Oil Flushing Procedure for Hydraulic System of Coal Mill

Date : 5th January 2012

Project Name : Oil Flushing Service for hydraulic Pipe lines of Coal Mill, Unit # 3 PLTU
Asam- Asam 2 x 65, South Kalimantan
Provided by : PT. Maxima Energi Indokemika

A. Project Descriptions
1. Scope of Work & Supply Descriptions
a. Install piping system, hydrotest & chemical cleaning if Responsible by PT. Wika
required
b. Cleaning Hydraulic tank Responsible by PT. Wika

c. Define installation of by pass hoses at hydraulic system Responsible by PT. Maxima

based on drawing of hydraulic system provided by Chengda
Responsible by PT. Wika
d. Provide and Install by pass Hose and Connections
Responsible by PT. Wika
e. Provide flushing oil with quantity 2 drums
f. Transfer flushing oil from drums to The Tank of Oil Flushing Responsible by PT. Maxima
unit
g. Oil Flushing Operation Responsible by PT. Maxima

h. Oil Cleanliness Test (NAS 1638 Standard Test) Responsible by PT. Maxima

i. Dismantle by pass hoses and re-connected hoses or pipes Responsible by PT. Wika
to the hydraulic system ready for commissioning
j. Provide Oil flushing daily report and Cleanliness Test Responsible by PT. Maxima
Report

2. Flow rate of oil Flushing Pump Required

Flow rate of Oil Flushing pump required based on oil flushing procedure provided by CHENGDA and Given By
PT. Wika is 40 lpm and rating of filter element 10 micron with Cleanliness Target NAS 1638: Grade 7

3. Oil Flushing unit Provided by PT. Maxima

- Flow rate : 60 LPM
- Pressure : 10 Bar (max)
- Filtration System : 3 micron
B. Procedure of Oil flushing

1. Preparation
- Place Oil Flushing unit close to the hydraulic system
- Place flushing Oil drums close to oil flushing unit
- Install by hoses at hydraulic valves and pistons as shown at drawing defined by PT. Maxima
(contact Person at site : Mr. Rio & Mr. Probo)
- Install Sampling point at return line

2. Transfer Flushing Oil From Drums to Tank of Oil Flushing Unit

- Open flushing oil drums and place Inlet Hose of oil flushing pump in the drum
- Open Inlet Hose of oil flushing pump and start the pump to transfer the flushing oil
- Stop the oil flushing pump when 2 drums of flushing oil has been completely transferred to Tank of
Oil Flushing unit
- Close inlet valve of oil flushing pump and connect the inlet hose to Tank of oil flushing unit

3. Oil Flushing Operation

- Connect outlet hose of Oil Flushing Pump to Inlet of the Hydraulic system and return line hose from
Tank of Oil Flushing Unit to outlet of the hydraulic system
- Open Valve of outlet oil flushing pump and valve of return line
- Start Oil Flushing pump
- Start Heater units and set temperature at 60 °C
- Check connections and make sure no leakage during oil flushing operation
- Stop the pump if found leakage at connections
- Fix the leakage and re-start the oil flushing pump

4. Oil Cleanliness Test

- Take oil sample after 3 hours oil flushing operation
- Check The cleanliness every 30 minutes
- Stop the oil flushing pump when cleanliness achieved is NAS 1638: Grade 7
- Signed the Cleanliness report by the representatives

5. Post Oil Flushing Operation

- Disconnect inlet hose of oil flushing pump and return line hose of oil flushing unit Tank
- Dismantle by pass hoses and connections at hydraulic system
- Re-connected the hydraulic system