SPECIFICATION

CLEANING AND FLUSHING OF HYDRAULIC SYSTEMS/COMPONENTS

Data Control Level

SPECIFICATION NO. ES 2184 REVISION: D

ISSUED: 2/12/97; PRD 62555-1

(Date and PRD No.)

1
Release Stamp

(Letter, Date and Releasing Document)

A; 10/28/98; PRD 65884-2 B; 12/11/01; PRD 14614-1 C; 04/11/03; CR 04655

Rev.

CR

Signature & Title Prepared By: Alex Lapid, Design Engineer Component Engineering & Subsystem Development, PG Approved By: Torben Hoejberg, Field Engineer, Product Support & Commissioning, O & G Approved By: Sam Navidi, Group Manager, Component Engineering & Subsystem Development, PG

Date 6-26-06 6-7-06 7-10-06

Pages Affected

12954 D

1-7

ATTENTION This document contains data pertaining to proprietary designs of Solar Turbines Incorporated. Reproduction, manufacture or use of any assembly, subassembly, or part indicated herein or the use of the design of any such assembly, subassembly, or part is permissible only if expressly authorized in advance and in writing by Vice President of Engineering, Solar Turbines Incorporated.

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Specification No. ES 2184

CONTENT Paragraph 1.0 2.0 3.0 4.0 5.0 6.0 Appendix A SCOPE APPLICABLE DOCUMENTS PREPARTION FOR FLUSHING PROCEDURE ACCEPTANCE CRITERIA POST FLUSH PROCEDURE CLEANING OF OIL TANK INTERNAL SURFACES AND TANK VENT PIPING PICKLING AND PASSIVATION OF PIPEWORK AND EQUIPMENT Page 1 1 1 2 3 3 6

Appendix B

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

FIGURE Figure 1 Typical Flushing System Page 4

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Specification No. ES 2184

1.0 SCOPE - This specification covers the preparation and acceptance criteria for the cleaning and flushing of components and piping used in lube, seal, and hydraulic systems on Solar packages. Proper cleaning and flushing will remove the contamination built into components and systems before operation so that sensitive components do not fail prematurely. Components to be cleaned and flushed include, but may not be limited to the following: Lube oil supply and drain lines; Seal oil supply and drain lines; Servo system supply and drain lines; Hydraulic start system supply and drain lines; Power take off system supply and drain lines; Lube oil reservoir level control (auto fill) system; Seal oil interconnect lines; Lube oil coolers; Lube oil interconnect lines.

Reservoirs, tanks, and tank vent piping require mechanical cleaning only, per Appendix A. Note that this is not a specification for field flushing and the procedures described herein have a universal application. The turbine package is normally flushed prior to delivery, and only the external cooler lines and the cooler needs to be flushed in the field. The cooler is pre-flushed at the suppliers facility, but a field flushing is strongly recommended because of residual debris that is generated due to vibration occurring during shipment. Any residual debris on the turbine package that is generated during shipment should be easily and immediately removed with the package filter. 2.0 APPLICABLE DOCUMENTS Solar Specifications ES 9-224 - Specification For Lubricating Oils For Use In Solar Gas Turbines ES 9-248 - Corrosion Preventive Oil For Long Term Preservation Other ISO 4406 - ISO Cleanliness Code 3.0 PREPARATION FOR FLUSHING - Rust, scale, machining chips, grit blast, weld slag, etc. shall be thoroughly removed from all tanks, vessels, pipes, etc. prior to flushing. Tanks, tank vent piping, and vessels require mechanical cleaning and inspection only, per Appendix A.

Carbon steel piping will require pickling and passivation to properly remove rust and scale per Appendix B before being flushed. Stainless steel piping is recommended as it does not need to be pickled. Sensitive components (bearings, seals, valve, etc) shall be removed or bypassed during the cleaning and flushing to avoid contamination. Equipment required: (See Figure 1 for typical flushing system) 1. 2. Flushing pump of sufficient capacity. Flushing fluid heater.
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Specification No. ES 2184

3.

Flushing fluid filter rated at 5 micron with an efficiency of 99.5% or better (Beta ratio, 5=200 or better) to remove contamination from flushing loop. Flushing fluid strainer(s) (100 mesh or finer) or filter bag(s) (25 micron or finer) at end of each pipe run or component being flushed for cleanliness verification. Particle Counter to determine fluid cleanliness (ISO 4406) or optical filter patch kit. Flow measurement device for each piping leg or component. Thermometer(s). Dead blow hammers or pneumatic vibrators. Flushing fluid that is compatible with the mineral based oils in Solar ES 9-224. Flushing oil reservoir. The reservoir is normally contained in a flushing rig external to the package. However, if the package lube from the lube oil tank is used to flush, then an extra flush loop filter should be installed where the flushing oil re-enters the tank (see Fig. 1, Note 4).

4.

5. 6. 7. 8. 9. 10.

4.0 PROCEDURE - The following flushing sequence is required to minimize the possibility of contaminating previously factory flushed components and assemblies. This assumes a first time flush. Those components previously flushed may be eliminated from the procedure. Adherence to this sequence will substantially minimize the effort and time necessary to successfully complete the final, full system flush. Required Flushing Sequence a) b) c) d) e) Pre-filter the package fill oil and, if applicable, the flushing rig fill oil to ISO 16/14/12 cleanliness level. Loop flush/filter the flushing rig, alone, to ISO 16/14/12 and no 100-mesh screen captured particles. Add the off-skid cooler piping to the flush loop (without package or cooler connection) and flush/filter to ISO 16/14/12 and no 100 mesh screen captured particles. Add the cooler to the flush loop and flush/filter to ISO 16/14/12 and no 100 mesh screen captured particles. Do not flush package oil lines through the bearings of the engine, driven equipment, and gearboxes. Disconnect package oil lines from bearing inlet ports, and loop these lines back to the flushing reservoir. Then flush/filter to ISO 16/14/12 and no 100 mesh screen captured particles.

Each flow line, cooler, etc. shall be flushed at a flow rate and temperature so that a minimum Reynolds number of 4000 is achieved through each section, or 150% of design flow, whichever is greater. The minimum average Reynolds number in oil cooler headers is 4000. Oil coolers with turbulators shall be flushed in both the forward and reverse flow directions. Lines that flow upward for more than 10 feet (3 meters) shall be flushed in a reverse, downward direction at least 33% of the flush time.

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Specification No. ES 2184

The Reynolds number can be calculated by:

Nr =

3160 GPM CS D

Where GPM = flushing fluid flow rate - gallons per minute CS = flushing fluid viscosity - centistokes D = pipe/tube inside diameter - inches Table 1 shows the minimum required flow rates for several pipe and tube sizes. Reynolds numbers in excess of 4000 will increase the effectiveness of the flush and will decrease the flushing time required to achieve the required cleanliness. Proper cleaning of individual details before assembly as well as clean assembly processes will also reduce flush times and reduce contamination hideout. Dead blow hammers and /or pneumatic vibrators should be used to help break loose and dislodge debris in the piping. Subjecting the piping to several thermal cycles (hot flushing fluid/cold flushing fluid) will also help reduce flushing time. Flushing fluid samples shall be taken downstream of the piping or component being flushed and upstream of any end of line filters or screens. The sample location shall be taken from a section with turbulent flow (Reynolds number > 4000). After flushing for at least one hour a fluid sample can be taken and the strainers or filter bags at the outlet of the flushing rig can be inspected. Acceptance criteria is listed in Paragraph 5.0. Reservoirs, vessels, tanks and tank vent piping require mechanical cleaning (only) to remove all visible rust, scale, and debris, per Appendix A. 5.0 ACCEPTANCE CRITERIA - The flush is successfully completed when: 1. The ISO 4406 cleanliness code range numbers for 4, 6, and 14 micron levels are 16/14/12 or lower (particle counter calibration per ISO 11171), and There are no visible particles on the 100 mesh screen, or no more than 5 non metallic particles no larger than 0.010 inch (0.254 mm) in the 25 micron bag(s).

2.

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

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Specification No. ES 2184

TI1 FS1 P1 H1 FS2 FM1

(see Note 4)

FS6

FS3 VH1

Section or Component Being Flushed

FS4

P2

FS5

FM1 - Flow Meter FS1 - Strainer, Flush Pump Suction FS2 - Filter, Flush Loop FS3 - Inspection Screen or Filter Bag FS4 - Strainer, Fill Pump Suction FS5 - Filter, Fill System FS6 - Filter, Flush Loop H1 - Heater (may be in tank) P1 - Pump, Flush Loop P2 - Pump, Fill System TI1 - Temperature Indicator VH1 - Valve, Sample

NOTES 1. Delta P indicators across filters are required. 2. Pump relief valves are required if positive displacement pumps are used. 3. Flow control valves, bypassing for positive displacement pumps, throttling for centrifugal pumps are required. 4. If the required flushing sequence on page 2 isnt followed or if the package lube oil tank is used instead of a separate fill system, then FS6 should be installed to prevent contamination of the package lube oil tank.

Figure 1. Typical Flushing System

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Specification No. ES 2184

Table 1. Flow Rates For Reynolds Number (Nr) = 4000 GPM Required For Nr = 4000 w/C32 Oil 80F Oil 120F Oil 150F Oil 48 CS 21 CS 12.5 CS 16.8 24.4 39.6 54.8 70.0 45.1 58.1 91.1 117.4 186.4 244.5 368.5 7.4 10.7 17.3 24.0 30.6 19.7 25.4 39.9 51.5 81.6 107.0 161.2 4.4 6.4 10.3 14.3 18.2 11.7 15.1 23.7 30.7 48.5 63.7 96.0

Pipe/Tube Size

0.375 X 0.049 tube 0.50 X 0.049 tube 0.75 X 0.049 tube 1.0 X 0.049 tube 1.25 X 0.049 tube 0.75 Sch 80 pipe 1.0 Sch 80 pipe 1.5 Sch 80 pipe 2.0 Sch 40 pipe 3.0 Sch 40 pipe 4.0 Sch 40 pipe 6.0 Sch 40 pipe

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Specification No. ES 2184

APPENDIX A CLEANING OF OIL TANK INTERNAL SURFACES AND TANK VENT PIPING 1.0 Surface Preparation A. Abrasive blast to produce a grayish metallic near white surface with 1 mil minimum profile depth. Steel plugs shall be used for thread protection during the blast and paint process. These plugs shall be removed from all threaded openings and the grit removed by using shop air or vacuuming. Brayco 785 shall be applied to the threads and plastic plugs inserted into the ports. All flange gasket surfaces must be protected during the blast and paint process. Brayco 785 shall be applied to the flange gasket surfaces and shipping covers shall be installed to protect the flange surface and avoid contamination of the lube oil tank. All pipe assemblies that will become part of the base assembly must be blasted internally and swabbed clean before being installed. Lube oil tank covers are to be painted to Solar system E unless otherwise specified by engineering drawing. Manifolds which are welded into oil tank covers shall be unpainted on the section that is internal to the tank. Tank associated vent piping is to be mechanically cleaned per section 2.0

B.

C.

D.

E.

F.

G. 2.0

All residual grit, scale, flakes, or other foreign matter shall be thoroughly removed from the tank or piping internal surfaces before the application of Brayco 785 or other approved preservative fluid. Pipe and manifold sections which are part of the tank assembly as well as the tank vent piping shall be thoroughly cleaned with shop air and have a clean swab or pig drawn through them until the swab or pig is clean of any detectable grit or debris. No residual grit is permitted. No flaky rust or mill scale is permitted. The assembly shall be considered clean when foreign material such as scale, rust, metal shavings, and sand are not visible to the eye and grittiness is not detectable to the touch. Cleaned and preserved piping shall be installed in the system and thoroughly sealed against subsequent external source contamination as soon as practical.

3.0

Application of Brayco 785 or Other Approved Preservative Fluid - Brayco 785 can be applied to a surface showing slight discoloration or oxidation provided that the surface does not have flaky rust or mill scale. Brayco 785 may be applied by spray, roller, or other means as required for coverage of all unpainted surfaces. Other approved preservative fluids shall be applied per the manufacturers instructions. APPENDIX B PICKLING AND PASSIVATION OF PIPEWORK AND EQUIPMENT

1.0

All carbon steel piping shall be pickled to the following minimum requirements:
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Specification No. ES 2184

A.

Ensure that all statutory and safety precautions are taken for carrying out the work and as determined by site conditions. Piping to be cleaned shall be isolated from all equipment, machined surfaces, and nonferrous components to avoid damage. Piping shall be dismantled in suitable sections to ensure sufficient flow of fluids in each section. Each section shall be degreased. Degreasing shall be performed by use of heavy duty alkaline or detergent solutions maintained at 175 to 195F for a duration sufficient to remove oils or greases in the piping. After degreasing the piping shall be thoroughly flushed with potable water to remove all traces of degreasing solution. Acid cleaning or pickling shall be carried out by use of 10% solution of hot (not exceeding 150F) inhibited hydrochloric acid. The piping shall be flushed with acid solution repeatedly until cleanliness is achieved. Pickling shall continue until all loose rust, mill scale, or other foreign materials are not visible in the piping. The strength of the acid shall be monitored to maintain the required concentration and the solution shall be replaced if ferric content exceeds 0.6% by weight. The piping shall be thoroughly rinsed and flushed with potable water as rapidly as possible after the acid cleaning to remove all traces of acid and iron salts to prevent rust. The rinsing/flushing shall continue for 10 minutes after the pH of the effluent water equals the pH of the in going water. Passivation of piping surfaces shall be performed after the pickling and flushing. This will be done by circulating a 3% phosphoric acid solution at 160 to 175F for an adequate duration. The piping shall be thoroughly rinsed after passivation with potable water. After rinsing the piping shall be drained of water and air dried with hot, dry, filtered air at 150 to 170F. Piping that will not be immediately flushed with oil and put into service shall be internally coated or flushed with a preservative oil per Solar ES 9-248, and capped with metal blind flanges or threaded plugs.

B.

C.

D.

E.

F.

G.

H.

I.

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