HFO piping system See the flow diagram WDAAA180387. switch to mesh 100. 17 The person responsible for the flushing must approve the result of the flushing. Also close the booster inlet valve from the pipe racks and turn the valve position from service filter to automatic filter. after four hours of continuous flushing with mesh 100. 16. ● Monitor the pump bearing (casing) temperatures. 18 Close all valves. ● Monitor the cleanness of the mesh in the flushing filter. dirt or other harmful particles. NOTE Cavitation is very harmful for the pumps. begin by stopping the fuel oil unit feeder pump.1 Hand cleaning of piping between buffer tank. 15 If the mesh of size 60 in the booster service filter is clean as well. Cleaning and flushing of external piping Installation Manual 10 During the flushing. it is necessary to first stop the fuel oil unit feeder pump and then stop the booster pump. the mesh in the bypass flushing filter is free of sand. 14 When the mesh 60 filter is clean. it is only necessary to stop the fuel oil unit feeder pump and to close the valves from the flushing filter. ● During each mesh-cleaning stop. ● Monitor the fuel level in the LFO tank. Cut off the power supply to the units. ● Check for leaks. start the LFO feeder pump first. metal. 12 In order to clean the booster service filter mesh. 19 Remove the flushing equipment and install it to the next DG set for flushing. observe the following important things: ● Cavitation can be reduced by turning the booster three-way valve in position to let part of the return fuel oil from the fuel oil unit run to the booster mixing tank. day tank and separator unit If the piping is of a very large diameter (> DN 100) and it is difficult to get a flushing pump of suitable capacity. the booster pump second and the feeder pump from the fuel oil unit last. 20 Reinstall the filter inserts inside the fuel oil unit fine filter casing. When restarting the pumps.Status: Approved Confidential Document id: DBAC063079 . or if each pipeline is very short.Page 30 (48) 16. When restarting.8. 16. Check it every 4 hours. first start the booster pump and then the fuel oil unit feeder pump. 11 In order to clean the flushing filter mesh. 13 If the LFO feeder suction filter needs to be cleaned and the unit does not have a bypass possibility. Next. change to size 100.

5 Install the flushing hose from the flushing filter/pump to the pipeline from the buffer tank to the HFO separator unit. 11 Open the tank outlet valve and fill the piping. 7 Separate the piping from the HFO separator connection flanges and install the bypass pipe or hose. Use strong hose clamps of good quality. protect the piping with lube oil. Use enough oil for the flushing process.Status: Approved Confidential Installation Manual Document id: DBAC063079 . 4 Use LFO. 6 Inspect each pipe carefully before the final assembly. All flushing hoses must be of a suitable diameter for the pump capacity or of the same diameter as the piping.Page 31 (48) 16. close the outlet valve and fill the tank with flushing LFO. the bypass can be equipped with a flushing filter to reduce the flushing time. 4 Install the flushing hose from the flushing or buffer tank to the flushing filter/pump. Flushing when using a large buffer tank requires a large amount of flushing LFO because the tank must be filled up to the height of the outlet pipe. See drawing WDAAA167687. vent the air and record the pressure in the flushing filter. WDAAA116767i Confidential 16-27 .2 See the flow diagram WDAAA172686. Use strong hose clamps of good quality.8. 3 Perform the pickling process in a suitable way. Procedure 1 Fabricate and arrange all needed flushing equipment. 2 If the volume of the buffer tank is larger than 150 cubic metres. rags and – if possible – compressed air to clean the piping pipe by pipe. it is possible to use a separate flushing tank (> 400 l). 2 Perform a pressure test. If the pipe is long. 6 Check the pipelines from the HFO buffer tank to the HFO separator unit and return. The flushing pump must have a large pumping capacity. 10 Inspect the cleanness of the tank. Also inspect tanks and the unit side of the piping. 3 Open the first flange connection after the buffer tank and the outlet pipe and valve. Flushing of piping between the buffer tank and the separator unit 16. All steel flushing equipment must be cleaned with pickling solution. 8 Install the flushing filter and hose to the end of the pipeline. Separate the pipe flanges in order to connect the flushing hoses. Also check venting and draining devices. 12 Start the flushing pump. 5 After the cleaning. 9 Install a mesh of size 30 inside the flushing filter(s) first. Check that there are no leaks. Do not remove the blind plates from the HFO separator connection flanges. Cleaning and flushing of external piping Procedure 1 Carefully clean welds and flanges to remove welding slag. Check that there are no leaks. A rising pressure will indicate the intervals for cleaning the flushing filter mesh.

6 Drain the piping and the flushing tank. ● Check the flushing meshes every three hours. Cleaning of the pipeline from the HFO separator to the HFO day tank 16. 16 If the piping will be kept dry for a longer period of time. 17 Close the flushing tank outlet valve. assemble the HFO separator unit. inspect the piping and connect all pipes permanently without any blind plates. 15 The flushing is ready when after three hours of continuous flushing using mesh 100 the mesh is free of dirt or harmful particles such as sand. 2 Check the clean HFO piping from the HFO separator to the HFO day tank. If the buffer tank was used. ● Check the pressures. cover or if possible. ● Gently hammer the welding seams with a piece of DN 50 pipe or similar.2. 3 Move the flushing filter with the hose from the HFO return pipe to the clean HFO pipe before the HFO day tank and flushing tank. when mesh 60 is almost clean. Procedure 1 Change the location of the bypass before the HFO separator. perform the following checks and actions: ● Check the LFO level in the flushing tank. If bypass has equipment with flushing filter the mesh size can remain 100.4 5 Continue flushing according to steps 11–17 in section 16. drain the piping and inspect the cleaning. 4 Change mesh 30 to inside of the flushing tank. Cleaning and flushing of external piping Installation Manual 13 During the flushing. 16-28 Confidential WDAAA116767i . change to mesh 60 and correspondingly. Close all draining and venting devices.Page 32 (48) 16.8. metal or welding slag. Remove the blind plate. Make sure the tank openings are covered. ● Check that there are no leaks. 7 Remove all flushing equipment.Status: Approved Confidential Document id: DBAC063079 . Inspect the return pipe to the buffer tank. 16.8. Diesel oil flushing of piping from HFO day tank to HFO feeder and return See the flow diagram WDAAA173337.3 See the flow diagram WDAAA172738. ● Check the pump temperatures and pay attention to signs of cavitation. 14 When the flushing filter mesh 30 is almost clean. Do not let flushing oil leak onto the ground or onto the concrete floor. The HFO return pipe can be connected to the HFO buffer tank. This will give protection to the pipes. The person responsible for the flushing and commissioning must approve the cleaning. inspect the cleanness and close the tank.8. from the HFO inlet pipe to the clean HFO outlet pipe. change to mesh 100. mix the flushing oil with lube oil and circulate it the last few hours of the flushing process.

Status: Approved Confidential Document id: DBAC063079 . 14 Slowly start to fill the piping with flushing oil. Do not run the pump dry. Cleaning and flushing of external piping NOTE All temporary steel piping materials used in the flushing procedure must be cleaned with pickling solution. Also check venting/draining devices and flange connections. install a blind plate between the flanges in the outlet of the feeder and in the piping from the feeder to the pipe rack/ booster. 12 Inspect the cleanness of the tank and fill it with clean flushing oil. 2 If a separate flushing tank is needed. If pressures are not too high and the pumps are not cavitating. Rising pressures later on will indicate that the flushing mesh is dirty and that the pumps need to be stopped for cleaning of the mesh. and connect it to the return pipe with a hose of the same diameter as the pipeline. Cover and store the valve in a dry place. 3 Install the flushing tank slightly higher up than the HFO feeder unit and in a suitable place near the HFO day tank. Use a filter when filling the tank. use both pumps for flushing. carry out a first grease filling on the pump bearings in accordance with the pump manual and check that the pump rotates properly. 11 Install a mesh of size 30 inside the flushing filter. Check venting/ draining devices and flange connections. Keep an eye on the temperatures of pump bearings and electric motors. Start one of the pumps and run it only short periods of time. 4 Connect a hose or steel pipe from the flushing tank to the pipeline leading from the day tank to the feeder. Check the flushing oil level in the tank. 5 Check the piping leading from the day tank or flushing tank to the feeder. 7 Close the feeder outlet valve and for safety reasons. if the tank is not completely ready or if it is already filled with clean separated fuel. Carefully vent the air from all pipes. The hose has to be of the same diameter as the piping or larger. stop one of the pumps for a while. Keep an eye on the pressures. 9 Check the return piping from the HFO feeder to the HFO day tank. 6 Check the condition of the HFO feeder unit and install a flushing mesh of size 30 inside the suction strainers. Check that there are no leaks. 13 Open the feeder unit inlet valves. start the second pump as well. separate the piping from the HFO day tank closing valve and install a blind flange on the valve for safety. Alternatively. 15 Run the pump and record the suction pressure after the pump. install the flushing filter in the manhole at the top of the day tank or flushing tank. 16 If the unit has two feeder pumps for HFO. Use a reinforced rubber hose of good quality and mount the hose as straight as possible. 10 Install and connect the flushing filter in a suitable place at the end of the return piping between the HFO day tank and the pipe flange connection. Check that there are no leaks. WDAAA116767i Confidential 16-29 .Page 33 (48) Installation Manual 16. If the flushing oil starts foaming excessively. Procedure 1 Use a separate flushing tank (400 l or larger) if the HFO day tank is larger than 150 cubic metres. 8 Loosen the tension adjusting screw in the feeder pressure control valve or alternatively. replace the valve with a pipe spool. Never leave the flushing process unsupervised.

Cleaning and flushing of external piping Installation Manual 17 Begin flushing using mesh 30. metals or other harmful particles. Check the flange connections. turn the valves in bypass position and only let the flushing oil pass through the meter the last few hours of the process. 18 The flushing is ready when after three hours of continuous circulation using mesh 100. Procedure 1 Check that the HFO feeder outlet valve is closed. Connect the HFO feeder return to the flushing tank (HFO day or separate flushing tank). Install a mesh of size 30 inside the filter. If so. 22 Do not remove the flushing arrangement since some of it will be needed later on.Status: Approved Confidential Document id: DBAC063079 .Page 34 (48) 16. NOTE All temporary steel piping materials must be cleaned with pickling solution. Gently hammer the welding seams during the flushing. Do not spill oil on the floor! 2 Check the piping leading from the feeder up to the pipe racks inside the power house. If the pipeline has the option of a flow meter. 5 Lock the return line valves position to HFO buffer tank position. the feeder line pressure must be adjusted back to 4 bar (this is required for the following part of the flushing process). 20 Drain the pipes slightly in order to open a few flange connections and inspect the cleanness of the pipes. Also check flange connections as well as venting and draining devices. All steel parts must be cleaned with pickling solution. the position of the valves and the venting/draining devices. Keep an eye on the temperatures of pump bearings and electric motors. The needed hoses must be of at least the same size as the piping. change to mesh 60 and finally to mesh 100. Never leave the flushing process unsupervised. The pressure regulating valve in the HFO feeder will work as a safety valve. Flushing of HFO piping from the day tank up to the pipe racks and return from the pipe racks 16. Do not run the pumps dry. Remove the blind plate or flange and connect the outlet piping to the feeder. 16-30 4 Check the return piping from the bypass up to the HFO buffer tank. 7 Install a mesh of size 30 inside the flushing filter and a mesh of size 60 inside the suction strainers in the HFO feeder. check if the pressure regulating valve adjusting screw has loosened. Drain the flushing tank at regular intervals to avoid water in the oil. The flushing tank openings must be covered during the flushing. When the mesh is almost clean. sand. Confidential WDAAA116767i . the mesh is free from dirt. If the valve was removed. 21 Close all valves and clean the flushing filters. 3 Separate the HFO inlet and the return fuel pipe from the pipe racks. Cover the flushing tank and piping openings.8.5 See the flow diagram WDAAA190746 and WDAAA190747. 6 Change the tank area flushing filter from HFO feeder return to pipe racks return. Fabricate and install a bypass with a flushing filter. 19 Before terminating the flushing procedure. reinstall it and test the working pressure.

8. metal. The flushing is ready when. but make sure that it is not of a smaller diameter than the pipeline. Only run the pump short periods of time. When the mesh is clean. the mesh is free of sand. ● Make sure that there is no cavitation noise in the pumps and check the pump casing temperatures. 3 Fabricate and install a bypass for the last booster unit in the pipe rack connection. The person responsible for the flushing must approve the cleanness of the pipes before the process is terminated. Check the oil level in the flushing tank and check for leaks during the filling. 14 Close the piping. 15 Start the last part of the HFO pipe flushing in the pipe racks and the booster(s). 4 Close all HFO inlet valves to the booster in the pipe racks. change to mesh 60 and finally to mesh 100. Flushing of the HFO pipeline in the pipe rack and booster connection(s) inside the power house 16. Procedure 1 Check the pipe rack's internal piping and the HFO piping leading from the HFO feeder up to the pipe racks. 10 When the whole system has been filled and vented. dirt or any other harmful particles. The bypass can be a steel pipe or hose. remove the bypass before the pipe racks. ● Make sure that there are no leaks. inspect the piping and connect the pipes to the pipe racks. the piping needs to be drained and a few flange connections must be opened for the inspection. 2 Fabricate and install a bypass with a valve at the end of the pipe racks. start the other feeder pump as well. ● Check the flushing mesh every four hours. Cleaning and flushing of external piping 8 Check the flushing oil level in the flushing tank and open the valves in the feeder and in the flushing tank. 13 For the approval of the flushing.6 See the flow diagram WDAAA173409. Record the suction and line pressures. The bypass can be a hose or steel pipe of the same diameter as the piping or larger. Close the bypass valve. 5 Turn the booster unit’s inlet three-way “change-over” valve to the LFO position. perform the following important checks and actions: ● Gently hammer the welding seams with a piece of pipe or similar. The bypass should lead from the end of the HFO pipeline to the return fuel pipe end of the pipe racks. run the pump continuously. If the pressures are fine and there is no cavitation. 12 Begin flushing the pipes using a mesh of size 30. after 3–4 hours of continuous circulation using mesh 100. Vent the air from the pipelines. 11 During the flushing. ● Check the flushing oil level in the tank. Check that there are no leaks.Status: Approved Confidential Installation Manual Document id: DBAC063079 . Keep an eye on the pressures.Page 35 (48) 16. 9 Start filling the piping with flushing oil. WDAAA116767i Confidential 16-31 . The bypass is for the “counter connection flanges” between connections A and D. Rising pressures later on will indicate that the filter meshes need to be cleaned.

fabricate and install a flushing filter in the return fuel pipeline in a suitable place near the pipe racks – if possible. Confidential WDAAA116767i .8.1 Flushing the HFO pipes in the pipe rack (step 1) See the flow diagrams WDAAA190756 and WDAAA190757. Check the flushing oil level in the flushing tank.Page 36 (48) 16. The flushing should be performed starting from the last booster unit. 2 Start the HFO feeder pump and check the pressures. Procedure 16-32 1 Close the flushing bypass valve at the end of the pipe rack. When the flushing oil is circulating. metal or other harmful particles. check the pressures and check that there are no leaks in the pipe rack or in the bypass. Keep an eye on the pump and electric motor bearing temperatures. NOTE All temporary steel equipment used in the flushing procedure must be cleaned with pickling solution. 7 To reduce the flushing time. the flushing filter for the return to the flushing tank. the flushing is ready. Procedure 1 Start the HFO feeder pump. start with mesh 60. 8 Install or change the mesh in: ● the tank area. start the second pump as well and check the pressures. change the mesh inside the filter to size 100. mesh 100 ● the HFO feeder suction strainers.6. sand. mesh 100 ● the pipe rack flushing filter for return fuel. 2 Open the bypass valve in the end of the pipe rack. Never leave the flushing process unsupervised. 4 When the return line flushing filter mesh 60 near the pipe rack is clean.Status: Approved Confidential Document id: DBAC063079 . proceed with step 2 (flushing of the booster connections). Rising pressures will indicate the intervals for cleaning the mesh. Flushing the booster connections (step 2) 16. 16. Make sure that there is no cavitation noise. Never run the pumps dry. See the flow diagram WDAAA190764 and WDAAA190765. with valves. step 1 of the flushing procedure (flushing of the HFO pipes in the pipe rack) must be completed and the actions recorded.2 Prerequisites Before starting the flushing of the booster connections. 3 Record the HFO feeder suction and outlet pressures.8. When after 3–4 hours of continuous circulation mesh 100 is free of dirt. Cleaning and flushing of external piping Installation Manual 6 Turn the booster’s return three-way valve in such a position that the return fuel from the engines flows to the mixing tank.6. Postrequisites When step 1 of the flushing procedure has been completed.

7 Blow with air after erection of the pipe system. 10 Fill the lines with gas.5 bar(g). 3 Wash with alkaline solution in hot water at 80 °C for degreasing. move the flushing equipment to the next booster unit and start the same process. the pickling containing rinsing is not required. 9 Fill the lines with nitrogen at a pressure of 0. 6 The flushing is ready when all booster units have been flushed. 4 Start the second HFO feeder pump as well.9.Page 37 (48) 16. check the lines for leakage (natural gas leaks easier than air). This will protect the pipes. 4 Perform the pickling (including neutralizing/rinsing of piping). mix the flushing oil with lube oil and circulate it for a few hours before removing the equipment. Postrequisites After startup. 1. Check and record the pressures. use tools such as a steel brush. Cleaning and flushing of gas systems of SG and DF engines 16. 5 Dry by blowing with air. rust and scaling.1 Cleaning TIG welded carbon steel piping Procedure 1 Remove slag. 2 Perform a visual inspection. for instance. Cleaning and flushing of external piping 3 Slowly open the booster HFO inlet valve in the pipe rack and check that there are no leaks. or hammer.5 times the nominal pressure. if the plant has more than one booster unit. 16.9. remove all flushing equipment.Status: Approved Confidential Installation Manual Document id: DBAC063079 . Do not spill any oil on the ground or floor! 9 The HFO pipelines are ready for commissioning after the trace heating and insulation assembly. 7 If the HFO pipelines will be empty of fuel for a longer period of time. to prevent corrosion. Cleaning TIG welded stainless steel piping 16. Grind the flanges. Confidential 16-33 .2 Procedure 1 WDAAA116767i Perform a visual inspection. 6 Perform LFO or water flushing for long pipe lines. 5 When after 3–4 hours of continuous circulation the return line flushing filter mesh 100 is clean.9 Gas pipes can be made of carbon steel or stainless steel. 8 Perform the pressure and leak tests. Stainless steel pipes require less work. and assemble all pipes and flanges permanently. 8 Drain the piping and the units. which saves time.

Another method is glass ball blasting. 6 Fill the lines with gas. etc. ensure that the sand is truly clean (not recycled). Passivation is carried out similar to pickling.9. Pickling After the pipe fabrication (welding. Do not clean stainless steel pipes with any type of metallic wire brush other than stainless steel. At least all welds shall be pickled.). pitting and stress corrosion. If a very heavily contaminated stainless steel surface is to be cleaned by sandblasting. Avoid grinding or polishing with grinding wheels or belt sanders. The nitric-HF [1] pickling method is the most widely used and effective method (10% HNO3. or water in general with a high content of chlorides will speed up the corrosion. Blowing of the lines is done as follows: ● First with an open valve ● Then by sequentially opening and closing the valve several times so that there will be pressure shocks. pickle the pipes in order to get the best corrosion resistance. a new. Small parts can be passivated by immersion and large parts can be sprayed or brushed. Passivation If pickling is not performed. intact oxide layer is formed on the pipe surface.9. cutting. Do not use steel shot blasting. the pipe must be passivated or treated by acid cleaning. Different types of paste used for different grades of stainless steel. The chlorine ions can initiate crevice. Postrequisites After startup.3. Place stainless steel pipes in a dry and ventilated location.g. there should not be any corrosion. The pickling can be done by immersion or locally by pickling paste. check the lines for leakage (natural gas leaks easier than air). If the pipes are greased. The passivation time is 20–60 minutes. particularly water standing still in pipes. 16. Always pickle the pipes if they are sandblasted.3 Storing and cleaning of stainless steel pipes If the stainless steel alloy is correctly selected and stored. This must be done to avoid leaving residue of chlorine ions. NOTE After pickling. 3 Blow with compressed air. but the active component is simply 18–30% nitric acid (HNO3) at room temperature. Do not use blasting methods that could roughen the surface. [1] HF = Hydrofluoric acid 16-34 Confidential WDAAA116767i .Status: Approved Confidential Document id: DBAC063079 .Page 38 (48) 16. The oxide layer prevents the pipe from corrosion. The parts must be rinsed thoroughly in water after the treatment. 316) than in high performance stainless steels. use a non-chlorinated solvent to remove the grease. Pickling paste is sold at least by the stainless steel manufacturers (e. if they are to be stored for a long period. Cleaning and flushing of external piping Installation Manual 2 Perform pickling and passivation according to section 16. Sea water. The risk of this is higher in “normal” stainless steel grades (304. 2% HF and the rest water at 50–60 °C). 5 Fill the lines with nitrogen if a flammable mixture is possible. 4 Perform the pressure and leak tests. Avesta Polarit). as they tend to overheat the surface to the point where corrosion resistance cannot be restored even with pickling. This risk is reduced by choosing a higher grade of stainless steel or by pickling the pipes.

WDAAA116767i Confidential 16-35 .Status: Approved Confidential Document id: DBAC063079 .1 for the compressed air system. perform the final cleaning of the compressed air pipes prior to commissioning as follows: NOTE Clean the compressed air system before pressurizing the engine or any auxiliaries. 3 Hammer the weld seams thoroughly throughout the piping system. The discharge from the hoses must be directed in such a way that the blowing air stream will not be able to damage or disturb the surroundings. CAUTION Make sure that the personnel are aware that the compressed air system will be blown clean. The same procedure applies to auxiliaries connected to compressed air.Page 39 (48) Installation Manual 16. 2 Disconnect the flexible hoses for the starting air and instrument air at the engine inlets and fasten the hoses firmly with rigid steel clamps to the closest structures. 4 For the starting air system: Open up the isolating valves for some fifteen seconds and close the valves again.10 Flushing of compressed air systems In addition to the information in section 16. close the isolating valve from the outlet of the starting air bottle manifold and the instrument air dryer. Inform everyone possibly concerned and close off the area by means of zebra (warning) tape. Procedure 1 Once the pressure test of the system is completed successfully. CAUTION Environmental risks and health hazards must be considered when working with acid solutions. 16. Flushing of cooling water system NOTE Perform the pressure testing and record the results before flushing the system.11 For the compressed air system: Open and close all valves several times. Repeat this procedure one more time to obtain the best results. NOTE The flushing pump arrangement is not delivered by Wärtsilä. Cleaning and flushing of external piping NOTE Passivation will only strengthen the old oxide layer. 5 16.

Procedure 1 Disconnect the pipes from the pipe module. Cleaning and flushing of external piping 16. reconnect the pipes to the pipe module and the radiators.g. 16. There is no need to install a separate flushing pump. Run until the engine is warm. NOTE Protect the pumps with adequate strainers on the suction side during the flushing sequence. Fig 16-6 16. 16.11. Fill up the whole system with untreated water.11. Remove the running-in filters at the first 50 hours service interval of the engine. If no debris is found in the filters or in the expansion tanks. Therefore. Drain all water from the system and refill it with chemically treated water.1 Installation Manual Flushing the expansion pipes Flush the expansion pipes with water until they are clean from debris. The pipe module and the radiators do not need to be flushed. then shut down the engine. This mesh is for trapping the debris.11. disconnect the pipes from the module and the radiators and build a pipe loop as shown in Fig 16-6. 2 Install a mesh in the pipe end of the return pipe to the cooling tower basin.3 Flushing arrangement for cooling water pipes GUID-873F61CA-48BF-4A4E-8A6C-DA87D77308A1 v1 Flushing the whole cooling radiator system When the pipes between the pipe module and the radiators are clean. clean the bigger pipes by hand.2 Flushing the pipes between pipe module and radiators Before the flushing with water. Install running filters on HT and LT inlet pipes to the engine.4 Flushing the pipes between pipe module and cooling tower Cooling tower installations will basically follow the same principle as radiator installations. use an external flushing pump arrangement (e. For the flushing. by using the fire water pump) that has an adequate flow capacity and is equipped with strainers to collect the debris coming from the pipes during the flushing procedure. 3 Use the cooling tower pumps.Page 40 (48) 16.Status: Approved Confidential Document id: DBAC063079 . Check the running-in filters. 16-36 Confidential WDAAA116767i .11. Drain the expansion system and completely clean the bottom of the expansion tanks. the system can be considered clean.

The priority is to blow both sides clean with steam to ensure the gentlest treatment. compared to the normal concentration for own consumption boilers. 3 After mechanical cleaning.Page 41 (48) Installation Manual 16. Exhaust gas boiler manufacturers recommend cleaning with boiler chemicals mixed to double concentration. If no debris is found in the filters or in the expansion tanks.12 Procedure 1 The storage. reconnect the pipes to the pipe module. In plants with steam turbines or other equipment that are sensitive to impurities.5 and section 16. the system can be considered clean. 2 Tube boilers may require cleaning of the tubes or the furnace. steam drums.4 also applies to the cleaning of the items specified in the title of this chapter. if an auxiliary boiler container is provided in the scope of supply. Cleaning and flushing of external piping Flushing the whole cooling tower system Procedure 1 When the pipes between the pipe module and the cooling towers are clean. a portable steam generator can be rented locally in many cases. 3 Run until the engine is warm.Status: Approved Confidential Document id: DBAC063079 . The priority is to conduct a blow-through of the coil-type boiler with steam. 6 Remove the running-in filters after the first 50 hours service interval of the engine. Excessively corroded coil-type boiler sections can be pickled and neutralized in a normal fashion as stated earlier. If steam is not available at the plant. according to a specific detailed program provided by the supplier. Cleaning of steam boilers. 4 Check the running-in filters.11. depending on which method is most applicable on location. feed water tanks and related water spaces 16. The information about neutralizing and rinsing of pickled items and sand blasting in section 16. if available. The procedure is linked to the validity of the warranty. WDAAA116767i Confidential 16-37 . 5 Drain all water from the primary circuit and refill it with chemically treated water.2. 2 Fill up the primary circuit (engine and pipe module) with untreated water. NOTE Flush steam and condensate lines before taking them into use. Steam treatment provides a well acceptable result. sea transportation or improper covering or protection of the equipment may result in extensive corrosion of the water spaces. Furthermore. then shut down the engine. its steam generation should be considered for cleaning purposes. This step is an integral part of commissioning procedure that must be documented. Tanks and vessels can be either sandblasted or pickled. a clean boiling procedure must be executed before taking the boiler into use.5 16. the flushing of the live steam line has to be approved by the turbine (equipment) manufacturer before taking the equipment into use. or both.

5000 ppm + 500 ppm ● Trisodium phosphate + caustic soda + soda ash. 16-38 3 Let the boiler soak six hours with the acid solution. The water must be properly treated and deaerated to guarantee minimum formation of scaling as soon as the boiler is set in operation.12.1 Procedure 1 Before a full output boiler is put in service or if there is oil in the water. 3 Blow down the boiler or each piece of the system every 8 hours. 4 Continue boiling for 40 hours. There are two methods of cleaning: alkaline boil out and acid cleaning. 3000 ppm + 3000 ppm.1% inhibitor. to keep within the limits. Acid boiling-out 16. 0. After every blow down. Control the temperature with the bypass damper in the exhaust gas outlet. Procedure 1 Heat up the boiler until the boiler metal reaches a temperature of 70–80 °C. Cleaning and flushing of external piping 4 Installation Manual Boiling-out of the boiler shall be done: ● before initial start of full output boilers ● in case of oil in the waterside ● in case of heavy corrosion. Take condensate samples through the sample points to ensure that impurities are no longer present.5% ammonium biflouride. Alkaline boiling-out 16. 2500 ppm + 2500 ppm ● Trisodium phosphate + caustic soda. Use a solvent composition of 5% hydrochloric acid. Fill the boiler to the normal level with softened water.Status: Approved Confidential Document id: DBAC063079 .12. Confidential WDAAA116767i . Normally. The amount of blown water equals half the sight glass.2 Use this procedure when rust or mill scale is known to exist to a high degree in the boiler. Add feed water if required. Fill the boiler first half full with soft water and then top it up with the chemical blend. 4 Ensure that the vents are open. add the chemical mix to replenish the concentration. and 0. Any of the following combinations will give a proper cleaning result: ● Trisodium phosphate + caustic soda. acid boiling is not required for new boilers. 3 × 1500 ppm ● Caustic soda + soda ash. Prepare this solution by diluting the chemicals with warm water. 2 Dissolve the chemicals entirely prior to pouring the mix into boiler. 2 Fill up the boiler with solvent solution of about 65 °C.Page 42 (48) 16. Add the chemical solution through the manhole or the chemical feed connection. boil out the impurities.

3 Procedure 1 Fill up the boiler with a 1% sodium carbonate solution to the normal level.12. Open the venting valves while draining. The boiler is rinsed as soon as the pH value of purged water exceeds 5. 3 Stop the heating. fill it with a 0. Shut the valves and run the feeder pump to get it rinsed. Procedure 1 WDAAA116767i When the boiler has cooled down.4 Procedure 1 While the unit is still hot. Cleaning and flushing of external piping The vents must be open because hydrogen gas is evolved through the reaction between steel surfaces and acid. Avoid all open flame and sparks because the gas may ignite. inspect the steam drum and the boiler waterside surfaces. 6 Rinse the boiler with soft water.Status: Approved Confidential Document id: DBAC063079 . Open the venting valves while filling. if needed. flushing and precautions 16. a Fill the boiler with soft water. c Run the feed pump for rinsing. Inspection. 5 Drain the system by gravity and boost the draining with compressed air.Page 43 (48) Installation Manual 16. b Shut the vent valves.5 NOTE Never heat or fire boiler with exhaust gases while there is acid solvent in the unit. Neutralization boil-out 16. If indoors. Let the system run until you consider that a full cycle of fresh water has gone through. 7 Open the drain in the bottom of the boiler slightly and continue filling from the top with soft water.12. 2 Drain the boiler. let the pressure drop to 1 bar and then drain the boiler. run the boiler house fans to keep the space well ventilated. Run the boiler feeder pump and top up the boiler to normal operating level. Confidential 16-39 . 2 Raise the pressure to the normal operating level and maintain it for approximately four hours.12.5% sodium nitrite solution and let soak for one hour. Passivation 16.

Procedure 1 Fill up the boiler. Boil-out of an oil-fired boiler 16. Procedure 1 16-40 Disconnect the pipes at the inlets to the boilers.13 Steam pipes that are not clean on the inside are to be pickled prior to the cleaning by steam blowing (see section 16. manufacturers suggest trisodium phosphate and caustic soda. b Fill the boiler with water.6 The interior of oil-fired auxiliary boilers may have protective coatings that must be boiled out. 3 Store neutralizing boil out chemicals in a dry place prior to use. See the flow diagram. 4 Keep protective clothing available for those working with the process handling chemicals.Status: Approved Confidential Document id: DBAC063079 . Cleaning and flushing of external piping Installation Manual Remove any loose iron oxide or other scaling manually with a steel brush or flat chisel. and protective glasses).2). Flush out the loose deposits with clean water. 16. c Add the acid solvent to the top of the tubes.1 Cleaning the pipes between auxiliary boiler. boots.Page 44 (48) 16.13. 5 Keep a record of the process and have it signed duly by both parties. 2 Put the manholes back in place and close the access doors. 2 Heat the boiler to the boiling point and let the boiling last for five hours. 5 Perform a visual inspection to determine if the result is acceptable. aprons. a Prepare a 2. document number WDAAA196364. Feed water pipes are to be flushed with water only. 3 Wait until the boiler has cooled down a to a safe level and drain the water to the sewage. Fasten them firmly to the closest structures with rigid steel clamps. 4 Rinse the tubes with high pressure water. Inform everyone possibly concerned and close off the area by means of zebra (warning) tape.12. The boiler is ready for normal service. Do not damage the passivated layer. Confidential WDAAA116767i . Cleaning of steam pipes and feed water pipes 16. Always use proper protection (rubber gloves. Normally. steam header and exhaust gas boilers Prerequisites CAUTION Make sure that the personnel are aware that the steam system will be blown clean.5-% mixture in a separate container.

Procedure 1 Disconnect the pipes at the inlets to the consumers. 2 WDAAA116767i Blow the main and the condensate return lines. pipe rack. Fasten them firmly to the closest structures with rigid steel clamps.Page 45 (48) 16. a Direct the discharge of the pipes in such a way that the blowing air stream will not be able to damage or disturb the surroundings.13. Let the temperature of the pipes go down between the blows. Let the temperature of the pipes go down between the blows. Blow all steam pipes for the consumers. 2 Blow the steam beginning from the auxiliary boiler to the steam header and further on to the pipe rack. document number WDAAA196376. consumers inside the power house and blow-down tank See the flow diagram. Repeat this procedure several times. Procedure 1 Disconnect the pipes at the inlets to the consumers. Confidential 16-41 . Cleaning and flushing of external piping Direct the discharge of the pipes in such a way that the blowing air stream will not be able to damage or disturb the surroundings. During this procedure. The discharge of the pipes must be directed in such a way that the blowing steam stream will not be able to extract any items from the surroundings.2 Cleaning the steam pipes between header. hammer the pipes in order to dislodge particles from the inside of the piping. 2 Blow the steam beginning from the auxiliary boiler to the steam header and further on to the exhaust gas boilers. 5 Install an extra pipe loop at the end of the circulation pipe out to the consumers and blow the condense pipe line. Install an extra pipe loop between the main line and the condensate return line. hammer the pipes in order to dislodge particles from the inside of the piping. 16. 3 Plug the extra pipe loop at the pipe rack(s).3 Cleaning the steam pipes between header. 4 Open the valves to the consumers’ circulation pipe and start the clean blowing at the very back engine. 16.13.Status: Approved Confidential Installation Manual Document id: DBAC063079 . During this procedure. b Install an extra pipe loop at the pipe rack. Fasten them firmly to the closest structures with rigid steel clamps. Repeat this procedure several times. document number WDAAA196366. consumers outside the power house and blow-down tank See the flow diagram.

Let the temperature of the pipes go down between the blows. 4 Install an extra pipe loop at the end of the steam and condensate lines and blow the whole piping system back to the blow-down tank. 16-42 3 Blow the steam lines to the consumers.Status: Approved Confidential 16. If there is a loop in a tank. Confidential WDAAA116767i .Page 46 (48) Installation Manual This procedure is to be repeated several times. Cleaning and flushing of external piping Document id: DBAC063079 . the loop shall also be blown by disconnecting the flange connection to the condensate line. At the same time the pipes are to be hammered in order to get possible particles to come off from the inside of the piping.

Page 47 (48) .Status: Approved Confidential Document id: DBAC063079 .

Finland.com/addresses .wartsila. By emphasising technological innovation and total efficiency.wartsila.Status: Approved Confidential Document id: DBAC063079 . Wärtsilä is listed on the NASDAQ OMX Helsinki.com WÄRTSILÄ® is a registered trademark. © 2011 Wärtsilä Corporation. See also www.Page 48 (48) Wärtsilä is a global leader in complete lifecycle power solutions for the marine and energy markets. Finland 24hrs Phone +358 10 709 080 Switchboard +358 10 709 0000 Fax +358 10 709 1380 Find local offices at www. Wärtsilä maximises the environmental and economic performance of the vessels and power plants of its customers. Wärtsilä Services Main Office Vaasa.