Specification No.

ES 2184

CONTENTS

Paragraph Page

1.0 SCOPE 1

2.0 APPLICABLE DOCUMENTS 1

3.0 PREPARTION FOR FLUSHING 1

4.0 PROCEDURE 2

5.0 ACCEPTANCE CRITERIA 3

6.0 POST FLUSH PROCEDURE 3

Appendix A CLEANING OF OIL TANK INTERNAL SURFACES 6

AND TANK VENT PIPING

Appendix B PICKLING AND PASSIVATION OF PIPEWORK AND EQUIPMENT 7

TABLE

Table Page

1 Flow Rates for Reynolds Number (Nr) = 4000 5

FIGURE

Figure Page

1 Typical Flushing System 4

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 Specification No. ES 2184

1.0 SCOPE - This specification covers the preparation and acceptance criteria for the cleaning and
flushing of components and piping used in lube, seal, and hydraulic systems on Solar packages.
Proper cleaning and flushing will remove the contamination built into components and systems before
operation so that sensitive components do not fail prematurely. Components to be cleaned and flushed
include, but may not be limited to the following:

• Lube oil supply and drain lines

• Seal oil supply and drain lines
• Servo system supply and drain lines
• Hydraulic start system supply and drain lines
• Power take off system supply and drain lines
• Lube oil reservoir level control (auto fill) system
• Seal oil interconnect lines
• Lube oil coolers
• Lube oil interconnect lines

Reservoirs, tanks, and tank vent piping require mechanical cleaning only, per Appendix A.

2.0 APPLICABLE DOCUMENTS

Solar Specifications

ES 9-224 - Specification For Lubricating Oils For Use In Solar Gas Turbines

ES 9-248 - Corrosion Preventive Oil For Long Term Preservation

Other

ISO 4406 - ISO Cleanliness Code

3.0 PREPARATION FOR FLUSHING - Rust, scale, machining chips, grit blast, weld slag, etc shall
be thoroughly removed from all tanks, vessels, pipes, etc. prior to flushing.

Tanks, tank vent piping, and vessels require mechanical cleaning and inspection only, per Appendix A.

Carbon steel piping will require pickling and passivation to properly remove rust and scale per
Appendix B before being flushed.

Stainless steel piping is recommended as it does not need to be pickled.

Sensitive components (bearings, seals, valve, etc) shall be removed or bypassed during the cleaning
and flushing to avoid contamination.

Equipment required: (See Figure 1 for typical flushing system)

1. Flushing pump of sufficient capacity

2. Flushing fluid heater

3. Flushing fluid filter to remove contamination from flushing loop

4. Flushing fluid strainer(s) (100 mesh or finer) or filter bag(s) (25 micron or finer) at end

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 Specification No. ES 2184

of each pipe run or component being flushed for cleanliness verification.

5. Particle Counter to determine fluid cleanliness (ISO 4406) or optical filter patch kit

6. Flow measurement device for each piping leg or component

7. Thermometer(s)

8. Dead blow hammers or pneumatic vibrators

9. Flushing fluid that is compatible with the mineral based oils in Solar ES 9-224

4.0 PROCEDURE - The following flushing sequence is required to minimize the possibility of
contaminating previously factory flushed components and assemblies. Adherence to this sequence
will substantially minimize the effort and time necessary to successfully complete the final, full system
flush.

Required Flushing Sequence

a) Pre-filter the package fill oil and, if applicable, the flushing rig fill oil to ISO 14/12 cleanliness level
b) Loop flush/filter the flushing rig, alone, to ISO 14/12 and no 100 mesh screen captured particles.
c) Add the off-skid cooler piping to the flush loop (without package or cooler connection) and
flush/filter to ISO 14/12 and no 100 mesh screen captured particles.
d) Add the cooler to the flush loop and flush/filter to ISO 14/12 and no 100 mesh screen captured
particles.
e) Add the package to the loop and flush/filter to ISO 14/12 and no 100 mesh screen captured
particles.
Each flow line, cooler, etc shall be flushed at a flow rate and temperature so that a minimum Reynold’s
number of 4000 is achieved through each section.

The minimum average Reynold’s number in oil cooler headers is 4000.

Oil coolers with turbulators shall be flushed in both the forward and reverse flow directions. Lines that
flow upward by more than 10 feet (3 meters) shall be flushed in a reverse, downward direction at least
33% of the flush time.

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 Specification No. ES 2184

The Reynold’s number can be calculated by:

where GPM = flushing fluid flow rate - gallons per minute

CS = flushing fluid viscosity - centistokes

D = pipe/tube inside diameter - inches

Table 1 shows the minimum required flow rates for several pipe and tube sizes. Reynold’s numbers
in excess of 4000 will increase the effectiveness of the flush and will decrease the flushing time
required to achieve the required cleanliness. Proper cleaning of individual details before assembly
as well as clean assembly processes will also reduce flush times and reduce contamination “hideout”.

Dead blow hammers and /or pneumatic vibrators should be used to help break loose and dislodge
debris in the piping. Subjecting the piping to several thermal cycles (hot flushing fluid/cold flushing
fluid) will also help reduce flushing time.

Flushing fluid samples shall be taken downstream of the piping or component being flushed and
upstream of any end of line filters or screens. The sample location shall be taken from a section with
turbulent flow (Reynold’s number > 4000). After flushing for at least one hour a fluid sample can be
taken and the strainers or filter bags at the outlet of the flushing rig can be inspected. Acceptance
criteria is listed in paragraph 5.0.

Reservoirs, vessels, tanks and tank vent piping require mechanical cleaning (only) to remove all visible
rust, scale, and debris, per Appendix A.

5.0 ACCEPTANCE CRITERIA - The flush is successfully completed when:

1. The ISO 4406 cleanliness code range numbers for 6 and 14 micron levels are 14/12
or lower (particle counter calibration per ISO 11171), and

2. There are no visible particles on the 100 mesh screen, or

no more than 5 non metallic particles no larger than 0.010 inch (0.254 mm) in the 25
micron bag(s).

6.0 POST FLUSH PROCEDURE - After flushing, the piping, system, and components shall be
sealed with metal blind flanges or metal plugs to prevent recontamination. If the piping or component
will be in storage for any length of time it shall be completely drained and flushed with preservative oil
per Solar ES 9-248 or partially filled with a vaporizing preservative oil that is compatible with the mineral
based oils in Solar ES 9-224. Preservative oils shall be filtered to meet the cleanliness requirements
of this specification. Tanks and vessels shall be preserved per Appendix B.

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 Specification No. ES 2184

Figure 1. Typical Flushing System

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 Specification No. ES 2184

Table 1. Flow Rates For Reynold’s Number (Nr) = 4000

GPM Required For Nr = 4000 w/C32 Oil

80?F Oil 120?F Oil 150?F Oil

Pipe/Tube Size 48 CS 21 CS 12.5 CS

0.375 X 0.049 tube 16.8 7.4 4.4

0.50 X 0.049 tube 24.4 10.7 6.4

0.75 X 0.049 tube 39.6 17.3 10.3

1.0 X 0.049 tube 54.8 24.0 14.3

1.25 X 0.049 tube 70.0 30.6 18.2

0.75 Sch 80 pipe 45.1 19.7 11.7

1.0 Sch 80 pipe 58.1 25.4 15.1

1.5 Sch 80 pipe 91.1 39.9 23.7

2.0 Sch 40 pipe 117.4 51.5 30.7

3.0 Sch 40 pipe 186.4 81.6 48.5

4.0 Sch 40 pipe 244.5 107.0 63.7

6.0 Sch 40 pipe 368.5 161.2 96.0

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APPENDIX A

CLEANING OF OIL TANK INTERNAL SURFACES AND TANK VENT PIPING

1.0 Surface Preparation

A. Abrasive blast to produce a grayish metallic near white surface with 1 mil minimum
profile depth.

B. Steel plugs shall be used for thread protection during the blast and paint process.
These plugs shall be removed from all threaded openings and the grit removed by
using shop air or vacuuming. Brayco 785 shall be applied to the threads and plastic
plugs inserted into the ports.

C. All flange gasket surfaces must be protected during the blast and paint process.
Brayco 785 shall be applied to the flange gasket surfaces and shipping covers shall
be installed to protect the flange surface and avoid contamination of the lube oil tank.

D. All pipe assemblies that will become part of the base assembly must be blasted
internally and swabbed clean before being installed.

E. Lube oil tank covers are to be painted to Solar system “E” unless otherwise specified
by engineering drawing.

F. Manifolds which are welded into oil tank covers shall be unpainted on the section that
is internal to the tank.

G. Tank associated vent piping is to be mechanically cleaned per section 2.0

2.0 All residual grit, scale, flakes, or other foreign matter shall be thoroughly removed from the tank
or piping internal surfaces before the application of Brayco 785 or other approved preservative
fluid.

Pipe and manifold sections which are part of the tank assembly as well as the tank vent piping
shall be thoroughly cleaned with shop air and have a clean swab or pig drawn through them
until the swab or pig is clean of any detectable grit or debris.

No residual grit is permitted. No flaky rust or mill scale is permitted. The assembly shall be
considered clean when foreign material such as scale, rust, metal shavings, and sand are not
visible to the eye and grittiness is not detectable to the touch.

Cleaned and preserved piping shall be installed in the system and thoroughly sealed against
subsequent external source contamination as soon as practical.

3.0 Application of Brayco 785 or Other Approved Preservative Fluid - Brayco 785 can be applied
to a surface showing slight discoloration or oxidation provided that the surface does not have
flaky rust or mill scale. Brayco 785 may be applied by spray, roller, or other means as required
for coverage of all unpainted surfaces. Other approved preservative fluids shall be applied
per the manufacturer’s instructions.

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 Specification No. ES 2184

APPENDIX B

PICKLING AND PASSIVATION OF PIPEWORK AND EQUIPMENT

1.0 All carbon steel piping shall be pickled to the following minimum requirements:

A. Ensure that all statutory and safety precautions are taken for carrying out the work and
as determined by site conditions.

B. Piping to be cleaned shall be isolated from all equipment, machined surfaces, and non-
ferrous components to avoid damage.

C. Piping shall be dismantled in suitable sections to ensure sufficient flow of fluids in each
section.

D. Each section shall be degreased. Degreasing shall be performed by use of heavy duty
alkaline or detergent solutions maintained at 175 to 195°F for a duration sufficient to
remove oils or greases in the piping. After degreasing the piping shall be thoroughly
flushed with potable water to remove all traces of degreasing solution.

E. Acid cleaning or pickling shall be carried out by use of 10% solution of hot (not
exceeding 150°F) inhibited hydrochloric acid. The piping shall be flushed with acid
solution repeatedly until cleanliness is achieved. Pickling shall continue until all loose
rust, mill scale, or other foreign materials are not visible in the piping. The strength of
the acid shall be monitored to maintain the required concentration and the solution
shall be replaced if ferric content exceeds 0.6% by weight.

F. The piping shall be thoroughly rinsed and flushed with potable water as rapidly as
possible after the acid cleaning to remove all traces of acid and iron salts to prevent
rust. The rinsing/flushing shall continue for 10 minutes after the ph of the effluent
water equals the ph of the in going water.

G. Passivation of piping surfaces shall be performed after the pickling and flushing. This
will be done by circulating a 3% phosphoric acid solution at 160 to 175°F for an
adequate duration.

H. The piping shall be thoroughly rinsed after passivation with potable water. After rinsing
the piping shall be drained of water and air dried with hot, dry, filtered air at 150 to
170°F.

I. Piping that will not be immediately flushed with oil and put into service shall be internally
coated or flushed with a preservative oil per Solar ES 9-248, and capped with metal
blind flanges or threaded plugs.