EC-B-54.00-01a: Mechanical Commissioning of Operating Systems

Construction Specification:
EC-B-54.00-01a
Engineering Division Construction Division CONSTRUCTION, INSPECTION AND MAINTENANCE Page 1 of 50
MECHANICAL COMMISSIONING OF
OPERATING SYSTEMS
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INCLUDED REFERENCES TO EC-A-50.00 AND ERASED MIREYA BALLESTEROS ALVARO GUTIERREZ, EVA MARIA DIEGO GARCIA FERNANDEZ
01a JUNE 2019 REFERENCES TO NRM-310 ARRIBAS
E.A.G. +02'00'
2019.07.01 13:51:42 2019.07.05 D.G.F.
17:08:10 +02'00'
01 SEPTEMBER 2014 FIRST ISSUE. FOR IMPLEMENTATION. E.A.G. E.A.G. A.L.S.
REV. DATE DESCRIPTION PREPARED BY CHECKED BY APPROVED / AUTHORIZED BY

(name and signature) (name and signature) (name and signature)
SPECIFICATION REVISIONS
© REPSOL S. A. Madrid, last update 2014 - 2019
Doc. Code: Construction specification:
EC-B-54.00-01a
OPERATING SYSTEMS
Engineering Division Construction Division CONSTRUCTION, INSPECTION AND MAINTENANCE JUNE 2019 Page 2 of 50
TABLE OF CONTENTS
1. PURPOSE .................................................................................................................................................. 3
2. SCOPE ....................................................................................................................................................... 3
3. SAFETY DURING COMMISSIONING OPERATIONS .................................................................................3
4. DEFINITION OF THE OPERATING SYSTEMS TO BE COMMISSIONED ...................................................3

4.1. General considerations ............................................................................................................................... 3
4.2. Identification of the operating systems. Handover priority ............................................................................ 4
4.3. Circuits to be cleaned ................................................................................................................................. 5
5. CLEANING OF SYSTEMS .......................................................................................................................... 6

5.1. System cleaning treatments ........................................................................................................................ 6
5.2. Criteria for selecting the cleaning treatment ................................................................................................ 7
5.3. Temporary or provisional materials required for Cleaning Circuits ............................................................... 9
5.4. Phases for executing the Cleaning of Circuits. Cleaning management documentation. ...............................11
5.5. Monitoring of the progress of cleaning work ................................................................................................ 15
5.6. System cleaning material records ............................................................................................................... 16
6. PROCEDURES FOR EXECUTING CLEANING OPERATIONS ...................................................................16

6.1. Flushing Procedure ..................................................................................................................................... 16
6.2. Degreasing Procedure ................................................................................................................................ 19
6.3. Chemical Cleaning Procedure (Pickling) ..................................................................................................... 20
6.4. Blowing Procedure ...................................................................................................................................... 22
6.5. Oil Flushing Procedure ............................................................................................................................... 23
7. PROCEDURES FOR PREPARING FOR START-UP ..................................................................................29

7.1. Procedure for starting up the Auxiliary Services .......................................................................................... 30
7.2. Procedure for vaporizing, inerting and leakage tests for Process Systems ..................................................34
7.3. Preparation for start-up of the Reaction Systems ........................................................................................ 36
8. COMMISSIONING OF DYNAMIC EQUIPMENT ..........................................................................................40

8.1. Lubrication systems .................................................................................................................................... 41
8.2. Dynamic Sealing Systems...........................................................................................................................42
8.3. Freewheeling of Driving Machines .............................................................................................................. 42
8.4. Hot aligning................................................................................................................................................. 43
8.5. Other aspects to be considered when commissioning machines .................................................................43
8.6. Recording dynamic equipment commissioning ............................................................................................ 44
9. STANDARDS AND SPECIFICATIONS OF REFERENCE ...........................................................................44

9.1. Repsol standards and technical specifications ............................................................................................ 44
10. INDEX OF TABLES INCLUDED IN THIS SPECIFICATION .........................................................................44
11. APPENDIXES ............................................................................................................................................. 44
TABLE OF CONTENTS © REPSOL S. A. Madrid, last update 2014 - 2019

EC-B-54.00-01a
OPERATING SYSTEMS
1. PURPOSE
This specification establishes and describes the technical procedures to be followed for carrying out the
mechanical commissioning of new units or changes to existing units. It also proposes and designs a system
and the respective forms for facilitating the management and control of such commissioning activities.
2. SCOPE
The mechanical commissioning work of a system includes all the activities required to ensure it is ready to be
started up from a mechanical standpoint. This includes, for each operating system, the activities required as
regards cleaning the pipes and static equipment in the system and the subsequent vaporizing and inerting
tasks and leakage tests to make it ready for start-up. It shall also be necessary to perform the respective
mechanical adjustment tests in the system's dynamic equipment.
This specification describes the procedures for executing the most common mechanical commissioning
activities. In the case of specific works or requirements not described in this specification, Production shall be
responsible for developing the respective execution procedure before starting the works.
For the purposes of this specification, Production refers to the organization responsible for commissioning
activities (and if applicable, start-up) of the system. Similarly, Construction refers to the organization
responsible for assembling and pre-commissioning the system.
To perform commissioning work, by means of the respective Handover Document, Production shall receive the
1a
operating systems from Construction and accept them. The conditions in which the operating systems shall be
delivered and the responsibilities of the different organizations (Production vs. Construction) regarding the
systems/circuits, during the handover and completion of the works, shall follow the procedures specified in
each project.
3. SAFETY DURING COMMISSIONING OPERATIONS
During commissioning work, compliance with safety requirements established in the procedures of the project
1a shall be ensured.
Signs in working areas:
Areas with restricted access during commissioning operations shall be marked and delimited using fencing
and/or be taped off.
The specific signs regarding prevention and information included in the Safety Protocol for Commissioning and
Start-up that are related to conditions and activities to be executed shall be put up in visible places, to prevent
people from entering or manipulating in circuits or equipment in zones that may require restricted access.
4. DEFINITION OF THE OPERATING SYSTEMS TO BE COMMISSIONED
4.1. General considerations
An operating system is a set of lines, equipment and instruments with clearly-identifiable limits and
components that provide the plant with a service or constitute a functionally-related and independent unit.
Operating systems should be defined at an early stage, when P&IDs are available in the AFD (Approved for
Design) review. They shall be approved by the Facility Commissioning Manager from Production and, if these
are not the same person, by the Facility Start-up Manager, to ensure they are complete and fully agreed when
issuing the 0 review (AFC rev., Approved for Construction) of the P&IDs.
The limits of the operating system shall be defined in such a way that they have precisely that function, i.e.,

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they are operative and not constructive, so that once their mechanical completion has been executed, each
operating system can be received separately for performing on it the respective commissioning tasks (i.e., for
the entire process of cleaning and preparation for start-up).
It shall be possible to isolate the defined operating systems by using blocks (valves); these limits shall be
located at ground level, if possible.
When defining the operating systems, the following criteria shall be observed:
 A distinction shall be made between auxiliary lines and process lines. Each auxiliary system shall be
regarded as an independent operating system.
 A distinction shall be made between the different processes in the Unit
o Based on the product
o Based on similar pressure and temperature conditions
o Systems that can be rendered independent
 Additional works (such as reactors, furnaces, etc.)
Systems examples include: Unit charge system, cooling water system, reaction system, etc.
The defined systems shall be included in the process and auxiliary services P&IDs using an established color
code. If this is done electronically, each system shall be represented by a layer in the specific color that
differentiates it. Ordering by layers allows a single system to be obtained, as required by the representation.
These P&IDs, validated by the Commissioning Manager, shall be the “master” documents used to prepare the
database containing all the elements that make up the defined systems. Furthermore, it shall serve as a
starting point for defining the instructions of the diverse treatments to be executed on each one.
4.2. Identification of the operating systems. Handover priority
The description of the operating systems shall be set out in a table, in accordance with the form in Appendix I
“Definition of operating systems”, indicating the following:
 System number, formed by the number of the annex, the letter P for process systems or U for auxiliary
services (utilities) and a two-digit identifier. This identifier shall start at 01 for the first system of each
appendix and it shall reflect the handover priority for the system by Construction, in accordance with a
priority code established with Production. (See the criteria for establishing the handover priority below).
In the event of commissioning a single Unit the annex number can be eliminated.
 System Name
 Brief description of the operating system and of the equipment included in the system.
 Color used for the graphic representation of the system in the P&IDs.
 P&IDs sheets affected, indicating the numbers of the P&IDs involved, the page/s and the corresponding
review.
 Type of cleaning treatment/s to be used in the system or in any of its parts (flushing with water, with demi,
blowing, chemical cleaning…).
 Weight (%) with respect to all the cleaning work: the weight of the system with respect to all the cleaning
work needed for the Unit shall be shown as a percentage.
Priority in delivering the system (system number):
Once the operating systems have been defined and accepted, Production shall reach agreement with
Construction about the priorities for delivering the systems. (If Production is not responsible for start-up, the
system handover priorities proposed shall be submitted for the approval of the organization responsible for the
start-up). With regard to the facility process systems the establishing of a handover sequence for these shall
not always be critical; however, it shall be required whenever delivering Auxiliary Systems.
In establishing the handover priority or order (system number), the following criteria shall be considered, which
are also related to the requirements as regards putting the different systems into service:

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 The first cleaning activities to be done shall involve water flushing for both process systems and auxiliary
service systems (AS). To this end, underground operating systems (pump-out and sewer box network)
should also be delivered, to prevent paving from being flooded during flushing operations. Furthermore, the
outer ring of the CIS network shall be available to provide water for flushing.
 Once the flushing operations have been completed and the required auxiliary materials have been removed
(hoses, etc), the AS shall be put into service.
 First the steam, condensate, water and air AS shall be put into service and used to complete the cleaning
of systems (for instance, blowing with air or steam) and then the nitrogen systems for inerting.
 Then vaporizing and inerting can be started; afterwards, the rest of the auxiliary services can be put into
service (flare and fuel lines). Finally, the process systems can be implemented.
 Unless any other specific requirements are identified, the order number for process systems shall comply
with the P&ID flow diagrams and be increased correlatively, if possible following the normal operating flow
of the facility.
4.3. Circuits to be cleaned
Once the operating system has been defined, it shall be divided into one or more circuits to be cleaned in order
to differentiate between parts to be subjected to different treatments or prevent the flushing sections from being
too long or, if necessary, to space the flushing water consumption. Furthermore, every effort shall be made to
reduce preparation activities to a minimum and as a result, to reduce the need of reinstalling elements and
select the connection points so that they can be used to inject the cleaning fluid. The circuits defined shall
allow for compliance with best practices in executing the cleaning operations. These are described later in their
respective Procedures.
As a general rule, subdivision into circuits shall be executed by dividing the main system every time it is
interrupted after encountering a piece of equipment and the instruments of the equipment shall form part of the
circuit that discharges into it. Accordingly:
 Columns and tanks:
The columns and tanks shall belong to the circuit of the main process line that emerges through their
heads. For example, as regards towers, they belong to the distilled product line circuit.
If several circuits emerge from a tank/tower, each one starts at the union flange with the tank, except in the
case of a blind disc or a spectacle blind in the line, in which case the new circuit shall start from that
element.
 Exchangers:
Exchangers and their instruments (whether in the casing or in tubes) belong to the circuit of the product
entering through the tubes. However the casing side shall be taken into account in the circuit on this side
when flushing the equipment.
 Pumps:
The pumps belong to the circuit from which they pump. The pump casing vents belong to the pump circuit
as far as:
o The tank flange, if the vents end directly in a tank without being connected to any line.
o If they are connected to a line, they end at the last valve/retention before connecting to the line.
In the case of minimum recycle currents, these belong to the impulsion circuit, considering that:
o The circuit ends at the tank flange, if the minimum recycle current ends directly in the tank without being
connected to any line
o The circuit ends at the last valve/retention if the recycle current is connected to a line.
 Safety valves:
The safety valves belong to the circuit or equipment they protect, and they change circuit when discharged.
If the valve has a by-pass, that by-pass belongs to the circuit protecting the valve.

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OPERATING SYSTEMS
 Lines:
For union of two lines from different systems, the change in system takes place in the valve/retention valve
closest to the union; the valve belongs to the system with the greatest pressure. This does not apply in
cases in which there is a blind disc or a spectacle blind; in these cases the change in system is in the disc,
which belongs to the system with the greatest pressure.
 Control valves:
If the valve breaking the system is not a control valve, it shall belong to the system with the greatest
pressure up to the last block and including the by-pass valve.
 Atmospheric venting system:
Each of the specific lines belonging to this system is associated with the circuit from which it emerges.
This circuit subdivision shall be shown in a table, pursuant to the form in Appendix II “Definition of circuits to be
cleaned”.
5. CLEANING OF SYSTEMS
5.1. System cleaning treatments
Once an operating system has been received by Construction and accepted by Production, the commissioning
phase may begin; as part of this phase, equipment shall initially be cleaned to remove the dirt generated during
the mounting operations (rough edges from welding, remains of electrodes, iron oxide, sludge from pressure
testing).
Circuit cleaning work shall be directed by Production and executed with the necessary auxiliary resources
provided by Construction.
Different treatments can be used to perform these cleaning operations. The different types of the most
common cleaning treatments are defined below (the respective execution procedures are set out in Chapter 6):
a) Flushing:
This consists of flushing the system with suitably pressurized water, normally between 8 and 12 kg/cm2 of
raw water from the fire-fighting system; however, in some cases it shall be washed with treated water, for
instance, in the case of austenitic steel. Water flushing is the most common cleaning method for systems in
new units. Some systems require subsequent blowing with air and/or nitrogen to displace the surplus water
and dry and inert the lines.
b) Degreasing:
This method of cleaning consists of eliminating grease and oil from mounting operations using a sodium
carbonate solution before rinsing with treated or condensed water to remove all traces of basicity. This can
be done using the own system equipment (tanks, pumps and lines) or external resources, using pumping
equipment for piping the solution through the system lines and equipment.
c) Chemical cleaning:
A weak acid and inhibitor solution is piped through the lines and equipment to be cleaned; this is
subsequently neutralized with a weak base and final rinsing. This cleaning method involves the chemical
reaction of the acid on the dirt and incrustations which would otherwise increase the pressure drop and
reduce the performance and flow rate.
d) Blowing:
A gaseous fluid is used for this type of cleaning. It is piped through the lines at the appropriate flow rate and
emerges from the open end through an unducted outlet. The cleaning fluid may be:
o Steam. In lines where the required mass is high (steam lines at a high and very high pressure), a
silencer shall be installed to reduce atmospheric noise emissions.
o Air, supplied through the distribution networks, or using blowers if the installation features them.

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OPERATING SYSTEMS
o Nitrogen, from the distribution network.

One specific case of cleaning with air or nitrogen is rapid depressurization, which increases the
effectiveness of the blowing. It consists of leaving one of the ends of the circuit free to be cleaned and
placing a plastic cover or a temporary rupture disc on it. The fluid is injected from the opposite end until it
breaks the plastic cover, provoking the rapid depressurization of the circuit. The cleaning acceptance
criterion is visual, depending on the cloudiness of the emissions.
The design pressure shall be considered when selecting the rupture elements to be installed, so that they
always break at a pressure lower than that design pressure.
It can be executed in stages, with various increases in pressure, in all cases without exceeding the design
pressure. To do this, the necessary plastic elements shall be installed each time, to allow the rupture
pressure to be increased with respect to the previous blowing.
When executing this cleaning activity, special safety measures shall be taken to mitigate potential risks
posed by flying elements.
e) Cleaning of lines with large diameters:
In lines that, due to their diameter (≥24”), cannot be cleaned using any of the above methods, mechanical
cleaning shall be employed to eliminate dirt and/or iron oxide with manual brushing (wire brushes, scrapers)
followed by a visual inspection. If this is not possible (for example, in lines welded to equipment or areas
that are difficult to access) the lines shall at least be blown with air before closing the system and preparing
it for start-up.
This method is used, for instance, in general cooling water headers.
f) Flushing with oil:
This flushing operation consists of piping oil through the oil system in order to drag and remove all dirt and
particles from that system. To ensure flushing is effective, it should be done applying the maximum oil flow
rate with sharp temperature gradients.
The oil flushing procedure shall be used for:
o Newly-built oil systems: to remove all traces of manufacturing and assemblying work.
o Oil systems that have already been put into operation: in this case, the aim is to eliminate coked oil
adhered to the lines, particles given off by surface wear in relative movement and contaminants that
have entered the system from outside.
5.2. Criteria for selecting the cleaning treatment
Depending on the service of the line/equipment, different types of cleaning are required, as indicated in the
following table; in all instances, the Licensor's recommendations shall be taken into account.

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TABLA I. CLEANING TREATMENTS DEPENDING ON THE SERVICE
OPERATING SYSTEM CLEANING TREATMENT OBSERVATIONS
The Licensor's recommendations shall be

Process Systems
followed in all cases
Generally applicable to all carbon steels unless another treatment is specified: water flushing
Austenitic stainless steels Flushing with demineralized water
Amine circuits Degreasing
Mandatory for centrifugal compressors,
recommended for alternating compressors
Intake lines in critical dynamic equipment Chemical cleaning and steam blowing
and alternating water injection pumps when
considered critical
Sulfur recovery plant circuits Blowing with air
PSA circuits Rapid depressurization (air)
Circuits for the intake and recycling of Chemical cleaning in accordance with
hydrogen from HDS units the Licensor's recommendation
Package units and/or adding of additives As recommended by the Supplier
Degreasing and final test with ultraviolet
Oxygen
light
Hydrogen Degreasing and chemical cleaning
Auxiliary Service Systems (AS)
Generally applicable to all carbon steels unless another treatment is specified: water flushing
Tempered water, cooling water, drinking
water, treated water, softened or osmotized
Water services Water flushing water, plant or service water, fire-fighting
water, acid water. process water, boiler water
supply, wastewater
CWS/CWR circuits Specific treatment using additive
Cleaning and disinfection treatment to
Cooling tower
prevent Legionnaires' disease
High pressure steam (SH and SHH) Chemical cleaning and steam blowing
Medium and low pressure steam (SM/SL
Water flushing
and SLL)
High pressure condensate, medium pressure
Steam condensate Water flushing condensate, low pressure condensate, cold
condensate, oily condensate
Air from instruments Blowing with air from the AI header This is done when put into service
Plant or service air Water flushing and blowing with air
Washing with water and blowing with air
Nitrogen
from instruments (AI)
Fresh soda, spent soda, soda diluted at 20%,
Caustic soda Water flushing
soda at a concentration of 50%
Ammonia Water flushing
Acid Water flushing and blowing with air
Hypochlorite Water flushing
Fuel gas, natural gas, fuel oil supply and
Fuels Water flushing and blowing with air
return
Flare Blowing with air
Process drainage, oily drainage, rainwater
Drainage Water flushing drainage, acid/base drainage, sanitary
drainage

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5.3. Temporary or provisional materials required for Cleaning Circuits
To carry out commissioning work, it shall be necessary to foresee and make available a series of auxiliary
materials. The most common ones are described below:
1.- Hoses and accessories for connection to the FFS and S.S.:
Hoses shall be used for flushing operations using water from the Fire Fighting (FF) system. When connecting
the hose to the FF system, a retaining element shall be installed.
The dimensions shall be:
 45 mm hose with connector at intervals of 20 ÷ 25 m. with a Barcelona connector.
 70 mm hose with connector at intervals of 20 ÷ 25 m. with a Barcelona connector.
 Bifurcations of 70 mm. x 2 of 45 mm. with a Barcelona connector.
 Reductions of 70 mm. to 45 mm. with a Barcelona connector.
2.- Couplings and other accessories:
To wash the circuits, it shall be necessary to foresee and manufacture elements required for coupling to the
water mains hoses. In general, and as a guide, the main elements that may be needed in these operations are
set out below:
 Barcelona connector for coupling to ¾” hoses.
 1” flanges with ¾” reduction.
 1” flanges with ¾” reduction and 90º elbow.
 1 ½” flanges with ¾” reduction.
 1 ½” flanges with ¾” reduction and 90º elbow.
 2” flanges with 45 mm. Barcelona connector.
 2” flanges with 45 mm. Barcelona connector and 90º elbow.
 10” flanges with 2 x 70 mm. Barcelona connectors.
 10” flanges with 6” Storz connector.
 12” T flanges with 6” Storz double connector.
 14” T flanges with 6” Storz double connector.
 16” flanges with 6” Storz double connector.
 18” flange with 6” Storz double connector.
Note: The coupling accessories shall be adapted to the fluid to be piped. In the case of blowing operations
involving the use of air or steam, the same ones as those used for water flushing shall normally be suitable;

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however, specific ones shall be used for nitrogen.

Furthermore, other auxiliary elements may be necessary, such as:
 Paperboard joints for 1½” ÷ 18” pipes.
 Clamps for ¾” and 1”pipes.
 Flanged spool spacer to replace 2” valve (150 #).
 Tools for tightening 6” Storz hose connector.
Notes:
 In couplings for flushing from 4” up, a ½” or ¾” purge valve shall be installed to eliminate the residual
pressure after flushing. This shall help to drain the water from the hoses and make them easier to
dismantle.
 The holes in the flanges shall be oblique, so that the spools can be used to replace both 150# and 300#
valves, thereby reducing the number of spools required.
3.- Temporary filters:
They shall mainly be installed inside inlet lines to dynamic equipment, for the purpose of protection during the
first running-in test phase. Normally they shall consist of screen meshes installed to protect the final inlet filter
to the equipment, thus reducing even more the screen hole size. Adherence to the requirements established by
Vendors or licensees in this respect shall be ensured.
4.- Other:
Furthermore, the corresponding temporary elements shall be on hand for preparing the circuit (BDs, gaskets)
and the signage material mentioned in Chapter 3 of this specification, in order to guarantee the safety of the
works.
To execute oil flushing operations, special materials shall be needed; a description is provided in Appendix VII
1a “Flexible hose by-passes in lubrication circuits. Examples” of this specification.
The materials required for the application of specific treatments by specialist companies shall be provided by
those companies.

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5.4. Phases for executing the Cleaning of Circuits. Cleaning management documentation.
During the plant commissioning phase, it shall be necessary to execute a series of activities to clean each
circuit; said activities can be grouped into different phases, in chronological order:
a) Preparation (P): The following activities are included as part of this phase:
o Dismantling of elements. Some common examples are:
- Dismantling filtering elements that enter the circuit to be cleaned
- Dismantling demisters from the equipment involved in the circuit to be cleaned
- Dismantling flanged retention valves and installing a spool spacer to replace them, if they are
contrary to the wash flow (for very large diameters they may be rotated, but this shall be recorded).
For welded retention valves, assess flushing in the direction of the flow. Covers and internal
elements of retention valves shall never be dismantled.
- Dismantling all butterfly valves.
- Dismantling equipment and line instruments that can be damaged during the cleaning operations,
1a such us:
 Control valves, Two way valves, Safety valves and rupture discs.
 “Coriolis”, “Wedge”, “Magnetic”, "Thermal dispersion”, “Vortex” mass flow meters
 Pitot tubes or “Annubar” instruments.
 Orifice plates and restriction orifices.
 Analyzer probes.
 Process rotameters.
 Flame arrestor
 Blenders.
 Desuperheaters.
 Capillary and membrane instruments.
Likewise the additive injection nozzles and diffusers shall be dismantled.
- Disconnect the process intake of the flow rate, level and pressure transmitters along with their
manifold (if they are remotely sealed, close the block valves in the hook-ups).
- Disconnect the sample-taking elements.
- Dismantle and install a blind flange in all sheaths inside piping with a diameter equal to or less than
3”.
The instruments involved shall be disconnected from the root valve; therefore, all root intakes shall be
welded and tested.
o Installation of auxiliary cleaning elements:
- Mount the spools in the place of elements that shall be dismantled to add continuity to the cleaning.
This shall be limited exclusively to the spools that are deemed absolutely essential.
- Mount the temporary blind discs with or without separators. These blind disks shall match the line
ratings (150#, 300#, 600#, etc.), to prevent deformations therein that would make it necessary to
perform dismantling work on piping or cutting lines to remove them.
The temporary BDs used for commissioning work shall feature identification plates that are large
enough to not go unnoticed. They shall all have the same color and shape; they shall be different
from the color and shape of the BD identification plates used for other functions (for instance,
assembly work).
Provisional gaskets shall be installed. When cleaning the systems/circuits, provisional gaskets
installed during the mechanical assembly shall be reused for all points in which actions are ongoing

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to perform the above mentioned operations.

- Change the position of the reversible discs mentioned and shown in the P&IDs when necessary.
(Note: the reversible Battery Limit discs shall be kept in the blind position for cleaning.)
The elements to be dismantled, assembled, blind disks, etc. shall be listed one by one, if possible following
the flow direction and grouping those activities that, due to their sequence or proximity, can be executed
simultaneously.
The work involved in preparing the circuit shall be defined by Production and executed by the Construction
team assigned for providing commissioning and start-up (S/U) assistance; said group shall provide the
necessary auxiliary materials and resources.
b) Cleaning (CL): A sequential description shall be made of the checks and tasks involved in cleaning the
circuit, including water flushing, blowing with steam, air or nitrogen and special or other types of cleaning.
Furthermore, an indication shall be made of the coupling needs for connection of hoses, hoses theirselves
and separators and flange connections (that shall have at least four screws) and provisional connections to
give continuity to the circuits. The rating and diameter of the coupling and the hose connection diameter
shall be specified. The rating shall coincide with the flange rating in the circuit where the coupling is to be
connected.
The cleaning tasks shall be executed by Production, who shall be assisted by Construction in carrying out
occasional assembly/dismantling work to give continuity to the flushing.
c) Partial Reinstallation (R): installation of all elements dismantled, modified or rotated during the cleaning
circuit preparation phase, except those located on the circuit boundary, which shall be installed at a later
stage. The respective final gaskets shall then be installed.
This partial reinstallation of elements shall be executed by Construction personnel assigned to support the
S/U.
The spring supports shall be unblocked and they shall be placed in the cold position until start-up.
d) Construction (C): installation by Construction of elements that, with the prior agreement between
Production and Construction, have been left pending for assembly at the mechanical completion, to avoid
having to dismantle them or damaging them during cleaning operations (such as in-line instruments,
filtering elements, etc.).
Construction shall be responsible for these tasks, as they form part of its original scope.
e) Total Completion (T): completion of the mechanical circuit assembly by reinstalling the circuit boundary
elements that were dismantled during the Preparation phase and were pending the completion of work on
adjacent circuits (interference) and installing of the final gaskets. (The installation of the final gaskets shall
be an essential requirement for deeming the system as being ready to be prepared for start-up [process
systems] or for putting systems into service [AS systems]). Installing the Battery Limit BDs in the normal
operating position.
These tasks shall be executed by the Construction personnel assigned to support the S/U.
Once Total Completion (T) activities have ended, any additional work that Construction may need to
execute on the system (e.g. finishing work with respect to insulation or painting) shall require the respective
Permit to Work.
Cleaning Management Documentation:
A system and a series of forms are proposed below for cleaning management purposes:
1.- List of Cleaning Activities per Circuit:
To provide support in defining and monitoring the activities, a single document shall be used during the
commissioning phase, shared by the parties involved: Production and Construction. That document shall be
completed for each circuit before starting the cleaning work. The Excel sheet in Appendix III “List of cleaning
activities by circuits” is provided for the purpose of drafting this document; which shall also serve to record the
signatures for monitoring the progress of activities and allow Production to verify that the work has been
executed.
Appendix III includes an explanation of the structure of said document and the instructions for completing it.

EC-B-54.00-01a
OPERATING SYSTEMS
2.- Graphic representation of Activities per Circuit:

All tasks shall be shown in the cleaning circuit master P&ID. The subdivision into the “circuits to be cleaned”
shall be performed on the P&IDs where the operating systems are laid out, and graphic information shall be
provided in relation to:
a) Circuit limits or boundaries.
This shall be represented using a symbol of this type:
P-01-01
P-XX-XX
Furthermore, the names of the circuits on both sides of the boundary or limit shall be indicated, in text. If
the adjacent circuit is from a unit other than the main circuit's unit, it shall be preceded by its annex number
(e.g.: 602-P-08-03).
b) Blind discs, separators and connection couplings:
The BDs shall be represented using a symbol of this type:
652-P-01-01-02
XXX-P-XX-YY-ZZ
The text box shall indicate the full name/s used to refer to said blind disc in all existing records; this is
required as a disc may be included in more than one record and thus have different names, depending on
the circuit in which it is found. They shall all be indicated.
The nomenclature and manner of coding the blind discs for commissioning is explained in the following
section (3.- BD Record).
Additionally, the points at which separators shall be installed and the places at which couplings shall be
installed for connecting hoses to inject the cleaning fluid shall be clearly marked (for instance, using a color
that stands out).
c) Activity Number:
16T 6P
The activity number and key letter related to each group of tasks shall be shown (P-> Preparation, T-> Total
Completion, etc.), attached to the corresponding P&ID element. The circle and number shall be in the color
that corresponds to the group of activities to which they belong, pursuant to the document entitled “List of
Cleaning Activities” (Appendix III).
The cleaning activities per se shall not be shown (CL: flushing, blowing,..), with the exception of those
involving the installation/dismantling of an element, e.g. to give continuity to cleaning without having to
change the point at which the fluid is injected.
d) Type of fluid used and flow direction:
Criteria as regards colors and graphs shall be established to identify the cleaning fluid and the flow
direction.

EC-B-54.00-01a
OPERATING SYSTEMS
For example:
W Water
S Steam
Nitrogen and air shall be shown using their key letter (N2, A) and the color that defines them. Chemical
cleaning shall be indicated by its initials (CH), in the agreed color.
e) Calls for safety notes or metallurgy changes.
For example:
AUSTENITICO
AUSTENITIC
The following figure contains an example that includes several of the above-mentioned icons:
(TO U-602 VALVE)
VACUUM RESIDUE FROM VACUUM RESIDUE FROM

THE VACUUM UNIT THE INTERNAL TANK
DRAWING No. DRAWING No. 645-A-J-C10-

LINE No. 602-12”-P-0212-PXD29-ST LINE No. 10”-P-01534-C2-ST
The printed P&IDs showing the circuits and activities can also be used to mark by hand (for instance,
scratching out with slashes: ////) to show the progress of the cleaning work on each circuit.
3.- Blind Disk Record for commissioning activities:
The BDs for each unit shall be identified as follows:
a) Battery Limit Discs. The Process line discs shall be distinguished from the Utilities discs. Their
nomenclature shall be: Annex-BLX-nn, as part of which X represents “P” for the Process line and “U” for
Utility; nn shall be replaced by a two-digit disc number identifier starting from 01. For example: 652-LBP-

EC-B-54.00-01a
OPERATING SYSTEMS
01…99, for Process and 652-LBU-01…99 for Utilities.

The BL BDs shall be numbered consecutively from the first drawing onwards, starting at the top left corner
and progressing in a clockwise direction.
b) Equipment Discs. Their nomenclature shall be Annex-TAG-nn, as part of which TAG shall be the Tag of
the respective equipment and nn the same as in the preceding case. For instance, for the Coker
fractionator discs of unit 652: 652-C001-01…99.
That is to say, the BDs shall be grouped by equipment and numbering shall restart for each piece of
equipment. Furthermore, the BDs for exchangers shall be grouped by the type of flow, with process coming
first followed by the auxiliary service. In columns/tanks, the BDs shall be numbered from the charge inlet, in
a clockwise direction. In pumps, they shall be numbered using 1 for suction and 2 for impulsion. BD may be
used for commissioning in the flanges of the pump itself, where necessary (this shall be marked on the
P&ID).
c) Cleaning Circuit Discs. Mainly those that define the circuit limits (boundary discs). The auxiliary discs
assembled and dismantled based on the need for cleaning operations shall not be included, as in this case
the list of activities itself shall guarantee that the circuit is correctly aligned on completion of the work.
The nomenclature shall be Annex-X-YY-NN-nn, i.e.; the Annex that corresponds to the unit followed by the
System X type (Process or Utility) plus the System number identifier (YY), the Circuit number (NN) and the
disc number (nn). For example: 652-P-01-01-01.
In the event of commissioning a single Unit the annex number can be eliminated.
BDs for carrying out commissioning activities shall be manipulating and controlled pursuant to the procedure
set out in Appendix IV “Procedure for the Manipulation and Control of BDs during Commissioning”, unless
there is another approved procedure to this end in force at the industrial complex.
5.5. Monitoring of the progress of cleaning work
To ensure compliance with the established schedule, the progress of cleaning work shall be monitored on a
daily basis. To this end, the following system has been set out for assessing the progress and recording
information:
 In each circuit, different ratios are assigned to the different phases for executing cleaning work, depending
on the time required and the complexity involved in each case. Criteria shall be established that is standard
for all circuits. The following criteria are proposed:
TABLA II. PROGRESS ASSOCIATED TO EACH CLEANING PHASE
Phase Ratio (%)
Preparation (P) 40
Cleaning (CL) 20
Partial Reinstallation (R) 30
Construction (C) 5
Total Completion (T) 5
 The format of the table in Appendix V “Table for monitoring progress of circuit cleaning activities” shall be
used to show the progress of cleaning work, by systems, considering said ratios.
 In turn, ratios (%) shall also be assigned to the different systems depending on the complexity of the related
cleaning work and they shall be entered in the respective column in the table set out under Appendix I
“Definition of operating systems”.
 Considering the ratio of each system, the cleaning work progress curve shall be plotted and compared with
the progress curve of the system handover for commissioning. The time axis shall be daily or every two
days. Appendix VI “Example of a cleaning activities progress graph” contains an example of the graph.

EC-B-54.00-01a
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 If the work affects several process units/auxiliary services, ratios shall also be determined (over a total of
100%) for cleaning of the different units, as not all of them shall be of the same size or require the same
effort.
 In such an event, the overall progress of cleaning work, by weeks, shall be shown in a table format:
TABLA III. OVERALL PROGRESS OF CLEANING WORKS BY WEEKS
Systems Progress of cleaning work (%)

Systems
Units delivered
cleaned (%) Week 1 Week 2 Week 3 (…)
(%)
Unit X
Unit Y
(…)
Overall
progress (%)
Overall progress per week (blue boxes) shall be calculated by multiplying the progress for that week for
each unit times the ratio assigned to each unit, as set out in the preceding section, and adding all the
resulting figures together.
 Additionally, if the work affects several units, the total progress of the cleaning work for all the process units
/ auxiliary services involved shall be shown in a progress summary graph which has the same appearance
as the one in Appendix VI “Example of a cleaning activities progress graph”.
5.6. System cleaning material records
The cleaning of each circuit shall be recorded using the protocol DI-L.05 “Pipe cleaning check sheet (Flushing,
1a Steam/Air Blowing, Chemical Cleaning)” included in specification EC-A-50.00 “Pre-commissioning and
Commissioning Test Protocols”; this shall be included in the original dossier of the respective operating system
and subsequently in the End of Work Quality Control Book to be kept by the Owner on completion of the
project.
6. PROCEDURES FOR EXECUTING CLEANING OPERATIONS
6.1. Flushing Procedure
When flushing a circuit, the following should be considered:
6.1.1. Check the circuit:
 Check that it complies with the P&ID and is in safe condition for flushing:
o it shall not be pressurized, the flanges shall be fastened…
o for gas lines, a check shall be made to confirm that it is designed to withstand the weight of the water
o circuits with a design pressure lower than that of FFS water shall be identified. Manometers shall be
used to prevent excess pressure.
o When flushing austenitic stainless steel, a check shall be done to ensure that the water has a chloride
content of less than 50 ppm (demineralized water).
Note: In the absence of a high demineralized water flow rate with sufficient pressure, another cleaning
method shall be used such as blowing and/or rapid depressurization. In some cases, for low operating

EC-B-54.00-01a
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pressures and temperatures, flushing with raw water that contains a certain percentage of chlorides
(>50 ppm) shall be accepted. This shall be established by the Plant Inspection department. Another
option, if identified in sufficient time and agreed by Construction and Production, would be to use the
austenitic stainless steel line hydraulic test as flushing, provided it is correctly purged at all points.
 Plan in advance all the elements required for the flushing operation: the point from where the cleaning fluid
shall be injected, the materials required (hoses, connections, marking tape).
 Risks shall be assessed in the area in which flushing is to be done (the point at which the fluid shall
emerge, whether it can accumulate in areas where there are cables or trenches…).
6.1.2. Before starting flushing operations:
 Calculate the flow rate: an estimate shall be made of the water consumption needed to flush the circuit,
considering that the flow rate shall be sufficient to eliminate dirt.
In calculating the flow rate, the estimated operating flow rate for the line with the largest diameter in the
circuit to be flushed shall be considered and a flushing fluid flow rate of approx. 120-130% of that flow rate
shall be estimated.
When determining the number of flushing circuits in an operating system, the flow rates required shall be
considered in addition to the FFS pumping station capacities. Thus, flushing operations can be carried out
simultaneously in different process/auxiliary service units.
As a reference value, a flow rate of 300m3/h shall be adequate and sufficient to flush lines with Ø up to 8”-
10” (this does not mean that it is not necessary to make the respective check in each case, to ensure
flushing with a value higher than the process flow under normal conditions. Furthermore, availability in each
system shall be checked, depending on the FFS network flow rate and the sewage system capacity [oily
water/rainwater]). For lines with a larger diameter, the flush flow rate shall be defined in each case, as well
as the supply source: FFS, process tank (with water from tests or cleaning), cooling tower or other.
The limits of the circuits may vary if this entails a substantial improvement in the flushing process, provided
the operating system limits are not modified.
Before starting to flush, the water consumption required and the fluid connection points shall be established
and informed.
Normally, static equipment are isolated with blind discs following mechanical completion and they do not
get flushed. However, in some cases, it might be convenient to flush certain static equipment (overhead
drums of towers or columns) and use them for storage and distribution of water to other systems, if this
entails a reduction in water consumption.
 The areas from which the fluid shall emerge shall be marked, and signs shall be put up warning of the risk.
Emptying equipment and lines shall be done at a low point; sufficient vents shall be opened to allow air to
enter. To this end, the release of water at high points shall be avoided; if this is not possible, hoses shall be
installed to the nearest drainage network or a warning shall be issued of the potential discharge of water
from the height, with canvasses installed to protect the equipment.
6.1.3. Flushing the circuit:
 After executing the preparatory work and executing and recording all “P” phase tasks as set out in the List
of Activities document (Appendix III), the fluid shall be injected into the circuit; in all instances, an output
shall be opened to avoid pressurization of the hoses.
 Flushing shall be carried out, whenever possible:
o in the direction of the process flow
o from lines with larger diameters and main branches to lines with smaller diameters
o from a high point to a low point
o pursuant to the defined circuits, therefore flushing the system following its different component parts.
 It shall be flushed in a sequential manner and all the areas cleaned shall be marked on the P&ID.
 The flushing of a circuit is considered complete when, following a visual inspection, clear water emerges

EC-B-54.00-01a
OPERATING SYSTEMS
from its open ends and from the intermediate points defined.
o The input and output connections on automatic valves and their by-passes shall be washed at the same
time as the circuit: every time a control valve or an on-off valve (which shall be dismantled) are reached,
they shall be washed with the valve by-pass closed and with the water being released from the first
valve block. Once clear water is released, the block shall be closed, the second block shall be opened
and lastly the by-pass shall be opened. Once the water emerges clear, the second block shall be closed
and the cleaning of the circuit shall continue.
o Before shutting off the supply of water for cleaning, the different instrument intakes shall be cleaned. To
this end, the root valve shall be opened until clear water emerges.
When this occurs the circuit shall be emptied from all its low points.
 Considerations regarding flushing equipment:
o The separators required shall be installed to prevent dirty water from entering the equipment. Water
should never be injected into the equipment until a check has been run that the water emerging from the
input flange is clean.
o Float or spillway level shafts shall be washed after dismantling the root intake transmitters and
equipment to prevent them from becoming blocked. If level transmitters are directly connected to the
equipment, blind discs shall be installed on the nozzles to isolate the equipment.
o No fluid may pass through a pump without first having flushed the circuit to which it belongs (up to the
reversible disc at the inlet).
o Cleaning of columns or towers shall be done using mechanical means. However, the bottom through to
the flash zone shall be cleaned with water, along with the bottom output line. Care shall be taken to
wash the level stand-pipes and all the bottom circuits.
o In towers or columns, a check shall be performed to ensure the reflux or flushing lines headers and
distributors have been cleaned and tested before installing the nozzles (diffusers). In the event of doubt,
clean them.
o In low design pressure columns, when cleaning the head steam output line, if including the condenser in
the flushing circuit, check that the design pressure of the condenser withstands not only the water
pressure but also the corresponding water column pressure due to elevation.
o The equipment that gets washed shall always be inspected before being closed.
 Other considerations:
o Steam jacketed pipes shall be cleaned by sections.
o Take special care when cleaning lines to sulfur wells, as no water shall reach them.
6.1.4. After flushing:
 Gather together the hoses

 Close the circuit limit valves and if necessary, install seals (take note of the number) and an identification
card.
 Circuit boundary discs shall have as many labels as circuits they belong to. Once a circuit has been
washed, their removal shall be authorized in the blind disc record and in the list of flushing activities. The
identification card of the disc shall be removed. The person responsible for the last circuit shall remove the
disc and check that authorization has been given for the rest of the circuits involved.
 The discs designated as such shall be left in the blind position; an identification card shall be attached to
them and a note shall be made in the blind disc record.
 The battery limit discs shall all be left in the blind position. An identification label shall be attached thereto
and a note shall be made in the corresponding record.
 The battery limit valves shall be closed, sealed and the number shall be recorded in the corresponding
battery limit document.
 The marking tape shall be removed.

EC-B-54.00-01a
OPERATING SYSTEMS
6.1.5. After flushing:
 The circuit shall be reset by Construction and Production shall check that it complies with the P&ID (with
the final gaskets, reinstalled instruments, correct direction of control valves, retention valves and orifice
plates).
 For systems where flushing has ended, all the lines and elements therein shall feature in the master copy of
the P&IDs, marked with the agreed code (for example, scratching out with slashes - ////// -, as mentioned
above), to facilitate visual control of the progress made. Progress shall also be recorded in the tables and
graphs referred to in chapter 5.5 “Monitoring of the progress of the cleaning tasks” of this specification.
 The spring supports shall be unblocked tightening the screwed adjustment elements to equal the load
exerted by the spring support to the load exerted by the pipe; in turn, this shall facilitate the removal of
blocking elements. Once the anchoring elements have been removed, the supports shall be calibrated in
the cold position until start-up.
 The purge valves to drainage and blind discs to the unit emptying system shall be left in the normal
operating position.
6.2. Degreasing Procedure
Degreasing treatment shall be applied to process units with amine absorption and regeneration systems and in
amine distribution systems. This type of treatment shall be mandatory in the following cases:
 Absorption columns and lean/rich amine lines
 Lean amine distribution systems
 Lean and rich amine headers in the interconnections rack
 Fixed or mobile amine filtering systems (if any).
In the presence of oils or grease, amines form foam; this poses a serious operating risk to these systems.
Therefore, after the installation phase and before start-up, any oil/grease remaining from the construction
process shall be eliminated.
In the P&IDs of circuits in which the degreasing operations are marked, the equipment involved shall also be
marked.
Degreasing consists of flushing the whole system, or the circuits involved, with a caustic solution. This is
performed in phases:
 Filling:
Columns and vessels shall be filled with the caustic solution and it shall be recirculated through the circuits
to be degreased. A 2% by weight sodium carbonate solution shall be used. The caustic soda shall slowly
and carefully be mixed with water to prevent lumps forming that could block the lines.
 Degreasing:
The solution shall be heated (70 – 80º C) with steam and left to recirculate through the circuits involved.
The temperature and duration shall depend on the level of contamination shown in the results of the pH,
temperature, cloudiness and alkalinity analysis.
 Flushing and Drying:
When the degreasing operation is considered to be completed, the circuit shall be washed thoroughly with
cold water (cold condensate or demineralized water) until a neutral pH is obtained.
Lastly the circuit shall be dried by blowing it with air.
In all cases, degreasing treatments shall be performed by specialist companies, who shall develop specific
working procedures for each circumstance to be approved by Production.

EC-B-54.00-01a
OPERATING SYSTEMS
6.3. Chemical Cleaning Procedure (Pickling)
Chemical cleaning, like degreasing, shall be executed by specialist companies, who shall present specific
working procedures to be approved by Production.
The aim of chemical cleaning is to eliminate iron oxide and particles stuck to the walls of lines and equipment
that cannot be removed by flushing.
Once the operating systems are established, the circuits that require chemical cleaning shall be determined.
Chemical cleaning shall be mandatory when there are critical dynamic equipment downstream from the circuit:
 Alternating pumps and compressors: to protect them and their valves drums and intake piping shall be
chemically cleaned before start-up (s/u).
 Steam turbines with high and very high pressures (≥ 40 kg/cm2): the admission lines shall be pickled and
afterwards blown with the operating steam, performing the corresponding impact tests.
Chemical cleaning is also required on steam generation systems, as, due to their operating pressure and
temperature, if the iron oxide is not eliminated before S/U, it could cause corrosion during operations.
In all instances, the drums demisters (where applicable) shall be dismantled prior to pickling.
6.3.1. Chemical cleaning products. Precautions.
The following products are available for chemical cleaning:

 Inhibited hydrochloric acid
 Inhibited phosphoric acid
 Citric acid
For the first two, all elements made of dissimilar metals shall first be removed from the circuit. For the third, as
it is the least aggressive, there is no need to remove them; therefore, this product shall be chosen unless a
request is made to the contrary by the Licensor.
In all chemical cleaning processes, due to the aggressive nature of the products used, there is a risk of the
equipment construction material being diluted or coming loose. As a result, the most appropriate inhibitors shall
be used; inhibition shall be subject to continuous control by a measuring device. Furthermore, corrosion plates
or probes shall be installed and monitored throughout the entire process to estimate resulting wear (loss of
weight in mg/h/cm2). The ferric iron content (Fe3+) of the circulating acid shall be carefully monitored to identify
any sign of excessive impacts on the metallic iron of the pipe.
The following instruments shall be protected from the solutions used for cleaning:
 Orifice plates, control valves and safety relief valves: they shall be removed from the lines.
 Valves close to level, flow and pressure instrument connection lines: they shall be closed and the line to the
instrument shall be disconnected.
 External level instrument valves (displacer level and crystal level transmitters): they shall be closed.
 Sheaths for temperature instruments: they shall be removed and replaced by blind flanges.
There shall be vents equipped with valves in the high points of the system/circuit through which the solutions
shall pass.
All heating operations shall be executed outside the systems/circuits that are to be cleaned. Steam shall not be
injected into the system under any circumstances, and heating the acid solution to temperatures in excess of
80 °C should be avoided.
The acid solution should not be left to accumulate on any piece of equipment or any part of the circuit. The
time required to fill and establish the circulation shall be reduced to a minimum; to this end, the pump flow rate
shall be as high as possible, in light of experience and the adequate protection of the base metals.

EC-B-54.00-01a
OPERATING SYSTEMS
6.3.2. Chemical cleaning treatment. Phases.
The pickling process shall consist of the following phases:

 Degreasing:
Initial cleaning shall involve the use of an alkaline solution or a strong detergent. The temperature and
duration shall be established in line with the level of contamination.
 Flushing:
Thorough flushing involving the use of clean water shall be applied to remove the cleaning solution used in
the preceding phase.
 Pickling:
The system shall be treated by circulating the acid solution pursuant to the procedure proposed by the
specialist company that shall execute the works, and approved by Production. The procedure shall
establish the details of the acidification and the drainage and disposal of the acid solution.
 Final flushing:
After the acid cleaning process, lines and equipment shall be flushed immediately with clean water to
remove excess acid from all surfaces and prevent subsequent corrosion.
All low points shall be kept open to allow the acid to flow out.
Flushing shall continue until the pH of the outflowing water is equal to that of the inflowing water.
 Passivating:
This shall be carried out immediately after washing activities to protect the circuits/equipment from
corrosion or subsequent impacts during the system operating phase.
It consists of injecting a product (corrosion inhibitor) that forms a thin film to protect the circuit/equipment
against corrosion.
The passivating solution shall circulate through the system at the temperature and for the time
recommended by the specialist firm executing the work.
 Drying:
Drying operations shall be carried out by purging the lines with air at the available supply network pressure.
The different phases described above shall be executed quickly and in succession, particularly the final
washing and subsequent passivating after the pickling phase, as this is a critical phase in which the probability
of corrosion is very high, especially in the case of carbon steel.
After executing all the phases described above, the inter-stage K.O. drums shall be opened in alternating
compressors to reinstall their demisters, as well as all the elements removed for pickling.
6.3.3. Chemical cleaning of steam-generation systems:
To chemically clean these systems, the same criteria set out in the preceding sections shall apply, except for
the passivating phase, which shall be executed as described below, and the drying phase, which shall not be
executed.
The system shall be laid out so that circulation is guaranteed throughout the system and involves the lowest
possible number of interventions, planning the respective provisional connections and a suitable place for
disposal and neutralization.
The passivating phase shall consist of:
 Generating a layer of magnetite inside the steam vessel and in all lines containing water in operation, to
prevent the potential progressive formation of iron oxide in the base material of the pressurized parts.
The formation of magnetite is achieved by adding large quantities of hydrazine or similar compounds and
increasing the system pressure to 60% of the operating pressure for 3 to 4 hours.
 The system is then partly drained, running checks on the amount of iron oxide when purging it. The

EC-B-54.00-01a
OPERATING SYSTEMS
operation is repeated until the recommended values are obtained; said values can be found in the
corresponding procedure.
 After the chemical cleaning phase, the system should be filled with water treated with the additives involved
in water treatment as part of the steam generation systems. The amounts shall depend on the total system
volume.
6.4. Blowing Procedure
For blowing operations involving steam, air or nitrogen, the lines and branches with the largest diameters shall
be blown first, following the flow direction. Cleaning gas shall be injected, all the purge valves shall be opened
and the discharge of the liquid to be removed shall be checked.
Due to the special attention and preparation required, a description is given below as regards the procedure for
cleaning steam lines with very high, high and medium pressures to the appointed critical dynamic
equipment (normally turbines). A minimum of three blowing operations shall be performed on headers that had
been chemically cleaned.
This blowing operation shall be performed from the unit's Battery Limit to an atmospheric vent installed as
close as possible to the critical equipment admission flange; this shall serve to direct the discharge of the
steam blown into the atmosphere to a safe place.
6.4.1. Prior considerations:
 The blowing operation shall continue for one day, at times when very few employees are at the Plant, using
the steam from normal operations as the cleaning fluid.
 To ensure the efficiency of the blowing operation, for diameters up to 16”, steam flow rates of about 45
tons/h shall be used. For diameters larger than 16” and lengths of more than 1,000 m, flow rates of 60
tons/h shall be used to shorten the blowing time.
 The tools built for the blowing operations shall be made of the same material as the high or very high
pressure line (HS, HHS), to avoid false impact analysis results.
 The vent installed for blowing shall be fitted with silencers and standard impact plates. The plate shall be
made of 304 or 316 polished stainless steel and shall be replaced after each blowing operation. This vent
shall be installed by Construction. If not laid out in the drawings, the line or cap shall be cut to install said
vent; this shall consist of a connection with the same diameter as the line with a blind flange and cover. An
X-ray inspection shall be performed on the welding, no hydraulic testing shall be conducted.
 The use of PPE for protection against noise shall be mandatory.
6.4.2. Performing Blowing Operations:
 Heating of the header to be blown:

Heating shall be done at a low steam flow rate of between 5 and 10 t/h. The duration shall be between 30
minutes and 1 hour, depending on the length of the header.
 Blowing the header:
The blowing operation shall be done at a steam flow rate of between 45 and 50 t/h and maintained for a
time of between 30 minutes and 1 hour, until no further particles are released. Afterwards, the impact plate
shall be installed and blowing shall continue for another 15 minutes.
 Cooling the header:
Once the blowing time ends, the steam flow shall be shut off and the header shall be left to cool for at least
5 or 6 hours. Once this period of time has passed, a new blowing process can be started (heating-blowing-
cooling).

EC-B-54.00-01a
OPERATING SYSTEMS
6.4.3. Validation of blowing operations:
Blowing shall be deemed as having been completed satisfactorily when no particle impacts are observed at
first glance on the plate installed to this end in the vent. Unless indicated otherwise by the Supplier, a plate with
fewer than three particle impacts for every cm2 is considered acceptable, provided no mark is greater than 1
mm.
When checking the impact plate, the person responsible for commissioning the critical equipment in question
on behalf of the Supplier shall also give his approval.
Blowing operations shall be repeated until the acceptance criteria are met. When the blowing is considered
acceptable after checking the impacts, the vent shall be removed and the dismantled elements reinstalled.
At this time, if all the insulation and sheet cladding have been installed on the header, it shall be ready for start-
up, always taking into consideration the corresponding indications or common practice at the Industrial
Complex.
For newly-installed dynamic equipment or auxiliary systems of said equipment, the Supplier of the equipment
shall be responsible for:
 Adapting this procedure to the specific system characteristics and to the availability of time and means
 Preparing the diagrams, sketches and lists of materials required for its execution
 The final certification that the system has been cleaned.
6.5. Oil Flushing Procedure
This procedure consists of attempting to remove and drag all the particles stuck to the walls of the oil system
lines. This dirt shall circulate with the oil and be decanted into the bottom of the main tank or tanks and then
eliminated during the final cleaning of said tanks after emptying the flushing oil.
6.5.1. Preparations for oil flushing:
a) Previous cleaning of oil tanks and subsequent inspection:

In some systems, all the circuits share the same oil, while in others the sealing circuit is completely
separate and receives its supply from an independent oil tank. In both cases, each circuit may have its own
tank. All tanks shall be cleaned before flushing.
Tanks shall be cleaned using lint-free cloths.
Normally, all the tanks shall be made of stainless steel and this level of cleaning shall be sufficient. For
tanks made of carbon steel in which blasting is required, sand should not be used given the danger of sand
particles becoming trapped in a section of the pipe and going unnoticed; instead, hydro jet blasting shall be
used or blasting with the used oil followed by manual drying with lint-free cloths.
Tanks with no manhole, such as raised sealing oil tanks, shall be subjected to chemical cleaning
(disconnecting them from the system and dismantling them), as the complexity of their internal structure
limits the efficacy of flushing.
b) Provisional elimination of all blockages affecting the flow:
To ensure the highest possible flow rate, all system oil flow restrictions should be provisionally removed. All
these elements shall be checked, cleaned and stored in a safe place until their final reinstallation. Their
positions shall be recorded to ensure that they are subsequently installed in the correct places.
The following restrictions shall be eliminated:
o Pressure / differential oil pressure control valves: remove and install blind covers. Open by-passes.
o Orifice plates: remove.
o Anti-return gate valves: remove the gate or replace the valve with a spool.
o Anti-return disc valves: remove the disc or replace the valve with a spool spacer.
o If, when flushing the oil is to be circulated in a raised tank, the anti-return valve in the supply line to that

EC-B-54.00-01a
OPERATING SYSTEMS
tank shall be replaced by a plug or conventional valve. This valve shall make it possible to isolate the
raised tank from the rest of the circuit, reducing the time required to check the condition of the meshes
that filter the oil. During flushing, this valve shall be open to allow the tank inlet and outlet lines to be
cleaned.
o The oil filter filtering cartridges shall have been removed before initial flushing.
c) Cleaning of internals and calibration of control valves and instrumentation of the system
This work shall be executed within the scope of the instrumentation commissioning.
d) Installation of flexible hose by-passes:
Flexible hose by-passes shall be installed to add continuity to the oil circuit without entering any equipment.
To this end, the material required should be obtained:
o Flanges of the appropriate dimensions
o Hoses with the appropriate length, diameter and resistance. The hose diameter shall be greater than or
equal to the smallest diameter of the fixed pipes of the circuit to which they belong (this shall reduce
charge losses and increase the flow rate and therefore the efficiency of flushing; Furthermore, hoses
shall not break due to excess pressure). Normally, a flexible plastic tube of 2” shall be sufficient, with a
spiral-wound iron frame. The resistance of the hoses shall be at least 10 bar at 80º C.
o Clamps
o Gaskets
o Valves. Valves shall be installed in the flexible hose by-passes, always upstream of the hoses. This
shall isolate part of the circuit and thus increase the oil flow rate in the areas where this is required.
To facilitate the correct installation of the flexible hose by-passes, graphic diagrams shall be prepared
1a showing the connecting points, in addition to lists of the necessary materials with an indication of the
amount, description, size and material of each element. See examples in Appendix VII “Flexible hose by-
passes in lubrication circuits. Examples”.
e) Installation of mesh filters:
In newly-installed systems that, therefore, contain a great deal of debris resulting from installation
operations, metallic meshes shall be installed in the oil pump intakes and in the returns to the main oil tank
or tanks, based on the following criteria:
o A #50 mesh shall be mounted on the oil pump intake filter
o #150 meshes shall be mounted, protected by a #20 mesh, in the following inputs to the main oil tank or
tanks:
- Pressure control valves returns in oil pumps
- Oil returns (there may be only one common line for all the circuits or multiple lines that are separate
for each one).
- Instrument vent line or lines.
f) Filling of the main tanks with flushing oil:
In newly-built systems, the oil in all the main tanks shall be changed after flushing; therefore, different oil
can be used for cleaning to the oil required in normal operation by the equipment fed by the oil system. In
this case, a low-viscosity oil would be a good option for flushing as it offers a higher flow rate and is also an
oil with few additives, which is more economical. This shall be done provided that said oil and the normal
operating oil are compatible, pursuant to the equipment Vendor's specifications.
If the main tank or tanks have no filling filter equal to or finer than 100 microns (approximate size of a #200
mesh), the oil filling operation shall be carried out using a #200 mesh protected by a #20 mesh.

EC-B-54.00-01a
OPERATING SYSTEMS
6.5.2. Cleaning of all system parts through which the oil shall not circulate during flushing:
Cleaning shall be extended to the whole system without exception and shall be executed simultaneously to
flushing. All parts and equipment shall be cleaned:
 Dismantling and cleaning using a hydro jet
 When dismantling equipment is not possible, cleaning shall be done by hand
 Another option that would not involve dismantling would be to circulate steam and then air at high flow
speeds through certain system parts. As regards new equipment, this shall be authorized by the equipment
Vendor's representative.
 Also, chemical cleaning may be executed, both on the parts separately and by circulation through non-
dismantled sections of the circuit.
Chemical cleaning is mandatory for sections of the circuit with intricate interior layouts where it is
impossible to establish an adequate flow rate, in which case flushing shall be ineffective. This applies to
raised sealing oil tanks.
When performing chemical cleaning, the compatibility of the products to be used with the materials of the
elements to be cleaned shall be verified, taking always into account the Vendors' recommendations.
Cleaning shall include dead-end points in the system and in particular, instrument connections, which shall be
purged to eliminate dirt that has accumulated on them.
6.5.3. Start of oil circulation (flushing):
a) Oil temperature adjustment:

The oil tank shall be heated with the steam coil or using other methods if steam is not available. The oil
shall be heated to a temperature of between 65 and 70 ºC. Under no circumstances may flushing be started
at temperatures of less than 25 ºC and it shall be ensured that the temperature never exceeds 75 ºC.
One of the two exchangers for adjusting the oil entry temperature shall be supplied with water (cooled or
tempered water, as applicable); this allows the flow to alternate between one exchanger and the other,
provoking sudden changes in temperature that favor peeling by generating successive internal expansions
and contractions of the lines.
b) First start-ups of the oil pumps:
The suction and impulsion of all oil system pumps shall be cleaned. To do this, flushing shall be carried out
alternating the use of one and the other. If the circumstances make any of the pumps unavailable, their
suction and impulsion valves shall be closed until the corresponding said pump becomes available again. If
it is not available during the entire flushing operation, it should not be forgotten to clean all elements in the
unused section.
Procedure for starting flushing in all the independent circuits in the oil system:
o First, open the suction and impulsion valves of the pump to be used.
o Open the return to the tank of the oil pumps' pressure control valve (PCV).
o Start up the motor pump
o Stop the pump 5 minutes after the first start-up.
o Check the mesh installed in the intake filter. Clean it and assemble it again.
o Check the mesh installed in the PCV return tank input. Clean it and assemble it again.
o Start the pump up again.
o Slowly close the PCV return by-pass.
o Stop after 5 minutes.
o Check the mesh installed in the general oil return tank inlet. Clean it and assemble it again.
o Start the pump up again.

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OPERATING SYSTEMS
o Repeat the start-ups, stoppages and checks every 5 minutes with the PVC return by-pass closed until
the mesh is clean.
o Start up the pump and maintain the circulation of oil.
o After 24 hours of flushing, stop and replace the #150 meshes with new #200 meshes, supported by #20
meshes.
6.5.4. Flushing progress and monitoring:
In newly-built oil systems, oil circulation should be stopped every 24 hours to check the cleaning of the meshes
installed in the pump intake circuit and in the tank return lines. Clean, reassemble and start up again.
Using the valves installed in the flexible hose by-passes, alternate the flushing in different parts of the system,
isolating some and then others in sequence, to increase the flow received by each part. When opening and
closing by-pass valves, take care not to block all the system outlets to prevent excess pressure, particularly in
systems with positive displacement pumps.
To achieve sharp variations in oil temperature that facilitate peeling and elimination of dirt inside the lines,
alternate between both system exchanges in sequence, piping cooling water through only one of them.
Knocking the line welding area (but without damaging it) to eliminate traces of welding is also recommended,
thereby preventing them from becoming detached and mixing with the oil during normal system operation.
6.5.5. Certification that the system has been cleaned:
a) API 614 standard certification:

The following check shall be made as a basis for ensuring the system clean, based on the API 614
standard:
o In newly-built systems, when the meshes installed as described above are found to be clean in the 24-
hourly inspections, flushing shall be stopped. In systems with a separate contact-type oil circuit, flushing
in that circuit shall also be stopped.
o Assemble the system oil filters.
o Install #100 meshes supported by #20 meshes in all oil station outlets.
o Assemble #100 meshes supported by #20 meshes in all flexible hose inlet points in all the oil system
circuits.
o Start the pumps up again in all the independent system circuits. Continue flushing for one hour,
checking that the oil temperature remains between 66 and 71 ºC.
o During this hour of circulation, check the differential pressure in the oil system filters. They may become
blocked in a short space of time as part of the dirt is not decanted in the tank, and instead it is sucked
by the pumps and pumped with the oil. Under these circumstances, the filters shall be changed, and
flushing shall continue for one hour. Once that hour has passed, stop flushing and remove the #100
meshes.
o The system shall be considered clean if the number of particles in all the #100 meshes is lower than the
maximum values indicated in the following table and if these particles are distributed at random in each
mesh.

EC-B-54.00-01a
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1a TABLA IV. OIL FLUSHING: ACCEPTANCE CRITERIA ACCORDING TO API 614
Number of particles
Pipe φ (nominal
inches) Double extra
≤ 40 Schedule 80 Schedule 160 Schedule
strong (XXS)
≤ 1” 6 5 4 --
1 1/2” 15 10 10 5
2” 20 20 15 10
3” 45 40 35 25
4” 80 70 60 50
6” 180 160 130 115
If the count described above does not provide satisfactory results, the entire cleaning certification
process shall be repeated a number of times. If, after doing so, no progressive or direct improvement
can be seen, the filters and all the #100 meshes installed to certify cleaning shall be removed and the
flushing operation shall continue for a longer period time, under the same conditions as prior to the first
attempt to certify cleaning.
Part of the system may be declared clean; however, flushing should continue for the rest of the system.
The valves installed in the flexible hose by-passes shall allow the circuits declared as being clean to be
isolated, facilitating the intensification of flushing in circuits where there are still considerable amounts of
dirt.
b) Additional analysis of oil samples:
The certification of cleaning pursuant the API 614 standard ensures the presence of a sufficiently low
number of particles of a size equal to or greater than 150 microns (approximate size of #100 meshes);
however, it does not guarantee that the oil shall not contain a large number of particles that are equal to the
system dynamic tolerance size (space between components in movement, to be occupied by the lubricant
film). It is these particles that cause the greatest damage due to equipment wear and should normally be
significantly smaller than 150 microns.
To control the number of particles measuring less than 150 microns, oil samples shall be taken at strategic
points of the system (usually sample-taking points already set out by Vendor) and a count shall be taken
using microscopic/automatic methods of the different-sized particles in those samples, per ml of fluid.
Unless otherwise indicated by Vendor, the level considered desirable and economically feasible for rotating
equipment in general is the ISO 15/12 criterion, pursuant to the “Solid Particle Contamination Level Code”
ISO 4406, which allows maximum contamination levels identified by grade 15 for particles ≥ 5 µm and
grade 12 for particles ≥ 15 µm, based on the following grades chart:
1a TABLA V. OIL FLUSHING: CODE OF POLLUTION LEVEL FOR SOLID PARTICLES ISO 4406
Number of particles per ml (n) Grade No.
80,000 < n ≤ 160.000 24
40,000 < n ≤ 80,000 23
20,000 < n ≤ 40,000 22
10,000 < n ≤ 20,000 21
5,000 < n ≤ 10,000 20

EC-B-54.00-01a
OPERATING SYSTEMS
Number of particles per ml (n) Grade No.
2,500 < n ≤ 5,000 19
1,300 < n ≤ 2,500 18
640 < n ≤ 1,300 17
320 < n ≤ 640 16
160 < n ≤ 320 15
80 < n ≤ 160 14
40 < n ≤ 80 13
20 < n ≤ 40 12
10 < n ≤ 20 11
5 < n ≤ 10 10
2.5 < n ≤ 5 9
1.3 < n ≤ 2.5 8
0.64 < n ≤ 1.3 7
0.32 < n ≤ 0.64 6
0.16 < n ≤ 0.32 5
0.08 < n ≤ 0.16 4
0.04 < n ≤ 0.08 3
0.02 < n ≤ 0.04 2
0.01 < n ≤ 0.02 1
6.5.6. Circuit reinstallation:
a) Elimination of oil used for flushing, final cleaning and inspection of tanks:
The oil used for flushing shall be eliminated by means of the drainage system at the bottom of the tank and
all low points in the system.
The tanks shall be cleaned using lint-free cloths. A visual inspection shall be made and approval given by
the equipment Vendor's representative.
b) Filling the main tank/s with oil for normal use:
If the tank/s has/have no filling filter equal to or finer than 100 micros (approximate size of a #200 mesh),
the filling operation shall be performed using a #200 mesh protected by a #20 mesh.
The operating oil specified by the Vendor shall be used.
Once the flushing operation has ended and the specified oil for the machine has been replaced,
atmospheric tanks with an inert gas connection (nitrogen blanketing system) shall be blown with this gas,
which shall be released through the vent, to prevent corrosion problems. Furthermore, this shall also
prevent the creation of explosive atmospheres inside the tanks.

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c) Removal of all provisional elements for flushing:

Remove the flexible hose by-passes.
Remove the oil pump intake circuit meshes.
Remove the meshes from the return circuits of the main tank/s.
Check that all the blind covers, blind discs and other provisional elements using during the flushing have
been removed.
d) Installation of all equipment removed during the flushing operation:
Install the pressure control valves/differential oil pressure control valves.
Install the anti-return valves replaced by spool spacers.
Install the anti-return valve of the raised tank inlet line, which had been replaced by a conventional valve.
Install the flaps and discs removed from all anti-return valves.
Install the orifice plates.
Install the oil filter cartridges.
e) Installing the mesh filters in the equipment inlets:
Clean and use the same #100 mesh filters that were used to certify cleaning.
Install these filters on the same flanges as the ones on which they were installed during the process to
certify cleaning, i.e. on the flanges where the flexible hose inlets were located.
f) Flushing using the equipment. Final check of the cleanliness of mesh filters and leaks:
A final flushing operation shall be executed with normal operating oil. This shall continue until the system is
put into service and for at least 12 hours.
This final flushing operation shall check the correct functionality of the system and that there are no leaks,
while also improving the system cleaning; the mesh filters shall serve as the final indicators of the state of
the system's cleanliness when put into operation.
7. PROCEDURES FOR PREPARING FOR START-UP
Once cleaning has been completed, the operating systems shall be ready for a second commissioning phase
or preparation for start-up:
 The process lines and equipment shall be ready for vaporizing and/or inerting.
 The lines/headers/systems and auxiliary service equipment, if for fuels (FG, FGP, NG, FOS/R and FL),
shall also be ready for vaporizing/inerting; once cleaning has been finished, the other auxiliary services
shall be ready to be put into service.
Once the cleaning phase has ended, the battery limit unit (B.L.U.) blind discs, which were turned to the
blanking position to isolate the Unit to be commissioned from the rest of the systems, shall be placed in their
normal operating position and recorded pursuant to the procedure set out in Appendix IV “Procedure for
handling and controlling blind discs for commissioning”. Production shall establish the order/priority for turning
them.
Once all the blind discs in the B.L.U. have been installed in the Unit's normal operating position, start-up
preparation work may commence:
 Put the Auxiliary Services into service
 Vaporize, inert and leak tests on the Process Systems
Starting up the auxiliary services and purging/inerting and leak testing the process systems shall be directed
and executed by Production.

EC-B-54.00-01a
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7.1. Procedure for starting up the Auxiliary Services
The auxiliary services (AS) shall be started pursuant to a pre-established order of priority. The criteria as
regards the need for certain AS to be put into service, as indicated in section 4.2 of this specification, shall be
considered; furthermore, consideration shall be given to the risk involved in putting given AS into operation.
Consequently, as regards the start-up priority, the AS shall be divided into three main groups:
 Steam and Condensate headers, Water headers and Air headers
 Chemical product headers and Gas headers (Nitrogen)
 Flare headers (FL) and Combustible Gas headers
When starting up the Nitrogen headers, it is essential to ensure that all manholes in vessels, drums, columns
and towers are closed. This shall have been checked in advance pursuant to the controls specified by the
Commissioning and S/U Manager.
The flare headers (FL) shall be put into operation before the fuel gas headers.
Once a header is put into operation, this shall be indicated and clearly visible signs to this end shall be
installed.
7.1.1. Steam headers:
Depending on the pressure, these headers are divided into the following categories: high pressure (SH ≈ 40
kg/cm2), medium pressure (SM ≈ 15 kg/cm2), low pressure (SL ≈ 4.5 kg/cm2), or also very high pressure (SHH)
or very low pressure (SLL).
They shall be put into service in two phases, with a total approximate duration of six hours:
 Preparing the circuit:
o Block valves next to equipment for consumption and production shall be kept closed and ¾” or 1” Ø
purge valves before or after the blocks shall be kept open, depending on the direction of the flow.
o ¾” Ø purge valves before all purges or steam traps in the system shall be kept open.
o Purge valves shall be kept open (normally ¾” Ø) at the ends of the headers/sub-headers.
 Heating of headers and putting into operation:
o Open the B.L.U. block valve by-pass valve completely, which shall normally be ¾” or 1” Ø. If there is no
by-pass valve, open the general block valve of the B.L.U. header a little and slowly inject steam into the
header.
o As the header is heated, the condensate shall be eliminated through the open purge points in the
system.
o When steam starts to emerge from said purge points, open the B.L.U. valve a little more. Preserve it as
such until steam emerges through all the purge points. In the event of a water hammering effect, reduce
the steam intake by closing the B.L.U. valve slightly until it disappears.
o Gradually limit the passage of the steam through the purge points to facilitate the gradual pressurization
of the header. Simultaneously purge the condensate through all low points.
o Continue opening the B.L.U. valve until it is fully open. Close the ¾” or 1” Ø by-pass.
o Keep the system's purge points slightly open to eliminate the condensate. Keep them in this position
until the condensate header is in operation and the steam traps (ST) are aligned with said header.
7.1.2. Steam condensate headers:
Depending on the pressure and the possibility of contamination when they exchange heat during the process,
these headers are divided into the following categories: high pressure condensate (CH), medium pressure
condensate (CM) and low pressure condensate, which may in turn be clean (CL) or oily (OC).

EC-B-54.00-01a
OPERATING SYSTEMS
They shall be started up in two phases:

 Preparing the header:
o Keep the downstream block valves of all steam traps (ST) closed; said traps shall be purging into the
atmosphere.
o Keep slightly open the purge points (usually ¾” Ø) at the ends of the headers and sub-headers.
 Heating the headers and putting them into operation:
o Slowly open the B.L.U. valve to put the condensate headers into operation.
o Close the purge points before the steam traps, keeping the rear ones open. Check that the STs are
operating correctly.
o Align all the STs that are working correctly with the header. Repair faulty ones. If an increase in the
pressure of the header in the B.L.U. is detected, or if messages as regards the arrival of steam with the
condensate in the recipient tanks are returned, the correct functionality of the STs shall be checked.
7.1.3. Cooling water headers:
Cooling water supply and return headers (CWS/CWR) shall be started up as follows:
 Open the B.L.U. valves, both the supply and the return valves, slightly. Open the vent valves located in the
high points of the headers and the header by-passes, where applicable.
 The air shall be eliminated through those vents and both headers shall gradually be filled (CWS/CWR).
 When there is apparently no air left in the circuits, open the return and supply valves until the headers are
in line with the system.
 Maintain the circulation through the by-passes for at least six hours before closing them.
7.1.4. Other water headers (Treated water, Plant water, Drinking water, Tempered water):
This shall be done in two phases:

o Maintain the block valves near consumption equipment closed.
o Keep the purge points (normally ¾” Ø) open at the ends of the headers/sub-headers.
 Start-up:
o Slightly open the general block valve in the B.L.U. header, so that water is gradually injected into the
header.
o As the header is filled, the residual water shall be eliminated through the open purge points in the
system.
o When the header is pressurized, continue opening the B.L.U. valve until it is completely open, with the
header in operation.
7.1.5. Instrument air headers (IA) and plant air headers (PA):
 Plant air header:

o Check that all the connection valves to consumption equipment are closed
o Open the B.L.U. valve to leave the header in line (same pressure) with the distribution system.
 Instrument air header:
o Disconnect all pneumatically-supplied equipment from the instrument air system.
o Eliminate the humidity from the header by performing blows with the instrument air a number of times.
o Install the filters in the connections to pneumatic instruments and the connection to the consumption

EC-B-54.00-01a
OPERATING SYSTEMS
points.
o Align the header with the distribution system.
7.1.6. Chemical product headers:
Caustic soda with a concentration of 50% and diluted to 20%, sulfuric acid, hypochlorite.
o Preserve closed the block valves to the consumption equipment.
o Keep closed all the system purge points (normally ¾” Ø) at the ends of the headers/sub-headers.
 Start-up:
o Slightly open the general block valve of the B.L.U. header to gradually inject the product into the header.
o As the header fills, the residual water shall gradually be eliminated through the drainage points that lead
to the closed acid/basic system.
o Close the purge valves to the closed system and after pressurizing the header, continue opening the
B.L.U. valve until it is completely open, to leave the header in operation.
7.1.7. Nitrogen headers:

o Preserve closed the block valves to consumption equipment.
 Start-up:
o Slightly open the general block valve of the B.L.U. header to inject the nitrogen into the header.
o As the header becomes pressurized, the residual water shall be eliminated by slightly opening the
drainage points in the system.
o Close the purge/drainage valves and when the header has been pressurized, continue opening the
B.L.U. valve until it is completely open, to leave the header in operation.
7.1.8. Flare headers (FL):

o Keep closed the block valves in all the connections discharging into the flare header and all the PSV by-
passes.
 Inerting and start-up:
o Inject N2 at the end of the header opposite the B.L.U. and purge the nitrogen through the purge point
before the B.L.U. block valve.
o Continue with the purging operation for at least 8 hours and then check the oxygen using a portable
analyzer. When the O2 value is less than 0.5%, the header is ready to be started up by opening the
B.L.U. valve.

EC-B-54.00-01a
OPERATING SYSTEMS
7.1.9. Fuel-Gas (FG) and Natural Gas Headers:
(Note: Starting up Methane Gas headers, where applicable (in the specific case of Olefin/Pyrolysis plants),
shall also be done as follows.)
This shall be done in three phases:
o Preserve closed the block valves of all the nozzles to consumption equipment.
 Inerting the header:
o Inject steam through the steam-outs in the system. Vaporize for at least 6 hours. Vaporizing shall be
done in accordance with what is indicated in section 7.2 of this specification.
o After 6 hours, inject N2 and close the steam injections (steam-out). Once all the condensate has been
eliminated, put the header into operation.
 Start-up:
o With a positive N2 pressure in the header, open the B.L.U. valve until the header is aligned with the FG
distribution system.
o Push the existing nitrogen in the header towards the flare by opening the vent installed for that purpose
at the end of the header, getting the header this way into operation. In the event that traces of nitrogen
remain in the header, they shall be purged during start-up of the furnace pilots towards their hearths.
7.1.10. Fuel-Oil headers (FOS/FOR):
This shall be done in three phases:

o Preserve closed the block valves in all the connections to the existing furnaces' burners.
o Fully open the block valves of the return lines of the central header and the side sub-headers.
 Inserting the header:
o Inject steam through the steam-outs in the system. Vaporize for at least 6 hours. Vaporizing shall be
done pursuant to the provisions of section 7.2 of this specification.
o After 6 hours, inject N2 and close the steam injections (steam-out). Once all the condensate has been
eliminated, put the header into operation.
 Start-up:
o With a positive N2 pressure in the header, open the B.L.U. valve of the F.O. return line (FOR) to fill and
pressurize both headers (FOS/FOR) in the opposite direction, until the header is aligned with the
pressure of the return line (FOR).
o Open the FOS header B.L.U. valve slightly and at the same time, reduce the opening of the return
valves by 50%. Keep opening the FOS header B.L.U. valve until it is completely open and adjust the
return valve temperature to maintain the FO temperature in line with its viscosity. The residual nitrogen
shall be vented through the head tank supplying the FOS headers.
7.1.11. Closed drainage headers:
The closed drainage system headers (unit emptying type (hydrocarbons), acid/basic, amine, methanol) shall be
started up in the same way as the Process systems. See section 7.2. of this specification.

EC-B-54.00-01a
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7.2. Procedure for vaporizing, inerting and leakage tests for Process Systems
Operating systems shall be vaporized to eliminate air and check for the absence of leaks, followed by
inertisation with nitrogen and leak testing at the operating pressure of each system or the pressure available by
the N2 system.
The procedure described below applies to all the Process systems with the exception of reaction systems in
catalyst units and the compression systems of those units, which shall be subject to the procedure indicated
later in the respective sections of this document.
Likewise, this procedure shall apply to preparing the auxiliary closed drainage systems for emptying the unit for
S/U (hydrocarbons), acid/basic, amine, methanol.
Systems that shall not be exposed to water shall not be vaporized. Some systems, such as those at sulfur
plants, shall require a special treatment, to be specified by the Licensor.
The activities required to execute the vaporizing/inerting operations shall be set out in a table or “List of
activities for preparing for S/U” for each system; so that work to be done is documented and that it also serves
to monitor progress. It shall define the points where the steam (or N2) shall be injected and the points where
the purging shall be carried out.
This table shall be accompanied by the P&IDs with the systems marked, also showing the injection and purge
points referred to above.
The vaporizing and subsequent inerting sequence of the process systems is divided into two main phases:
7.2.1. Preparation of the operating system:
 Set to open the reversible discs in the B.L.U. lines according to the list of discs developed to this end (see
Appendix IV “Procedure for handling and controlling blind discs for commissioning)”. Install definitive
gaskets.
 Installation of reversible blind discs in drainage lines to closed drainage systems. Install definitive gaskets.
 Set to open the reversible discs in steam blowing injection lines existing in the system. Leave the same
existing provisional gaskets, since once the vaporizing ends, the reversible discs shall be set to blind and
their definitive gaskets shall be installed.
 Check that all the discs installed for the cleaning phase have been removed from the equipment.
 To prevent damage to instruments, flow rate and pressure transmitters, analyzers and level controllers,
when of differential pressure, shall be blocked. The root intake of the flow rate and pressure transmitters be
blocked. Only the pressure transmitters shall be left operating while in use, to check the pressure reached
while vaporizing. Close the block valves of all level instruments and open the ones in the stand-pipe.
 Open the block and by-pass valves of automatic valves.
 Check that the PSV block valves feature mechanical interlocking, when such a scheme is installed.
 Close the pump intake valves and open their purge valves.
 In circuits with water coolers, water shall be drained: to prevent heating and vaporization and, as a result,
excess pressure on the water side that could cause gaskets and/or manifolds to break, the vents on the
water side shall be blocked, purged and opened.
 In addition to the system steam injections set out to this end, they shall normally need to be completed with
provisional connections. Injections shall always be made at the low points of the system.
7.2.2. Vaporizing and inerting the system:
 Let the steam entering slowly through all the points, using the steam injections to the process and
temporary ones (if necessary) and purge the condensate through the low points of the circuit or system that
had been prepared. Open them sufficiently to eliminate the condensate.
 At the same time, allow the steam through the injections to the system equipment. Open the purge valves
at the bottom of the equipment to eliminate the condensate. Block all the pumps to prevent damage of
internals; but slightly open the pump intake valves to eliminate the condensate. Gradually close all these

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purges to allow the steam to emerge through the high points.

 Purging shall also be accomplished using the sight levels and level controllers when they are not of
differential pressure.
 Vaporize the equipment level instrument stand-pipes, keeping the instruments blocked.
 In circuits that feature sample intakes, these shall be vaporized.
 Keep all drains and vents open to expel the air. However, keep the vents open a sufficient amount to
eliminate the oxygen while forcing the steam to continue circulating throughout the entire system
(pressurize the system between 200 and 500 gr/cm2).
 The pumps shall have all their drains open and the steam or condensate shall be expelled through them.
 Also open the vents and purges of the exchangers that also belong to other systems that have not yet been
vaporized/inerted. This shall prevent the water hammer effect in the water they contain, which evaporates
when heating.
 At first, there shall be a large quantity of water to be drained through the low points. Therefore, steam shall
start to emerge through the vents located in the high points before later emerging through the drains.
 If there are purge valves through which no steam or condensate emerges, first check that the circuit
pressure is low and then unblock them, previously taking the necessary precautions to avoid being
splashed (in line with the respective product data sheet [usually PPEs, face shield]).
 As the steam emerges through the low points (drains), partly close the vent and purge valves so that only a
small quantity of steam emerges. This shall ensure that the steam pressure is not lost but it is increased,
forcing the steam to be piped through the circuits and pass through all the equipment.
 With all the steam injections open and steam emerging from all the points, vaporize the system for at least
eight hours. Ensure that there are no pockets of condensates and watch for potential decreases in the
temperature outside the line/equipment.
 Once the eight-hour time period has elapsed, close the vents and purge valves, except for those on the
pump bodies. Close the intake valves.
 Pressurize with steam up to a maximum of 1.5 kg/cm2 measured in a PI installed for that purpose. Check
that there are no leaks through collars, flanges, bushing, vents or other elements. If there are, repair them.
 With no steam leaks in the system, inject nitrogen (through a high point using specific coupling accessories)
and gradually close the steam so that the system pressure remains no lower than 1.5 kg/cm2.
 Purge through all the low points to eliminate the condensate from the steam trapped in the circuit.
 When nitrogen emerges through all the purge points, pressurize the system to a maximum pressure of 1.5
kg/cm2 for low pressure systems. For other systems, pressurize up to the nitrogen system pressure (which
is normally 7 kg/cm2).
 With this pressure, check that there are no leaks in the system. In the event of losses exceeding 50
gr/cm2/h, check the system flanges with a leak detector and repair them.
 Once the leak test returns satisfactory results, install the plugs in the purge and vent valves. The system
equipment vent blind covers shall be installed.
 Once the system has been inerted, the reversible discs in the blow steam injection lines shall be turned to
blind and with the final gaskets installed.
 Under these conditions, align the system for its start-up, eliminating all blocks to ensure that it is not
interrupted at any point.
 Unblock the root valves of the instruments that were blocked to prepare the system. Block in the manifold
itself and open the by-pass for the flow and level ones.
 In turn, the already inerted systems shall be isolated from the adjacent systems by block valves,
maintaining their limits as operating systems.
 Unblock the automatic system pressure control valves, adjusting the set points of the controllers to the
normal operating pressure values.

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Under these conditions, the operating system is ready for the injection of the corresponding fluid load for start-
up.
7.3. Preparation for start-up of the Reaction Systems
7.3.1. Inerting and leak tests on the reaction systems:
The procedure for executing inertization and leak tests on the catalyst unit reaction systems features two
different phases:
a) Vacuum test and inertization:
The reaction system shall contain no air, and so it shall be submitted to a vacuum test. For this purpose the
adjacent equipment/systems network shall be carefully isolated by means of blocking; furthermore, the
pressure of the equipment and/or lines with large diameters shall be closely monitored to prevent any
collapse, as they have not normally been designed for vacuum operations.
The recycling gas compressor shall be correctly isolated, using a double block valve, positive nitrogen
pressure and the proper lubricant and in-service sealant oil for centrifugal compressors. The supplying gas
compressor, when available, shall also be isolated to prevent the entry of air. The machine itself shall be
tested/pressurized with nitrogen and free from air.
The instruments shall all be isolated (unless they can withstand the vacuum). Only one or two operative
pressure/vacuum manometers (manovacuometers) shall be installed in the reaction system, at points that
are as far as is physically possible from the vacuum ejector.
It shall be verified that the steam line to the ejector has been carefully blown with steam before allowing the
steam to pass through it. Otherwise this could cause a malfunction in the Venturi ejector.
The ejector (vacuum pump) shall be started up, recording the descending pressure and stabilizing at < 60
mm Hg. The real time for obtaining the vacuum shall depend on the ejector's capacity.
The ejector shall be isolated and stopped when the system vacuum requirement has been met. Any
increase in pressure during a recommended period of 8 hours, indicating a loss of vacuum, shall be
recorded. Increases of less than 5 mmHg/h shall be considered acceptable. For increases in pressure (loss
of vacuum) of more than 5 mmHg/h, all the gaskets shall be covered, and a hole made and a soap solution
injected until the leak is located and repaired.
If the vacuum test is considered satisfactory, the vacuum shall be broken with nitrogen to reach 1 Kg/cm2.
The oxygen content shall be monitored. If the value is not less than 0.5% in volume in all sites, the
vacuum/pressurization process shall be repeated until the oxygen content is less than 0.5%. Then, all the
instruments shall be put into operation and the vacuum manometers shall be replaced by normal operating
ones.
With a value of < 0.5% in oxygen volume, the reaction system is considered free from air. The compressor
can now be aligned with the system, provided it contains no air and has a low positive nitrogen pressure,
like the system itself (operating the compressor at a negative pressure would cause severe damage to the
seal system labyrinth).
b) Leak test with nitrogen:
o All the control valves and orifice plates should now be reinstalled.
o The system has been isolated and the oxygen checked.
o The system pressure is balanced with the nitrogen system pressure, normally 7 kg/cm2; therefore, this
shall be the first pressure for detecting leaks. If a higher N2 pressure is available, it can be used to
continue the leak test, subject to the provision that it does not exceed 25% of the reactor design
pressure. In all circumstances, it shall be verified that the recycling compressor, whether centrifugal or
alternating, is designed to operate at the indicated pressure.
o The pressurization and depressurization shall follow the normal flow direction.
o The maximum pressurization/depressurization speed shall be no more than 20 kg/cm2/h. The increase
in pressure shall be monitored in different manometers. Leaks shall be located and repaired. Their
locations shall be recorded.

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o The leak test is satisfactory when the pressure decreases by less than 0.05 kg/cm2/h during a period of
four hours.
o The nitrogen used for the leak test shall be purged using the drains (low points) to eliminate the water
remaining after hydraulic tests, if any.
o The system shall continue to be isolated by block valves from the rest of the Unit systems. Afterwards,
the system shall be pressurized again to reach the level of available nitrogen pressure and start drying
the reaction system.
o During all phases, the temperature of the reactor walls shall be checked constantly and compared with
the temperature/pressure graph provided by Vendor. In next-generation austenitic steels, the pressure
shall not exceed 25% of the design pressure when the wall temperatures are below 39 ºC.
7.3.2. Drying the reaction system:
Reaction system drying operations shall be performed before charging the catalyst and at the same time as
drying the refractory material of the furnace to said reaction system. Both procedures shall be adapted to
comply with the requirements of both drying operations.
For this joint drying operation, the recycling compressor shall be started up to protect the furnace reaction
system loading tubes, which shall be cooled using the nitrogen flow to ensure that they do not reach flaming
temperature. Furthermore, the recycled nitrogen flow shall be used to move the water from the equipment to
the system's low temperature separators, through which points the accumulated water shall be drained.
Whilst the temperature is higher, the temperatures of the walls of the furnaces' tubes (skin points) shall be
monitored, and the correct distribution of nitrogen gas through the furnace passage points shall be ensured.
Throughout the entire drying process, special attention shall be paid to the following aspects:
 Check there are no gas or oil leaks in the centrifugal compressor seals.
 The recycling compressor shall be protected by a temporary filter.
 The air coolers on the high pressure separator shall be in normal operation, at the maximum air design flow
rate (maximum inclination of the cooler blades).
 Check the reaction system for leaks. If any appear, eliminate them and ensure the system is leak-proof.
 Monitor expansions in lines and equipment.
 Monitor the variable load support.
 The closed reaction system pressure shall exceed the minimum to allow the recycling compressor to
operate with nitrogen, in line with its characteristic curves.
 The maximum furnace output temperature shall be established pursuant to its maximum refractory drying
temperature, i.e. the temperature of the fumes from the furnace throughout the radiant and convective
zone.
 Temperature increases shall also be established in line with the furnace refractory drying curve, established
by the refractory cement supplier.
During the drying procedure, the water accumulated in the high pressure separator and at all the agreed low
points in the system shall be drained.
When no more water is recovered from said separator, the reaction system drying operation shall be
considered complete and the circulation of nitrogen gas shall continue in order to cool the equipment. To this
end, the cooling curve established by the furnace drying shall be monitored.
The reactors shall be cooled at a temperature considered safe for charging the catalyst, which is set at a
maximum of 50 ºC.
After reaching a temperature of 50 ºC, circulation of nitrogen gas shall continue and the furnace shall be shut
off for at least 6 hours; this serves to ensure that when the recycling compressor is stopped, the temperature in
the reactors does not rise above the value set by the radiation of the walls of the reactor/s.
Stop and isolate the compressor using the block valves.
After the cooling period, the reactor atmosphere shall be changed to air for charging the catalysts. This shall be

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done using the ejector installed to this end, which shall remove the nitrogen from the system by means of the
vacuum and afterwards by breaking the vacuum with air.
7.3.3. Drying the furnace refractory material:
a) Furnaces for feeding the Reaction systems:

This operation shall always be executed in line with the drying curve indicated by the furnace Vendor and,
as already described, shall be carried out at the same time as the reaction system is dried.
The nitrogen flow rate to be used is the maximum compatible with the power of the compressor motor
element and the temperature limit at its discharge.
This drying phase comprises two stages, in which the temperature is increased in line with the heating
curves supplied by the furnace Vendor:
o The first stage is the drying phase, which entails the elimination of the water.
o The second stage is the hardening of the refractory bricks or the refractory cement/concrete, thus
permitting the insulation material to adopt its final structure.
When the drying and hardening of the refractory material has been completed, the temperature in the
radiant zone shall be reduced within a range of approximately 20º C/h. The main burners and pilots shall be
shutoff when they reach a temperature of 200 ºC.
The circulation of nitrogen shall be maintained to cool the reactors to the temperature indicated above: <
50º C.
b) Furnaces feeding the fracionator and reboiler systems:
For drying furnace refractory material that does NOT belong to a reaction system, the procedure described
above shall also apply to said furnaces, with the following exceptions:
o Circulation through furnace tubes shall utilize the product treated in the Process Unit or the product for
starting up the Unit, when the product is heavy and has a high viscosity index (as is the case of loads
coming from the Vacuum units).
o Circulation of the product shall continue until the furnace tubes have been cooled and once the burners
and pilots have been shut off. The time shall vary between 30 minutes and 1 hour.
If permitted by the operating system handover program and the installation, the furnace tubes may be
protected by piping steam from the displacement and/or decoking steam injections, in the event that they
are available.
7.3.4. Loading the catalysts:
Correctly loading the catalysts is absolutely essential in order to obtain the expected results for the Process
Unit. To this end, the following shall be considered:
a) Safety criteria. Protection of people and the catalyst:
o After the cooling period, the atmosphere of the reactors shall be changed to make it breathable. To
achieve this, an ejector shall be installed.
o After changing the atmosphere, the reactors shall be isolated using blind discs. Before starting the
loading operation, it shall be verified that it is properly isolated. This check shall be recorded in a blind
discs list similar to the one that features in Appendix IV “Procedure for handling and controlling blind
discs for commissioning”; however, it shall be adapted for the loading of the catalyst in the reactor. This
is essential to ensure that there is no risk of choking during the load operations due to nitrogen entering
the reactors.
o The nozzles of the reactors shall be opened to allow access thereto (if there is no manhole, the product
inlet elbow in the reactor shall normally be removed; which should have been specified as removable for
this purpose.) Once the reactor access nozzle is open, the atmosphere inside shall be aired and
checked to ensure it is safe to enter (21% oxygen volume). This check shall be made through a Permit
to Enter Confined Spaces (permit to work).

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o Sufficient space shall be left around the reactors to allow for easy access to and correct handling of the
catalyst. The catalyst/inert beads (whether in drums or big bags) shall be discharged close to the
reactor, in a protected place. Attention shall be paid to ensure the catalyst is not broken or soiled.
Waterproof covers shall be installed to protect the catalyst from rain at all times and even during
handling and loading operations, if necessary.
o As few operations as possible shall be carried out on the reactor platform, particularly those involving
the handling of the catalyst; such activities shall be carried out at ground level.
o When loading the catalyst, personal protective equipment shall be worn to protect eyes, skin and the
respiratory system. Consequently, before starting work, it shall be ensured that sufficient safety material
and personal protection equipment are available: masks, breathing equipment, gloves, harnesses and
all the necessary communication methods.
o When loading by gravity, one person shall remain inside the reactor to level the catalyst bed and move
the loaded pellets. Nobody should walk directly on the surface of the catalyst, and therefore a flat,
mobile surface should be used for walking on. Working in an atmosphere laden with catalyst powder
involves a certain level of physical risk; the worker should wear self-contained breathing apparatus and
gloves. Another worker should stay outside, next to the loading nozzle, with the appropriate equipment
and rescue instructions, for the case it were necessary.
b) Loading the catalyst and inert beads.
o The inside of the reactors and the catalyst discharge lines shall be clean and dry.
o Certain internal parts of the mixing trays, quench lines and manholes shall be dismantled to allow the
catalyst to be loaded (either by gravity or using the dense load system), as well as leveled and checked.
Furthermore, the following shall be inspected:
- The output filter at the bottom of the reactor, to prevent the migration of the beads and the catalyst
to equipment downstream
- The mixing trays: closure, orientation and seals
- The distribution trays
- The baskets: number, position, closure (where applicable)
- The quench injection pipes: cleaning, orientation of the orifice and number
- The catalyst support structure
o The catalyst and the inert beads shall be charged pursuant to the diagrams prepared to this end by the
Licensor (reactors drawing with the catalyst layer elevations, guard beds, inert beads, etc. and the
expected amounts). To this end, a series of elements shall be installed at the site of operations:
- Elevation system for raising the mobile loading receptacle from the ground (hopper). This hopper is
filled with catalyst at ground level and the catalyst is discharged into the fixed load hopper installed
in the reactor load inlet.
- The load hopper, for approximately 1 m3 of catalyst, shall be fitted with a passage valve and hose.
This hopper shall be installed so that a space is left to facilitate access to the inside of the reactor
and to allow people to easily leave the reactor in the event of an emergency.
- A temporary platform shall be installed on the upper reactor platform to provide access to the
mobile hopper's valve for raising the catalyst.
- A platform shall be installed at ground level to fill the mobile elevation hopper with catalyst.
- It shall be verified that a hose made of the appropriate canvas is available (of the adequate length
and with a diameter of 150 mm). When loading by gravity, the catalyst shall be carefully loaded in
the reactor to reduce its free fall. The maximum free fall height permitted is 1 meter.
o Once the catalyst has been loaded pursuant to the loading diagrams, the ceramic beads shall be loaded
up to the heights indicated in said diagrams.
o It shall be verified for each reactor that the quantity loaded and its equivalent volume of catalyst
matches the design requirements. To do so, a comprehensive record shall be made of the catalyst
loading operation, number of drums and/or big bags and the number of operations. Beakers shall be
available for taking catalyst samples.

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Lastly, the reactor shall be closed and the blind discs used for isolation purposes shall be removed. Under
such conditions, the reaction system is ready to be started up.
7.3.5. Leak test with nitrogen at the operating pressure.
This test is optional, but it is recommended for reaction systems on high pressure Process Units such as
Hydrocrackers, which have pressures of around 155 kg/cm2, measured in the high pressure separator.
These tests are conducted by specialist companies with their own methods for vaporizing and compressing
liquid nitrogen supplied from tankers, to reach the operating pressure of the system in which the test is
performed.
To reduce the consumption of liquid nitrogen, the test shall be conducted once the reactor catalyst is loaded.
The nitrogen injection point shall be located in such a way that pressurization shall be carried out in the
direction of the combined feed flow (Hc+H2).
During the pressurization phase, Helium 1% shall be injected as a trace gas, in order to detect leaks with a
portable chromatograph used to this end.
The increase in pressure shall be made with a ramp of between 10 – 15 kg/cm2, to reach the system operating
pressure.
When 25% of the reactor design pressure is reached, the reactor wall temperatures shall have had to reach the
MPT pressure indicated by the reactor Vendor. (Note: the MPT is the minimum pressurization temperature for
reactors; this is 39 ºC for next-generation austenitic steels).
Once the operating pressure has been reached and after listing all leaks detected at all points that provide for
the possibility of leakage (flanges, collar flanges, equipment manholes, thermocouple sensors, bushing, vents,
drains, covers and other elements) and their leakage rates, depressurization shall be carried out; this shall
always be done in the direction of the flow.
The fall in pressure shall be achieved in line with the pressure/temperature curve provided by the reactor
Vendor.
Once the system has been depressurized, normally by a vent at the system ejector, the specialist company
conducting the test shall repair all leaks listed.
After repairing the leaks detected, the reaction system shall be ready for the initial start-up, together with the
Unit separation and fractionator systems.
8. COMMISSIONING OF DYNAMIC EQUIPMENT
Below, the operations required for the mechanical commissioning of dynamic equipment and its auxiliary
systems are described, with the exception of cleaning the lines, which has been described above.
This work shall be directed by the dynamic equipment commissioning manager of the Production group. The
work shall be executed with the support of the Construction S/U assistance group.
Before starting the commissioning work, it shall be verified that all the necessary technical information
regarding the equipment is available.
The commissioning of dynamic equipment and its auxiliary systems shall gather those operations that require
the supply of final energy and fluids for their execution, i.e., electric fluid, plant steam, fluids to be channeled
through each machine, final lubricant greases and oils and, occasionally, air or other auxiliary products. The
following activities are described below:
 Commissioning of auxiliary lubrication and sealing systems
 Freewheeling of driving machines
 Hot alignments
The results of dynamic equipment commissioning activities shall be validated in line with the required values
established by Vendor.

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8.1. Lubrication systems
8.1.1. Forced lubrication:
This refers to systems external to dynamic equipment that lubricate said equipment by means of a station that
features the auxiliary elements required.
Under these circumstances, the tank shall be cleaned and oil shall then be injected to do the flushing. All this
shall be done pursuant to the procedure set out in Chapter 6 of this Specification.
After flushing, the system shall be filled with oil that complies with the characteristics required to lubricate the
machine.
The level shall be the one indicated as “normal” in the tank, unless the Vendor indicates a larger quantity of oil,
considering that part of the lubricant shall occupy the pipes, coolers, filters and other lubrication system
accessories when the system is in operation. If the Vendor does not provide this information, the loss in level
once the station is in operation shall be considered and checked, for the purposes of replenishment.
With the oil installed, the system shall be put into operation until the operating temperature is reached.
Functionality of the main and backup circulation pumps shall be checked and their parameters controlled:
impulsion pressure, bearing temperature, vibrations. A failure in the main pump shall be simulated to check the
activation of the backup at the specified set point. While the oil is circulating, the correct functionality of the
visors and oil visual level instruments shall be checked.
Note: A lubrication oil manufactured by the Owner shall be used. The characteristics of the oil to be used are
provided by the equipment Vendor. If the specified oil does not match any of the oils manufactured by the
Owner, the Vendor or the in-house technical lubricant department shall be contacted to choose an in-house oil
that satisfies the machine's requirements.
8.1.2. Internal lubrication:
This is the case for lubrication when the lubricant is deposited on the bearing supports and the application of
the oil thereon is carried out by elements moved by the machine shaft.
The tank shall be flushed with oil (of a low viscosity), which shall be discarded using the emptying valve that all
supports should feature.
Oil that complies with final characteristics shall be inserted to the correct level. Depending on the design
specifications of the different machines, this level shall be indicated in the support by a threaded hole with the
corresponding cap; as a result, when that cap is removed it shall be possible to ensure that the correct level is
reached when the oil starts to pour through said orifice. At that point, the cap shall be installed and the
corresponding constant level lubricator shall be adjusted to maintain said level.
After performing the above operation, a check shall be run to ensure the correct functionality of the lubricator;
to this end, a small amount of oil shall be discharged from the oil emptying valve and the bubbling shall be
observed, to confirm that the lubricator replenishes the oil level inside the support.
With the equipment in operation, it shall be verified through the corresponding visor that the elevation system
(rings or discs) works correctly.
If the lubrication system is immersion operated, only the oil level and the correct display of its external visor
level need to be checked.
8.1.3. Lubrication with grease:
For equipment that is lubricated with grease, the grease compartment shall be cleaned taking care not to leave
any foreign particles inside or any traces of encrusted grease. Then, the correct amount of the specified grease
shall be inserted. If the grease point has a greaser, the inside of the greaser shall be cleaned and filled with the
specified grease.

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8.2. Dynamic Sealing Systems
Commissioning shall take care of adjusting the barrier fluid for the dual mechanical seal configurations,
whether pressurized or not, API 52 and 53 plans, injecting the corresponding fluid into the tanks up to the
required level.
If the machine sealing system involves seals that use oil, and this sealing oil is the same as the lubricating oil,
the checks already performed on the lubrication system shall have also checked the sealing system. If the
sealing system oil is completely different along with the tank and oil characteristics, then the tank shall have to
be cleaned, the system flushed and the tank filled with oil pursuant to the specification; and additionally, the
corresponding pumps shall be checked and controlled as indicated above for the lubrication system.
8.3. Freewheeling of Driving Machines
After checking the systems that could affect them (lubrication, cooling, steam supply, electric power), driving
machines shall be freewheeled, i.e., without being coupled to the driven machine. During this operation, the
direction of rotations shall be checked pursuant to the specifications; this should match the requirements of the
driven machine.
8.3.1. Electric motors:
For electric motors, they shall be maintained in operation for a sufficient amount of time for the bearing
temperature to stabilize, which shall be checked by the thermometers internally installed or by manually
operated external instruments. Consumptions and vibrations shall be controlled. When stopping the motors,
the vibration level shall be checked to establish whether their reduction is gradual, in line with the loss in
speed, or whether alterations occur that could be attributable to electrical causes.
8.3.2. Steam turbines:
For steam turbines, they shall be started up pursuant to their type and the Vendor's instructions, ensuring that
no condensate enters them and that the heating of the machine is uniform and generates no thermal shock; to
this end, the speed shall be gradually increased in line with the Vendor's instructions. (This shall not be
necessary in the case of quick-start turbines, which may be placed at the normal operating speed
immediately).
During the start-up process and until the operating speed is reached and maintained, the temperature of the
bearings and casings shall be controlled and the vibrations checked, until stabilization is reached.
If the turbine features carbon ring seals, an operating period at low speed shall be required to allow them to
adapt to the shaft. During this period the temperatures and vibrations in the bushing box shall be controlled
until they stabilize; at this point, the speed may be increased until the normal operating speed is reached.
Once the freewheeling operation ends, the speed shall be slowly increased until the alarm and set points are
reached and the value of these shall be monitored to ensure they are within the specified limits.
Whilst freewheeling, the correct operation of the speed governor shall be checked to ensure the maximum and
minimum speeds between which this accessory operates.
If the turbine features a steam extraction device at an intermediate phase, the correct operation of the valve
that controls it shall be checked.
8.3.3. Internal combustion engines:
This equipment shall also be tested without being coupled, and the temperatures and vibrations shall be
recorded whilst they are being operated throughout the established periods.
After finishing the freewheeling operation of any of the different driving machines mentioned above (electric
motors, steam turbines, diesel engines), the assembly and protection of the coupling element to the
correspondent driven machine shall be checked.

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8.3.4. Alternating compressors:
Even though this equipment is not driving machine, it can be freewheeled without a load. To do this, the intake
or impulsion valves in each cylinder compression part shall be dismantled, depending on whether it is single- or
double-acting. The covers of the dismantled valves shall be left on, but a space shall be left between them and
the cylinder through which the air that is displaced as a result of cylinder movement can circulate; but
preventing the accidental entry of foreign objects.
Before starting up the drive rotor, the wheel shall be rotated completely to ensure that the piston moves freely
and without interference along its entire run. The drive motor shall then be started up.
It shall be operated for short periods of time of approximately 5 minutes to ensure the absence of abnormal
noises or vibrations and to check the temperatures in the rod and piston stuffing box. If everything is working
correctly, the operating time shall be increased by intervals of 15 and 30 minutes, applying the same controls.
The entire freewheeling operation shall then be performed, which lasts for around four hours; during this
period, the indicated parameters shall be controlled externally. Under all circumstances, freewheeling shall
always last until the temperatures being controlled are stabilized.
Throughout the operating period, the oil lubricator functionality shall be checked.
8.4. Hot aligning
In the prior phases of installation and pre-commissioning of the equipment, “cold alignment” of the machines in
the equipment train shall already have been checked and corrected; where required, due to the operating
temperature, the displacement (offset) of the shafts when said temperature is reached shall have been taken
into account.
However, in critical cases or if there are doubts as regards the displacement (offset) of shafts, a “hot”
alignment check shall also be planned during the commissioning phase. To perform this operation, the
operating temperature of the machines shall first have to stabilize before the train can be stopped; everything
shall be prepared in advance to facilitate a quick check of alignment and to this end the use of a laser beam is
recommended. After this check, when necessary, the corresponding corrections can be made to the equipment
train alignment status.
8.5. Other aspects to be considered when commissioning machines
8.5.1. Permanent filters:
The installation and cleanliness of the filters located in the different circuits that affect the equipment shall be
checked.
8.5.2. Critical equipment:
Due to their complex nature, certain types of equipment may require the presence of the Vendor's technical
staff when installed and started up. In these circumstances, during commissioning, the specific instructions
provided by this technical staff in writing shall be followed; under all circumstances, an agreement shall be
reached in advance with the Plant staff responsible for commissioning work.
8.5.3. Critical speeds:
In case any machine has critical speeds below its operating speed, this shall be considered in order to avoid
such speeds during start-ups, shut-downs and, essentially, during operation. Said speeds shall be indicated in
places deemed appropriate as direct information for Production staff.
8.5.4. Marking the equipment:
During commissioning, all equipment shall be marked individually with its corresponding item, using plates that
shall be installed in visible places and serve as a reference for all staff working with them, mainly Production
and Maintenance.

EC-B-54.00-01a
OPERATING SYSTEMS
8.6. Recording dynamic equipment commissioning
The commissioning of machines and their auxiliary systems shall be recorded using the following protocols,
1a included in the specification EC-A-50.00 “Pre-commissioning and Commissioning Test Protocols”:
 DI-K.02 Installation and alignment checking for pumps, blowers, fans, air-coolers and mixers check
sheet (Commissioning)
 DI-K.03 Special equipment check sheet
 DI-K.04b Oil mist lubrication system check sheet (Commissioning)
 DI-K.05b Turbines and gears check sheet (Commissioning)
 DI-K.06b Diesel engines check sheet (Commissioning)
 DI-P.04 Motors check sheet (Commissioning)
These protocols shall be completed and included in the original dossier for the corresponding operating
system; they shall later be included in the Final Quality Control Book which shall be kept by the Owner on
completion of the project.
9. STANDARDS AND SPECIFICATIONS OF REFERENCE

1a
9.1. Repsol standards and technical specifications
9.1.1. Construction specification
EC-A-50.00 Pre-commissioning and Commissioning Test Protocols
10. INDEX OF TABLES INCLUDED IN THIS SPECIFICATION
TABLA I. CLEANING TREATMENTS DEPENDING ON THE SERVICE

TABLA II. PROGRESS ASSOCIATED TO EACH CLEANING PHASE
TABLA III. OVERALL PROGRESS OF CLEANING WORKS BY WEEKS
TABLA IV. OIL FLUSHING: ACCEPTANCE CRITERIA ACCORDING TO API 614
TABLA V. OIL FLUSHING: CODE OF POLLUTION LEVEL FOR SOLID PARTICLES ISO 4406
11. APPENDIXES
APPENDIX I DEFINITION OF OPERATING SYSTEMS

APPENDIX II DEFINITION OF CIRCUITS TO BE CLEANED
APPENDIX III LIST OF CLEANING ACTIVITIES BY CIRCUITS
APPENDIX IV PROCEDURE FOR HANDLING AND CONTROLLING BLIND DISCS FOR COMMISSIONING
APPENDIX V TABLE FOR MONITORING PROGRESS OF CIRCUIT CLEANING ACTIVITIES
APPENDIX VI EXAMPLE OF A CLEANING ACTIVITIES PROGRESS GRAPH
1a APPENDIX VII FLEXIBLE HOSE BY-PASSES IN LUBRICATION CIRCUITS. EXAMPLES.

EC-B-54.00-01a
OPERATING SYSTEMS
APPENDIX I
DEFINITION OF OPERATING SYSTEMS
EC-B-54.00-APPEND
IX I-01a.xlsx
See attached file EC-B-54.00-APPENDIX I-01a.xlsx
This table shall be completed as shown in the following example:
EC-B-54.00-APPEND
IX I Example-01a.xlsx
See attached file EC-B-54.00-APPENDIX I Example-01a.xlsx
APPENDIX II
DEFINITION OF CIRCUITS TO BE CLEANED
EC-B-54.00-APPEND
IX II-01a.xlsx
See attached file EC-B-54.00-APPENDIX II-01a.xlsx
This table shall be completed as shown in the following example:
EC-B-54.00-APPEND
IX II Example-01a.xls
See attached file EC-B-54.00-APPENDIX II Example-01a.xls

EC-B-54.00-01a
OPERATING SYSTEMS
APPENDIX III
LIST OF CLEANING ACTIVITIES BY CIRCUITS
EC-B-54.00-APPEND
IX III-01a.xlsm
See attached file EC-B-54.00-APPENDIX III-01a.xlsm

The attached file shows the instructions to be followed for completing the above form.
EC-B-54.00-APPEND
IX III Instructions-01a
See attached file EC-B-54.00-APPENDIX III Instructions-01a.pdf
This form shall be completed as shown in the following example:
EC-B-54.00-APPEND
IX III Example-01a.xls
See attached file EC-B-54.00-APPENDIX III Example-01a.xlsm

EC-B-54.00-01a
OPERATING SYSTEMS
APPENDIX IV
PROCEDURE FOR HANDLING AND CONTROLLING BLIND DISCS FOR COMMISSIONING
IDENTIFICATION AND RECORDING:

The blind discs required to isolate the plant and the different circuits (lines and/or equipment) for cleaning
activities included in commissioning shall be defined by Production and listed in the table “Sequence of
Activities” under Appendix III List of cleaning activities by circuits.
Production shall give this list to Construction, attaching the corresponding installation diagrams (marked on the
P&IDs or on sketches) showing the sites established for inserting or changing the position of the discs as
required and also indicating, where applicable, the sequences for positioning and removing them.
The blind discs (BD) installed for commissioning work in order to isolate the cleaning circuits shall be recorded
and monitored in the above mentioned Sequence of Activities table. A specific record shall also be kept of blind
discs for the battery limit and equipment blind discs using the form indicated below, which shows the required
status (blind or open) of the disc before beginning start-up activities (S/U record). Each piece of equipment or
battery limit (B.L.U.) shall have a single record, identified by its number or tag.
EC-B-54.00-APPEND
IX IV-01a.xlsx
See the form for recording blind discs for start-up works in the attached file
EC-B-54.00-APPENDIX IV-01a.xlsx
Production and Construction shall identify and mark the discs to be put in position on-site.
Once the list of discs is available and after checking the status on-site, Construction shall analyze the
conditions and prepare the resources and safety measures required for their implementation.
Once installed on-site, identification (plate of a certain size, shape and color, distinctive for the purposes of
commissioning work) shall be placed on all the blind discs used for commissioning. This element shall indicate
the disc number and the S/U record number to which it belongs, as applicable.
For discs that are used in different tasks on different circuits, an entry shall be made in all the corresponding
records (“Notes” column in the table “Sequence of Activities” and/or for blind B.L.U. discs and for sealing
equipment, the “Disc common to circuit No.” column shall be filled out in the mentioned BD records for S/U);
furthermore, as many identifications as necessary shall be placed on the disc on-site (different plates, each
one with the disc number corresponding to each task). Furthermore, a red danger sign shall be placed on disks
used for different tasks on-site. Once work on a circuit ends and the disc is no longer required for that circuit,
the corresponding plate shall be removed, with an entry made in the “Observations” column of the
corresponding record that the disc has not been removed as it also belongs to another/other circuit/s. To
remove the blind disc affected by different tasks (or reinstall if it has to remain installed once the
commissioning tasks are completed), all associated tasks shall have been signed off as complete in all the
records and all the plates shall have been removed. Production shall check that all works have been completed
and authorize Construction to remove the red sign. The blind disc may then be removed (or put in place, as
necessary); its removal shall be shown in the last record affected.
Production shall be responsible for keeping the disc records updated as regards of signatures for
installing/removing them. At the end of each shift, Construction shall sign-off on the discs that have changed
status. Under all circumstances, the updated record shall be kept by Production.

EC-B-54.00-01a
OPERATING SYSTEMS
INSTALLATION (SEALING):
For points at which a standard disc cannot be placed as it is physically impossible to do so, Construction shall
agree with Production on the type of disc to be used.
It may occasionally be necessary to install separators to keep the lines apart in order to execute the treatment.
Due to their particular importance, the battery limit unit discs shall be marked in blue. Normally these discs are
placed between sets of flanges or on valves in the unit manifold; however, in certain circumstances they may
be placed inside the Unit (for instance, due to blocking problems of the manifold valve).
REMOVAL (OPENING):
Once work has finished and on the provision that express authorization is received from Production,
Construction may remove the blind discs.
During the removal of discs that are used on different lines or pieces of equipment (marked red) all the above
precautions shall be taken.
Battery limit discs (blue mark) shall remain closed while cleaning is ongoing and they shall be placed in the
normal operating position when the preparing for start-up works begin, pursuant to their turning priority
sequence established by Production.
VALIDATION PRIOR TO START-UP:

Once completed the cleaning works, Production shall check all the B.L.U. BDs and equipment sealing to
ensure that they are in the correct position (blind/open) for the start-up; said department shall sign the
corresponding final checks in the “Record of Blind Discs for S/U” forms.
In case Production is not the organization in charge of the start-up, these records shall also be validated by the
organization responsible for the systems start-up.

EC-B-54.00-01a
OPERATING SYSTEMS
APPENDIX V
TABLE FOR MONITORING PROGRESS OF CIRCUIT CLEANING ACTIVITIES
EC-B-54.00-APPEND
IX V-01a.xlsx
See attached file EC-B-54.00-APPENDIX V-01a.xlsx
This form shall be completed as shown in the following example:
EC-B-54.00-APPEND
IX V Example-01a.xls
See attached file EC-B-54.00-APPENDIX V Example-01a.xls
APPENDIX VI
EXAMPLE OF A CLEANING ACTIVITIES PROGRESS GRAPH
U613_MEROX
FLUSHING ACTIVITY PROGRESS
Progress
System handover progress Flushing activities progress

EC-B-54.00-01a
OPERATING SYSTEMS
APPENDIX VII
FLEXIBLE HOSE BY-PASSES IN LUBRICATION CIRCUITS. EXAMPLES
EXAMPLE OF A BY-PASS CONNECTION DIAGRAM:

A) Example of a by-pass lay out in an oil system lubrication circuit.
The oil is by-passed to the drainage system.
NORTH
VISOR OLD
GIMPEL
OLD
VISOR FLANGE
VISOR VISOR
VISOR VISOR
VISOR
COUPL
VISOR
DISCHARGE
VISOR OIL FIRING SYSTEM
NEW POWER
GIMPEL PISTON BLOCKED
INTAKE
VENTCO
LUBRICATION
EXAMPLE OF A LIST OF MATERIALS FOR MANUFACTURING FLEXIBLE HOSE BY-PASSES:

Preparation of this list shall be left until the end, after determining the points to which the by-passes shall be
connected.
QUANTITY DESCRIPTION SIZE MATERIAL

50 Gasket 8” 150 lbs Oil resistance
20 Gasket ¾” 300 lbs Oil resistance
20 Gasket ½” 300 lbs Oil resistance
20 Flange 1” 300 lbs Carbon steel
12 Nipple ¾” NPT Carbon steel
12 Nipple 1” NPT Carbon steel
12 Female connection ¾” NPT Carbon steel
4 “T” connection 1” NPT Carbon steel
2 “T” connection ¾” NPT Carbon steel
4 Gate valve 1” NPT Carbon steel
Oil resistance
25 m Flexible hose Ø int. 1”
Resistance at 5 bar
Oil resistance
15 m Flexible hose Ø int ¾”
Resistance at 5 bar
2
5m Wire mesh 20 mesh Stainless steel
1 m2 Wire mesh 50 mesh Stainless steel
10 tubes Silicone ----- -----
100 Clamps Between ¾” and 1” Stainless steel

EC-B-54.00-01a: Mechanical Commissioning of Operating Systems

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EC-B-54.00-01a: Mechanical Commissioning of Operating Systems

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Construction Specification:

01 SEPTEMBER 2014 FIRST ISSUE. FOR IMPLEMENTATION. E.A.G. E.A.G. A.L.S.

REV. DATE DESCRIPTION PREPARED BY CHECKED BY APPROVED / AUTHORIZED BY

1. PURPOSE .................................................................................................................................................. 3

2. SCOPE ....................................................................................................................................................... 3

3. SAFETY DURING COMMISSIONING OPERATIONS .................................................................................3

4. DEFINITION OF THE OPERATING SYSTEMS TO BE COMMISSIONED ...................................................3

5. CLEANING OF SYSTEMS .......................................................................................................................... 6

6. PROCEDURES FOR EXECUTING CLEANING OPERATIONS ...................................................................16

7. PROCEDURES FOR PREPARING FOR START-UP ..................................................................................29

8. COMMISSIONING OF DYNAMIC EQUIPMENT ..........................................................................................40

9. STANDARDS AND SPECIFICATIONS OF REFERENCE ...........................................................................44

10. INDEX OF TABLES INCLUDED IN THIS SPECIFICATION .........................................................................44

11. APPENDIXES ............................................................................................................................................. 44

TABLE OF CONTENTS © REPSOL S. A. Madrid, last update 2014 - 2019

3. SAFETY DURING COMMISSIONING OPERATIONS

4. DEFINITION OF THE OPERATING SYSTEMS TO BE COMMISSIONED

4.1. General considerations

© REPSOL S. A. Madrid, last update 2014 - 2019

4.2. Identification of the operating systems. Handover priority

© REPSOL S. A. Madrid, last update 2014 - 2019

4.3. Circuits to be cleaned

© REPSOL S. A. Madrid, last update 2014 - 2019

5.1. System cleaning treatments

© REPSOL S. A. Madrid, last update 2014 - 2019

o Nitrogen, from the distribution network.

5.2. Criteria for selecting the cleaning treatment

© REPSOL S. A. Madrid, last update 2014 - 2019

TABLA I. CLEANING TREATMENTS DEPENDING ON THE SERVICE

OPERATING SYSTEM CLEANING TREATMENT OBSERVATIONS

The Licensor's recommendations shall be

Auxiliary Service Systems (AS)

© REPSOL S. A. Madrid, last update 2014 - 2019

5.3. Temporary or provisional materials required for Cleaning Circuits

© REPSOL S. A. Madrid, last update 2014 - 2019

however, specific ones shall be used for nitrogen.

© REPSOL S. A. Madrid, last update 2014 - 2019

© REPSOL S. A. Madrid, last update 2014 - 2019

to perform the above mentioned operations.

© REPSOL S. A. Madrid, last update 2014 - 2019

2.- Graphic representation of Activities per Circuit:

© REPSOL S. A. Madrid, last update 2014 - 2019

VACUUM RESIDUE FROM VACUUM RESIDUE FROM

DRAWING No. DRAWING No. 645-A-J-C10-

© REPSOL S. A. Madrid, last update 2014 - 2019

01…99, for Process and 652-LBU-01…99 for Utilities.

5.5. Monitoring of the progress of cleaning work

TABLA II. PROGRESS ASSOCIATED TO EACH CLEANING PHASE

Phase Ratio (%)

Partial Reinstallation (R) 30

Total Completion (T) 5

© REPSOL S. A. Madrid, last update 2014 - 2019

TABLA III. OVERALL PROGRESS OF CLEANING WORKS BY WEEKS

Systems Progress of cleaning work (%)

5.6. System cleaning material records

6. PROCEDURES FOR EXECUTING CLEANING OPERATIONS

6.1. Flushing Procedure

When flushing a circuit, the following should be considered:

6.1.1. Check the circuit:

© REPSOL S. A. Madrid, last update 2014 - 2019

6.1.2. Before starting flushing operations:

6.1.3. Flushing the circuit: