S.Page T.

Page
1 Page 7 Page

CONSTRUCTION SPECIFICATION

PROJECT NAME :

PLANT OWNER : AXIA ENERGIA

ENGINE TYPE : HiMSEN 14H35/40GV x 1set

TITLE : FLUSHING PROCEDURE

( 7 SHEETS WITH COVER )

DRAWN DESIGN CHECK APRD DESCRIPTION R

26.11.2015 26.11.2015
ISSUED FOR INFORMATION A
T.S.LEE T.S.LEE
DOC NO
ENGINE & MACHINERY IVISION
ENGINE DESIGN OFFICE CON-S-001
 2 of 7

CONTENTS

1. GENERAL

2. REFERENCE

3. PIPING PREPARATION

4. FLUSHING PROCEDURE
 3 of 7

1. GENERAL

To protect the engine components, it is very important that all systems including LO, FO, cooling
water and air system are carefully flushed as described in detail in the below-mentioned procedures,
before the engine is started-up. This specification is prepared for pre-commissioning chemical
cleaning and post-cleaning treatment of carbon steel piping of all systems including L.O and F.O
system. This specification covers the chemical cleaning of fabricated and erected carbon steel piping
at plant site prior to commissioning by chemical circulation method. The technical procedure is
prepared only for carbon steel surfaces.

2. REFERENCE

All work shall be performed in accordance with the following codes, specification and procedure as
applicable.

* ANSI N45.21 : Cleaning of Fluid System and associated components

* ANSI B93.54M : Method for Achieving Roll-off cleanliness - Hydraulic Fluid Power

- Assembled systems (Rev-1988).

* Project specification

* Piping Construction Specification

* Line Schedule

* P&ID

3. PIPING PREPARATION

Before mounting, all pipes and tanks should be cleaned and welding spatters are to be removed.
This emphasizes the importance of using pipe connections with flanges so that all welds can also be
inspected from inside the piping. After grinding, all FO, LO pipes and other pipes specified in
piping specification should be acid-cleaned and neutralized. If the oil flushing of the system is
not started immediately hereafter, the pipes and tanks are to be corrosion protected with a clean fluid
soluble in lube oil, and all open parts in the system covered in order to protect the cleaned system.
When filling the tanks, let all oil pass through a filter to ensure that all impurities from the
storage/settling/service tanks and filling lines are removed.

1) Piping supports / Instruments / Check valves

Ensure that all piping to be flushed is sufficiently supported to carry the additional weight of the
water. All supports shall have been properly adjusted or pinned prior to flushing. Instruments
used as an integral part of the flush shall have been properly calibrated and close instruments
not being used will be isolated. Flow element and other sensitive instruments in the flush part
 4 of 7

should be removed prior to flushing. Check valve internals may be removed when required to
establish a flow path.

2) Flushing method

SYSTEM PROPOSED METHOD REMARK

FUELOIL
FUEL GAS SYSTEM
SYSTEM RECIRCULATION
AIR BLOWING
LUBE OIL SYSTEM RECIRCULATION

RECIRCULATION/
COOLING WATER SYSTEM
ONCE-THROUGH

STARTING & CONTROL

AIR BLOWING
AIR SYSTEM

STEAM & CONDENSATE

ONCE-THROUGH
SYSTEM

SLUDGE / DRAIN & OILY

ONCE-THROUGH
WATER SYSTEM

FIRE FIGHTING SYSTEM ONCE-THROUGH

a) Once-through
This type of flushing consists of flushing the proper fluid through a pipe line to waste. Motive
force may be a temporary pump or the system pump.
b) Recirculation flush with an in-place strainer
Recirculation flushes primarily consist of flushing a fluid in a closed loop of any system utilizing
system pumps or temporary pumps.
c) Hand cleaning
Hand cleaning is mostly employed when cleaning tanks vessels and very large
diameter pipe. Wire brushing, grinding, etc., are a few methods for hand cleaning.
d) Fill and drain
This method merely fills the system and then the system is gravity drained in as short of time as
possible. This method is commonly used in pump suction lines.
e) Recirculation flush with feed bleed
This method allows a small amount of clean fluid to enter(feed) the system under recirculation
while at the same time draining (Bleed) a similar amount of fluid off at a downstream point.
Using this method will help remove and/or dilute organic contamination in the system.
 5 of 7

3) Flushing medium : Water/Chemical/Oil/Pneumatic/Steam

SYSTEM FLUSHING MEDIUM REMARKS

ACIDCLEANING
ACID CLEANING
FUELOIL
FUEL GAS SYSTEM
SYTEM
AND AIR
LIGHT DIESEL OIL

ACID CLEANING
LUBE OIL SYSTEM
AND FLUSHING OIL

* THIS ACTIVITY SHALL

COOLING WATER SYSTEM WATER BE DONE PRIOR TO
HYDROTEST.
STARTING & CONTROL * DEPENDING ON SITE
AIR / WATER
AIR SYSTEM CONDITION

STEAM &
STEAM / WATER
CONDENSATE SYSTEM

* THIS ACTIVITY SHALL

SLUDGE/ DRAIN & OILY
WATER BE DONE PRIOR TO
WATER SYS.
HYDROTEST.

a) Water flushing
The water left over from hydrostatic testing can be used to flush the lines and break in the pump.
Before proceeding with water flushing all orifice plates must be removed, orifice valves fully
opened and control valves rolled out to prevent the accumulation of dirt under the seats, and fine
mesh screens installed in all pump suctions. An effort should be made to run as many of the lines
as possible to correct and remove all trash, solids, slag, & etc. left over from construction.
b) Chemical flushing
This type of flush re-circulates water in which chemicals have been added to aid in the removal
contaminations. This type of cleaning is seldom used during start up unless special circumstance
dictate. Chemical cleaning of system piping or components will not be done as a routine basis,
but will be considered, the chemical concentration, composition, corrosiveness and solution
temperature must be considered in determining the appropriate chemical solution to be used.
Safety measures shall be taken when cleaning with chemical solution to ensure that all
applicable site safety requirements are adhered to.
c) Pneumatic flushing
Piping system which requires eventual air flushing shall be designed to supply and vent the air
and possible to include test plate. The design of the piping shall allow for support, thermal
expansion and discharge reaction forces during flushing. Equipment which can be damaged
during flushing is to be removed from the piping.

4) Flushing water
 6 of 7

Water used for the cleaning shall be equivalent in quality to the water used during system
commissioning, if possible. If demineralized water to be used for flushing and cleaning
operations on particular systems shall meet the following acceptance criteria.

. PH : 9 - 10

. Oxygen : < 0.2 ppm

. Hydrazine : 0.1 - 0.5 ppm

. Ammonia : < 5 ppm

. Iron : < 0.1 ppm

. Copper : < 0.02 ppm

. Oil : < 1 ppm

5) Temporary flushing oil tank, strainer, pump for all oil system flushing
Temporary flushing oil tank with 100, 200, 300 mesh strainers at return nozzle and flushing pump
shall be prepared. All cleaned equipment such as engine, aux. equipment shall be by-passed
with temporary piping.
6) Vibrator
Air/Electric vibrator or rubber hammers to be prepared on pipe and do the hammering during
flushing time continuously until removing the visible impurities.
7) All pipes of engine and cleaned aux. equipment are to be blanked.
8) Heater shall be provided to heat up the oil up to 60-65 deg. C.
9) All tanks and pipes including temporary piping shall be cleaned.

3. OIL LUSHING PROCEDURE

1) After all preparation and filling of flushing oil into temporary flushing tank, oil has to be kept being
heated up to 60-65 deg. C by using heater to increase the flushing efficiency. For the L.O, heater
in LO purifier unit can be used.
2) Flushing oil velocity and temperature
If necessary to obtain a satisfactory flow, it is recommended to circulate the lube oil through the
system with flushing pump. The flushing oil flow(pump capacity) should reach a minimum of
Reynolds Number 3000 in order to have sufficient turbulent flow in pipe.

Re = Vx D / υ x 1000

Re : Reynolds No. D : Pipe inner diameter(mm)

V : Average flow velocity (m/s)

υ : Kinematic viscosity (cSt)

The main LO can be used after consulting with HHI instead of flushing lube oil and DO can be used
 7 of 7

for the FO line flushing.

3) Vibration / hammering of piping

A portable vibrator or hammer should be used on the outside of the pipes during flushing in order
to loosen any impurities in the piping system. The vibrator is to be moved regularly so as to work
on the entire pipe system. Please be aware that an unfortunate combination of natural frequency
of the pipe system and the size of vibrator used may cause excessive stress in pipes and welds.
4) Increase filter fineness
Filter element shall be changed to fine one gradually. After the first 24 hours of flushing, 50 micron
filter basket should be either exchanged with a 10-25 micron filter basket or additional 10-25
micron filter element should be inserted inside the filter basket.
5) Verification of Oil flushing by particle counting
The degree of impurities of system oil shall be judged from the condition of filter. The flushing must
be continued and checked visually at intervals of two hours until, during such a two-hour period, no
solid particles are collected in the filter.
The cleanness of flushing oil is checked by particle counting, in order to find particle concentration,
size and type of impurities. When using particle counting, flushing should not be accepted as
being complete until the cleanness is found to be within the range in ISO 4406 level ≤ 19/15
as follows.
Number of particles per milliliter larger than

5 ㎛ 15 ㎛
Code No
Up to and Up to and
More than More than
including including
19/15 2,500 5,000 160 320

6) Flushing of starting air/control air system

Disconnect the starting air line engine inlet from the engine connection and blank off the engine
inlet as well as other openings to prevent the ingress of dirty particles.
Blow off the complete starting air system by opening the valve at Starting air receiver outlet.
Refit the all disconnected pipe lines.
Note
When blowing-off the system, fix the pipes and secure blow-out openings to guard against
possible damages.
7) After flushing
The remaining oil inside the pipe lines, aux. equipment, etc shall be blown-off by dry air or cleaned
manually and refit all dismantled pipes, equipment.