Flushing Guidelines PDF

ABB France Division Process Automation 3BFR4 B09166 E01 1000 08
Cellier Activity
Issued by Department Revision Page
FRFRA/PA A 1 / 29
Customer Plant ABB Contract No. Customer Contract No.
CHEVRON PAKISTAN KARACHI PLANT B09166 PO 001 01 37199
FLUSHING PROCEDURE
AFTER PIPING INSTALLATION OF LOBP

AND PROTECTION OF ABB’s EQUIPMENTS
PROJECT: SUPPLY OF CORE PROCESS EQUIPMENT
FOR KARACHI PLANT UPGRADE
A 13/06/17 First issue J. Tournier S. Laurent S. Dessolin

ABB Cellier ABB Cellier ABB Cellier Client
Rev. Status Date Description of the modification Written by Checked by Approved by Approved by
Date/Visa Date/Visa Date/Visa Date/Visa
Ce document est la propriété exclusive d’ABB Cellier. Il est interdit d’en faire usage ou de le communiquer sans autorisation préalable.
This document belongs to ABB Cellier. It is prohibited to use or transmit it without our prior consent.
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CONTENTS
1. PURPOSE ....................................................................................................................... 4
2. DOCUMENTS OF REFERENCE .................................................................................... 4
3. GENERAL REQUIREMENTS FOR FLUSHING ............................................................. 4
4. PRESSURE TESTS OF PIPELINES ............................................................................... 5

4.1 PRINCIPLE ................................................................................................................................ 5
4.2 COMPANY'S SPECIFIC OBLIGATIONS ................................................................................... 6
4.3 COMPANY'S RESPONSABILITY .............................................................................................. 6
4.4 COMPANY'S REPORT .............................................................................................................. 6
5. FLUSHING ACTIVITIES.................................................................................................. 7
5.1 PRINCIPLE ................................................................................................................................ 7
5.2 PROCESS & INSTRUMENT AIR LINES UPSTREAM TO ABB SUPPLY ................................. 7
5.3 TANKS ....................................................................................................................................... 7
5.4 SUCTION PIPES UPSTREAM PUMP ........................................................................................ 8
5.5 PROCESS PIPES DOWSTREAM PUMP ................................................................................... 8
5.6 ABB EQUIPMENT (SKID).......................................................................................................... 8
5.7 PIGGED LINES ( NOT RELATED TO MANIFOLD) ................................................................... 8
5.8 PIGGABLE MANIFOLD ........................................................................................................... 10
5.9 PIGGED LINES ( UPSTREAM AND DOWNSTREAM OF MANIFOLD) ................................... 10
5.10 STEAM & CONDENSATE LINES ............................................................................................ 11
5.11 DRAINING OF PIPELINES ...................................................................................................... 11
5.12 COMPANY'S REPORT ............................................................................................................ 11
6. PROTECTION OF ABB CELLIER SKIDS .................................................................... 12

6.1 FLUSHING LINES TO ILB SKID.............................................................................................. 12
6.2 FLUSHING LINES TO SMB SKID ........................................................................................... 15
6.3 FLUSHING LINES TO DRUM DECANTING SYSTEM............................................................. 18
6.4 FLUSHING LINES TO AUTOMATIC BATCH BLENDER / COCKTAIL TANK / VII ................. 21
6.5 FLUSHING LINES UPSTREAM AND DOWNSTREAM OF MANIFOLD TO PIGGABLE
MANIFOLD ....................................................................................................................................... 24
6.5.1 FOR INLET LINES 24
6.5.2 FOR OUTLET LINES 27
7. SAFETY AND ENVIRONMENT .................................................................................... 29

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1. PURPOSE
The purpose of this document is to establish the flushing procedure between the piping installation
of Lube Oil Blending Plant and the ABB equipment.
This procedure has to be followed carefully in view to protect sensitive equipment such as pumps,
flow meters, air regulators, steam traps, pigged valves and others which will be installed on pipes
lines and also to obtain, from the very first batch, a good level of produced oil in terms of clearness.
A part of this document is also dedicated to pressure tests done after construction completion
because this activity is relatively close and linked to flushing activity.
2. DOCUMENTS OF REFERENCE
Documents of reference are all last revisions of deliverable documents sent by ABB in Transmittals
from project B09166.
3. GENERAL REQUIREMENTS FOR FLUSHING

- As a general rule, the flushing activities will be performed per piping system after the installation
of the equipment.
- Prior to flush, pipes & accessories network will need to be mechanically receipted and therefore
pressure tested.
- The flushing of the plant shall be carried out by an experienced test engineer who shall have no
other duties during that task. The test engineer shall be mobilised sufficiently early to familiarize
himself with the specific job in hand. Flushing schedule will have to be issued a month before
flushing starts to make sure that site co-activities will be coordinated in a safe manner.
- The process lines and hot oil heating circuits have to be exclusively flushed with rinsing oil.
- The utilities lines like process water, service, fire, steam and condensates have to be water or
steam flushed.
- Instrument air and process air lines shall be cleaned with compressed air.
- For liquid media, the minimal amount of flushing fluid have to be at least 3 times the volume of
the pipeline to be flushed if recirculation is not possible (minimum indicative value).
- The use of temporarily hoses, spool pipes, blind flanges, iso-container or strainer (250µ) will be
needed for this operation.
- The drainage of the flushing fluid from the pipe network shall be by gravity when possible, or air
blowing or pigging.

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- Each ABB Cellier’s equipment (case of skid) is already tested, flushed and cleaned in
workshop, and has to be disconnected from the rest of the plant during flushing activities.
- A follow-up document is recommended to know the cleanliness of the pipes and their status.
- Attention: Flushing activity is not intend to remove rust into pipe. The rust has to be removed
before construction.
4. PRESSURE TESTS OF PIPELINES

Note: COMPANY = company in charge of pressure tests
4.1 PRINCIPLE
Pressure test has to be completed before flushing of the pipelines, latest during flushing. Anyhow
for flushing using liquid media, it must be done before liquid recirculation.
As a general rules, pressure tests are done at 1.5 times the max operating pressure of each line
and are performed in accordance with Customer or local contractor procedure and rules.
A special attention has to be given to the pigged lines. Indeed the pigged line has to be tested
at 3 different phases of the construction:
- Phase 1:
At the time of prefabrication, before mounting in the rack and without pigged equipment.
Accordingly, the pressure for tests can be as per normal pipe.
- Phase 2 Optional:
At the end of pipe construction and without pigged equipment installed. Accordingly, the
pressure for tests can be as per normal pipe. (Using spool replacing pigged equipment).
Phase 3:
At the end of the complete construction of the pigged line including pigged equipment
mounting.
Important note: Phase 3 has to be done only after flushing of the pigged line. The
flushing procedure of one pigged line is described in section 5.7:
The recommended steps for this phase 3 are:

a) Flushing, refer to section 5.7
b) A first leak test with air at 6 barg
c) Then a last pressure test with oil, the pressure test should not exceed 12 barg.
To practice this test, pigged equipment shall be connected to air instrument with a minimum
pressure of 5 barg, in order to avoid being free of movement.

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4.2 COMPANY'S SPECIFIC OBLIGATIONS
During the elaboration of the "test systems", some equipment will be an integral part of the system
to be tested (if in conformity with the specification of the piping class).
THE COMPANY in charge of the tests will proceed as follows:
- Perform a complete verification in order to be sure of the definition and conformity with the
drawings and engineering documents (piping class, rating of flanges, quality of seals, etc. ...)
· Preparation of the test file

· Checking of the test pressure for each system.
· Verification of the compatibility of the equipment with the required test pressure (see
§ 2 ref document + technical documentation)
· Implementation of the isolation and protection systems for the equipment and
accessories of which the test pressure would be lower than the piping pressure.
- Take all precautions to avoid the deterioration of the equipment.
- Disassemble safety valves, control or regulating valves (replaced by spool pipes) and other
regulation units as well as reassembling after cleanings and/or tests.
- Protect electric and pneumatic sensitive equipment in case of any liquid projection.
4.3 COMPANY'S RESPONSABILITY
The COMPANY will be responsible for all failures which may occur, either during the tests, or due
to the fact that they have not taken all necessary steps to empty completely the circuits after the
tests (in particular in case of frost).
4.4 COMPANY'S REPORT
A test report has to be issued by Company and has to be available at the request of ABB Cellier.

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5. FLUSHING ACTIVITIES
5.1 PRINCIPLE
Flushing principle:
Cleaning of the system by flushing with fluid (liquid or gas) until total elimination of internal waste.
Fluid media:
- For Instrument air and process air lines: Compressed air ( Dry air / 25 µm max)
- For the process lines and hot oil heating circuits: Oil ( 175 µm max)
- For utilities lines like process water, service, fire, steam and condensates: water or steam
flushed.
Draining:
The evacuation of flushing fluid will be carried out at the pipe extremity, as near as possible to the
connections of the equipment which will be temporarily protected. Equipment which may suffer
from blocking or damage must be disconnected (pumps, compressors, exchanger…)
5.2 PROCESS & INSTRUMENT AIR LINES UPSTREAM TO ABB SUPPLY
As process & instrument air lines are needed for others flushing works, it is strongly advised to
proceed of flushing of air networks as first step.
Blowing of the upstream side to ABB equipment should be carried out. All air regulators shall be
disconnected and protected from the dust or foreign matters.
Note: Air lines from ABB equipment shall not be flushed because they are considered clean when
installed.
5.3 TANKS
In a first time, all base oil storages tanks, additives storages tanks, minibulks tanks, holding tanks
and dedicated tanks will have to be cleaned manually by entering in the tanks itself (if possible)
and removing all dust, steel or other materials. Bases and walls of tanks will have to be brushed by
tissues or blooms containing base oil. Surfaces states must be perfect after this operation.
In some case, tanks can be delivered with special rustproof oil to prevent rust until final use of the
tanks. In case of rustproof oil isn’t compatible with fluid which will be allocated in the tank, it should
be cleaned taking into recommendation of rustproof oil supplier, then rinse with Base oil.

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5.4 SUCTION PIPES UPSTREAM PUMP
Suction pipes from tanks to pumps or others facilities to pumps will have to be cleaned manually
before mounting by removing all dust, steel or other materials to ensure that pumps will be fully
protected of damage caused by impurities.
5.5 PROCESS PIPES DOWSTREAM PUMP
Process pipes from pumps to blenders, kettles, Drum Decanting System, ILB, SMB or piggable
manifold will have be flushed with base oil using 3 times the volume of the length of the pipes.
5.6 ABB EQUIPMENT (SKID)
Each ABB Cellier’s equipment is already tested, flushed and cleaned in workshop, and has
to be disconnected from the rest of the plant during flushing activities.
As general rules, it is recommended to install removing spools upstream to the ABB

equipment in order to simplify the flushing operation.
Illustrations are shown in chapter 6.
If some modifications are done after start-up or during production, each existing ABB
Cellier’s equipment would be probably already cleaned in production or will be cleaned
separately, then shall be disconnected during flushing procedure.
5.7 PIGGED LINES ( NOT RELATED TO MANIFOLD)
Before proceed to the flush of one pigged line, the following requirements have to be completed:
- The pigged line construction has to be completed and pressure tests as defined in
section 4.1 have to be done (phase 1 and phase 2 optional).
- Then, pigged equipment have to be mounted on the line including pigged stations and
In-line equipment like twin valves, distribution valves or others
- They have to be connected to instrument air (5 barg min)
- They have to be connected to process air (set at 2 barg min)
- One pig has to be available (the one in spare dedicated for flushing and usually
provided by ABB)
- Pigged line has to be in rest position: pigged equipment in close position (pig passing
through the line) and no pressure into the pigged line.

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- One special blind flange in Stainless Steel has to be separately constructed (usually
not supplied by ABB) to proceed to flushing
Refer to below picture
Special blind flange for pigged line flushing
Then the procedure is as follows:

- One pig has to be introduced in the pigged launching station equipped with pig
introduction system.
- The special blind flange has to be connected on the opposite pigged receiving station
Refer to below picture for illustration

Special blind flange mounted on the opposite pigged receiving station
The outlet of the blind flange has to be

connected to a buffer tank or IBC via a
simple flexible or equivalent.
- Some amount of base Oil has to be introduced in the pigged line using product inlet
valve from launching station or nozzle available on the pipe (e.g. PI or PS).
Note: Recommended volume is using 1 m3 of Base Oil equivalent to one IBC.
- When targeted quantity is introduced into the pigged line, a pigging operation has to
be started. Air has to be injected go through air injection from pigged launching station
in order to push the pig. If needed air injection can be manually introduced by forcing
the solenoid valve (s).
- Then pig pushes the base oil and flush the line. When pig is closed to pigged receiving
station, base oil goes out from pigged line though the special blind flange.
- Pig stops against the special blind flange. The special blind flange is in stainless steel
and allow to check if pig is against flange by helping of one pig detector.

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- Finally, the line can be depressurized and special flange dismantled to recover pig.
The shape of the special flange allows extracting easily the pig.
Attention: Before dismantling this special flange, operators have to take care that
there is no pressure anymore in the pigged line.
- If cleanliness is considered acceptable, flushing is finished, otherwise procedure has
to be repeated again until acceptable.
For additional information, refer to specification 3BFR4 ST000 J000014 – Start-up and
maintenance instructions for a pigged line.
5.8 PIGGABLE MANIFOLD
The piggable manifold has been already cleaned when installed.
ABB doesn’t allow any flushing or air blowing passing through the manifold during
flushing period. Lots of sensitive gaskets and internal parts can be damaged quickly.
Inlet pigged or dedicated lines and outlet pigged lines have to be disconnected from the
manifold to be flushed using removable spool pieces (usually not supplied by ABB).
Refer to below chapter and illustration in chapter 6.5 for explanation.
5.9 PIGGED LINES ( UPSTREAM AND DOWNSTREAM OF MANIFOLD)
Pigged / dedicated inlet lines from the manifold

Piggable or dedicated lines upstream to the manifold, called inlet lines, have to be flushed as per
process pipe explained in chapter 5.5 and illustrated in chapter 6.5.1
Then for piggable lines only, an additional flushing has to be done with pig, as per described in
section 5.7.
Depending to the location of pig introduction system (on Manifold or at the opposite end), it is
strongly advised to push pig from Manifold toward end of the line in order to avoid bring back
waste into Manifold.
Pigged outlet lines from the manifold

Piggable lines downstream to the manifold, called outlet lines, have to be flushed as per process
pipe explained in chapter 5.5 and illustrated in chapter 6.5.2
Then an additional flushing has to be done with pig, as per described in section 5.7.
Depending to the location of pig introduction system (on Manifold or at the opposite end), it is
strongly advised to push pig from Manifold toward end of the line in order to avoid bring back
waste into Manifold.

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5.10 STEAM & CONDENSATE LINES
The steam lines must be flushed by steam or water to clear the carbon from the pipe internal.
ABB equipment should be disconnected and by-passed. For the rest of the plant, the sensitive
equipment on those lines are steam traps and piston valves seats that could be jammed or
damaged by foreign matters. They have to be removed and replaced by spool pipes or protected
before flushing.
5.11 DRAINING OF PIPELINES
After flushing, all pipelines except air circuits and pigged lines (special procedure) will be drained
and blown with compressed air to be completely emptied.
5.12 COMPANY'S REPORT
A flushing report has to be issued by Company and has to be available at the request of ABB
Cellier.

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6. PROTECTION OF ABB CELLIER SKIDS
6.1 FLUSHING LINES TO ILB SKID
Solution 1: Cleaning recirculation system

- 2 lines flushed at the same time
- Both tank sources A & B disconnected, transfer pumps not used
- Both connections on ILB disconnected and both feeding lines connected together
with flexible
- Use of special cleaning system with pump to recirculate oil.

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Solution 2:
- 1 line flushed at time
- Tank source used to introduce flushing oil, transfer pump used
- ILB disconnected and end of flushed line connected to one tank, truck, IBC, or
others
- No special cleaning system required

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Solution 3:
- Only one tank source A used to inject flushing oil (can be the same tank used
for all lines flushing), transfer pump A used
- Both connections on ILB disconnected and both feeding lines connected
together with flexible
- End of second flushed line connected to one tank, truck, IBC, or others

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6.2 FLUSHING LINES TO SMB SKID

- Both connections on SMB disconnected and both feeding lines connected together
with flexible

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Solution 2:
- SMB disconnected and end of flushed line connected to one tank, truck, IBC, or
others

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Solution 3:
- Only one tank source A used to inject flushing oil (can be the same tank used for all
lines flushing), transfer pump A used
- Both connections on SMB disconnected and both feeding lines connected together
with flexible

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6.3 FLUSHING LINES TO DRUM DECANTING SYSTEM

- Both connections on DDS disconnected and both feeding lines connected together
with flexible

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Solution 2:
- DDS disconnected and end of flushed line connected to one tank, truck, IBC, or others

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Solution 3:
- Both connections on DDS disconnected and both feeding lines connected together
with flexible

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6.4 FLUSHING LINES TO AUTOMATIC BATCH BLENDER / COCKTAIL TANK / VII
Important note:
If it is not possible to bypass the Blenders, washing nozzles (if any) have to be dismantled and
discharge pump has to be protected with a strainer (175 µm)

- Both connections on ABB / CT / VII disconnected and both feeding lines connected

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Solution 2:
- ABB / CT / VII disconnected and end of flushed line connected to one tank, truck, IBC,
or others

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Solution 3:
- Both connections on ABB / CT / VII disconnected and both feeding lines connected

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6.5 FLUSHING LINES UPSTREAM AND DOWNSTREAM OF MANIFOLD TO PIGGABLE

MANIFOLD
6.5.1 FOR INLET LINES

- 2 inlet lines flushed at the same time
- Both connections on Manifold disconnected and both inlet lines connected
together with a flexible
Note :
- Procedure is suitable for dedicated and pigged lines.
§ For pigged lines, an additional flushing has to be done with pig, as per
described in section 5.7.
Depending to the location of pig introduction system (on Manifold or at the
opposite end), it is strongly advised to push pig from Manifold toward end of
the line in order to avoid bring back waste into Manifold.
§ For dedicated lines, no other additional flushing is required.

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Solution 2:
- 1 inlet line flushed at time
- Tank source used to introduce flushing oil, transfer pump used.
- Manifold disconnected and connected to one tank, truck, IBC, or others
Note :

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Solution 3:
- 2 inlet lines flushed at the same time
inlet lines flushing), transfer pump A used
- Both connections on Manifold disconnected and both inlet lines connected
- End of second flushed lines connected to one tank, truck, IBC, or others
Note :

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6.5.2 FOR OUTLET LINES

- 2 outlet lines flushed at the same time
- No tank source used and filling facilities disconnected
- Both connections on Manifold disconnected and both end of lines connected
Note :
Further to this flushing, an additional flushing has to be done with pig, as per described in
section 5.7.
Depending to the location of pig introduction system (on Manifold or at the opposite end), it
is strongly advised to push pig from Manifold toward end of the line in order to avoid bring
back waste into Manifold.

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Solution 2:
- 1 outlet line flushed at time
- One tank source (from inlet line) used to introduce flushing oil, transfer pump used
- Inlet and outlet removable spools from manifold disconnected, then lines connected
- End of the outlet line connected to one tank, truck, IBC, or others
Note : Further to this flushing, an additional flushing has to be done with pig, as per
Depending to the location of pig introduction system (on Manifold or at the opposite end), it
is strongly advised to push pig from Manifold toward end of the line in order to avoid bring
back waste into Manifold.

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7. SAFETY AND ENVIRONMENT

Identification of potential safety and environmental hazards have to be studied including the
necessary measures and emergency plans needed.
Warning notices reading “keep away – pipeline under test” shall be placed at appropriate locations
while testing. Notice shall be in both English and the local/working language.
The customer or local contractor shall prepare an emergency plan which shall describe actions to
be taken in case of leaks or burst. The emergency plan should include, but not limited to the
following:
- How to deal with washouts and other damage.

- List of equipment or machines available or needed.
- Telephone number of control room which may have to be contacted.
- Locations of medical and first aid facilities.
- Telephone number of medical and other emergency services that may be needed.
Protective clothing, gloves and goggles shall be worn when handling chemicals. A safety shower
and eyes-bath shall be available at appropriate location.
Any leaking flanges visually inspected should be tightened only after the pressure in the test
section is reduced to a safe level (static head + 1 bar)
The tests on site shall be left in a clean condition and free of debris. The waste, chemicals, dyes
etc. shall be disposed of as per the customer disposal requirements.
End of document

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ABB France Division Process Automation 3BFR4 B09166 E01 1000 08

AFTER PIPING INSTALLATION OF LOBP

PROJECT: SUPPLY OF CORE PROCESS EQUIPMENT

FOR KARACHI PLANT UPGRADE

A 13/06/17 First issue J. Tournier S. Laurent S. Dessolin

P:\AXB\5017_B09166\F04_BE_ENG\1_GESTION-BE\7_COMMANDES\SPEC\3BFR4 B09166 E01 1000 08A - Flushing procedure.doc

P:\AXB\5017_B09166\F04_BE_ENG\1_GESTION-BE\7_COMMANDES\SPEC\3BFR4 B09166 E01 1000 08A - Flushing procedure.doc

2. DOCUMENTS OF REFERENCE .................................................................................... 4

3. GENERAL REQUIREMENTS FOR FLUSHING ............................................................. 4

4. PRESSURE TESTS OF PIPELINES ............................................................................... 5

6. PROTECTION OF ABB CELLIER SKIDS .................................................................... 12

7. SAFETY AND ENVIRONMENT .................................................................................... 29

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3. GENERAL REQUIREMENTS FOR FLUSHING

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4. PRESSURE TESTS OF PIPELINES

The recommended steps for this phase 3 are:

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4.2 COMPANY'S SPECIFIC OBLIGATIONS

THE COMPANY in charge of the tests will proceed as follows:

· Preparation of the test file

- Take all precautions to avoid the deterioration of the equipment.

4.3 COMPANY'S RESPONSABILITY

4.4 COMPANY'S REPORT

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5.2 PROCESS & INSTRUMENT AIR LINES UPSTREAM TO ABB SUPPLY

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5.4 SUCTION PIPES UPSTREAM PUMP

5.5 PROCESS PIPES DOWSTREAM PUMP

5.6 ABB EQUIPMENT (SKID)

As general rules, it is recommended to install removing spools upstream to the ABB

Illustrations are shown in chapter 6.

5.7 PIGGED LINES ( NOT RELATED TO MANIFOLD)

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Then the procedure is as follows:

Refer to below picture for illustration

The outlet of the blind flange has to be

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5.8 PIGGABLE MANIFOLD

The piggable manifold has been already cleaned when installed.

Refer to below chapter and illustration in chapter 6.5 for explanation.

5.9 PIGGED LINES ( UPSTREAM AND DOWNSTREAM OF MANIFOLD)

Pigged / dedicated inlet lines from the manifold

Pigged outlet lines from the manifold

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5.10 STEAM & CONDENSATE LINES

5.11 DRAINING OF PIPELINES

5.12 COMPANY'S REPORT

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6. PROTECTION OF ABB CELLIER SKIDS

6.1 FLUSHING LINES TO ILB SKID

Solution 1: Cleaning recirculation system

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P:\AXB\5017_B09166\F04_BE_ENG\1_GESTION-BE\7_COMMANDES\SPEC\3BFR4 B09166 E01 1000 08A - Flushing procedure.doc

P:\AXB\5017_B09166\F04_BE_ENG\1_GESTION-BE\7_COMMANDES\SPEC\3BFR4 B09166 E01 1000 08A - Flushing procedure.doc

6.2 FLUSHING LINES TO SMB SKID

Solution 1: Cleaning recirculation system

P:\AXB\5017_B09166\F04_BE_ENG\1_GESTION-BE\7_COMMANDES\SPEC\3BFR4 B09166 E01 1000 08A - Flushing procedure.doc

P:\AXB\5017_B09166\F04_BE_ENG\1_GESTION-BE\7_COMMANDES\SPEC\3BFR4 B09166 E01 1000 08A - Flushing procedure.doc

P:\AXB\5017_B09166\F04_BE_ENG\1_GESTION-BE\7_COMMANDES\SPEC\3BFR4 B09166 E01 1000 08A - Flushing procedure.doc

6.3 FLUSHING LINES TO DRUM DECANTING SYSTEM

Solution 1: Cleaning recirculation system