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Solar Turbines A Caterpillar Company SPECIFICATION CLEANING AND FLUSHING OF HYDRAULIC SYSTEMS/COMPONENTS cot | SPECIFICATION NO. ES 2184 ISSUED: evel (Date and PRD No.) 1 REVISION: F (Letter, Date and Releasing Document) Topas ‘Seme | A; 10/28/98; PRD 65884-2 S| 8; 12/11/01; PRD 14614-1 EFeco)) c} 04/11/03; CR 04655 1; 07/11/06; CR 12954 E; 02/12/97; PRD 62555-1 Signature & Title Prepared By: Don Cameron, [Consulting Design Engineer, Systems Engineering and [Controls Development ATTENTION "This copyrighted work and the information herein is proprietary to Caterpillar Inc., Solar Turbines Incorporated, andlor subsidiaries of ether, Without express writen permission from Caterpillar Inc, or Solar Turbines incorporated, any copying, disclosure, or use except that for which it is loaned, is prohibited.” i Caterer: Confidential GREEN Solar Turbines A Caterpillar Company CONTENT Paragraph Page 1.0 SCOPE 2 2.0 APPLICABLE DOCUMENTS. 2 3.0 PREPARATION FOR FLUSHING 3 4.0 PROCEDURE 4 5.0 ACCEPTANCE CRITERIA 6 6.0 POST FLUSH PROCEDURE 6 7.0 LUBE OIL COOLERS 6 8.0 PUMP ASSEMBLIES 7 Appendix A CLEANING OF OIL TANK INTERNAL SURFACES 9 AND TANK VENT PIPING ‘Appendix B PICKLING AND PASSIVATION OF PIPEWORK AND EQUIPMENT 10 TABLE Table Page 1 Flow Rates for Reynolds Number (Nr) = 4000 5 FIGURE Figure Page 1 ‘Typical Flushing System 4 2 Typical Pump Assembly Flushing System 8 1 CCaterilar: Confidorsial GREEN Solar Turbines Specification No. ES 2184 ‘A Caterpillar Company 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 oll 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 fil) system Seal ol interconnect lines Lube oil coolers Lube oi! interconnect lines Lube pump assemblies Reservoirs, tanks, and tank vent piping require mechanical cleaning only, per Appendix A. Note: this specification covers the flushing requirements for components (such as the turbine package, the lube oll cooler assembly and interconnect piping) at the suppliers facility, the Solar Turbines Incorporated manufacturing plant, and in the field. The procedures described herein have a universal applic The turbine package is normally flushed prior to delivery and only the external cooler interconnect lines and the coolers need to be flushed in the field ifthe turbine package integrity is maintained and if the fill cil meets the cleanliness requirements of Section 5.0 of this specification. Any residual debris on the turbine package that is generated during shipment should be easily and immediately removed with the package fitter. The lube oil coolers are pre-flushed at the supplier's facility to the cleanliness levels of this specification, but a field flushing of the oil cooler is recommended as a result of external factors related to transportation and storage prior to the lube oil cooler installation. Any interconnect piping that is used to connect the cooler to the package shall be cleaned to the ‘Acceptance Criteria of this specification, as shown in section 5.0. 2.0 APPLICABLE DOCUMENTS Solar Specifications ES 9-224 — Specification For Lubricating Oils For Use In Solar Gas Turbines 'S 9-248 — Corrosion Preventive Oil For Long Term Preservation Io ther ISO 4406 - ISO Cleanliness Code ISO 11171 — Calibration of Automatic Particle Counters ‘ASTM D6439.05 Standard Guide for Cleaning, Flushing, and Purification of Steam, Gas, and Hydroelectric Turbine Lubrication Systems 2 Caterpillar: Confidential GREEN Solar Turbines Specification No. ES 2184 ‘A Caterpillar Company 3.0 PREPARATION FOR FLUSHING Rust, scale, machining chips, grit blast, weld slag, ete. shall be thoroughly removed from all tanks, vessels, pipes, etc. prior to flushing, Tank internal surfaces, tank vent piping and vessels shall be cleaned per Appendix A. Pickling and passivation of carbon steel pipe work and equipment shall be treated, prior to being flushed, as per Appendix B. Stainless steel piping is recommended, as it does not need to be pickled. Interconnect piping needs to be designed in a fashion that facilitates proper cleaning, as referred by ASTM D6439-05. 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. Flushing pump of sufficient capacity 2, Flushing fuid heater 3, Flushing fluid fiter rated at 5 micron with an efficiency of 99.5% or better (Beta ratio, Bs = 200 or better) to remove contamination from flushing loop. 4, 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 5, Particle Counter (per ISO 11171) to determine fuid cleanliness (ISO 4406) or optical fiter patch kit 6. Flow measurement device for each piping leg or component. 7. Thermometer(s) 8, Dead blow hammers or pneumatic vibrators. 9. Flushing lud thatis compatile withthe mineral based oils in Solar ES 9-224 10. Flushing oil reservoir. The reservoir is normally contained in a flushing ig 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 oll re-enters the tank (see Fig. 4, Note 4), 3 Caterpillar: Confidential GREEN Solar Turbines Specification No. ES 2184 ‘A Caterpillar Company TH Fst opto FS2 (1) et > > Vy i FSS, FS 1 —Seetion or 1 : VH1 Being FM1 - Flow FS1 - Strainer, Flush Pump FS2 - Filter, Flush F83 - Inspection Screen or . ; F84- Strainer, Fill Pump OO ESS -Fiter Fil 6 - Filter, Flust FS4 0 P2 FSS HY Heater (may be in Pt - Pump, Flusi P2- Pump, Fill Tit - Temperature VHt - Valve, Figure 1. Typical Flushing System 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 centritugal pumps are required 4, Ifthe required flushing sequence on page 2 isn't followed or if the package lube oll tank is used instead of a separate fil system, then FS6 should be installed to prevent contamination of the package lube oll tank. 4.0 PROCEDURE The following flushing sequence is required to minimize the possibility of contamination of components and assemblies. It is to be followed at the manufacturing facilities and in the field. Adherence to this sequence as prescribed in Figure 1, will substantially minimize the effort and the time necessary to successfully complete the flushing operations. Each flow line, cooler, etc. shall be flushed at a flow r and temperature so that a minimum Reynolds number of 4000 is achieved through each section, or 150% of design flow, whichever is applicable, The Reynolds number can be calculated by: _3160:GPM CS-D Nr 4 Caterpillar: Confidential GREEN Solar Turbines Specification No. ES 2184 A Caterpillar Company Where GPM = flushing fluid flow rate - gallons per minute CS = flushing fluid viscosity - centistokes D = pipertube 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’ TABLE 1 FLOW RATES FOR REYNOLDS NUMBER (NR) = 4000 ‘GPM REQUIRED FOR NR = 4000 W/C32 OIL BOF OIL | 120°F Ol | 150° On aacs | 21cs_ | 125¢s PIPE/TUBE SIZE (0.375 X 0,049 tube. 0.50 X 0.049 tube 0.75 X 0.049 tube 7.0 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 v7.4 51.5 30.7 3.0 Sch 40 pipe 186.4 81.6 48.5 4.0 Sch 40 pipe 244.5 107.0, 63.7 6.0 Sch 40 pipe 368.5 161.2 96.0 Required Flushing Sequence Pre-filter the package fll oll or flushing oil to ISO 16/14/12 cleanliness level. Loop flushiter the flushing rig, and any associated piping, that is considered part of the flushing system, at the maximum capacity of the rig/ flushing system to ISO 16/14/12 and no 100-mesh screen captured particles. (Note; Steps a & b can be done together if the flushing rig has its own oil reservoir) a) (This step does not apply for cooler manufacturers.) Do not flush package oll 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 flushfiter to ISO 16/14/12, and no patticles captures on 100 mesh screen. b) (This step does not apply for cooler manufacturers.) Add the off-skid cooler interconnect piping to the flush loop (without package or cooler connection) and flushvflter to ISO 16/14/12 and no 100 mesh screen captured particles. Other means of cleaning the cooler interconnect piping may be used, however, the same ISO 16/14/12 cleanliness requirements shall be met. ¢) Add the cooler (as described in Section 7.0) to the flush loop and flushfiter to the cleanliness criteria mentioned in Section 5.0. The minimum average Reynolds number in oil cooler headers is 4000. il 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. Dead blow hammers and /or pneumatic vibrators should be used to help break loose and dislodge debris inthe piping. Subjecting the piping to several thermal cycles (hot flushing fluid/cold flushing fluid) will also 5 Caterpillar: Confidential GREEN Solar Turbines Specification No. ES 2184 A Caterpillar Company 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 fiters 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 described in Paragraph 5.0. For factory flushing or field flushing where the components may not cap the cover flanges to Section 6.0 e immediately installed. Seal and/or 5.0 ACCEPTANCE CRITERIA The following flushing acceptance criteria shall be met for the following conditions, ‘A. Flushing of components at the manufacturing facility: such as turbine package and lube oll cooler assembly shall meet Section 5.1 and 5.2. B. Field flushing of: the oll fil, flushing rig, cooler lines and cooler assembly shall meet Section 5.1 at 5.1. 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), 5.2 There are no visible particles on the 100 mesh screen, or no more than § non metallic particles no larger than 0.010 inch (0.254 mm) in the 25 micron bagi). 6.0 POST FLUSH PROCEDURE Aiter 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. 7.0 LUBE OIL COOLERS Air/Oil Cooler Air to oll coolers are to be flushed per the procedure shown in section 4.0 and shall meet the cleanliness. acceptance criteria of section 5.0 of this specification. Water to Oil Coolers 1. Plate and Frame Water to Oil Coolers Since the "plate and frame” type water to oll coolers can be inherently clean with clean assembly procedures, and since a Reynolds number of 4000 may not be achievable, these coolers should only need to be flushed to the following conditions. a. Flow: 1.5 times the design flow b. Temperature: 150 F c. Duration: At least 1-hour before a fluid sample can be taken and the strainers or fier bags at the outlet of the flushing rig can be inspected. . Direction: The direction of the oil flow shall be both in the forward and reverse, starting with the reverse direction of flow first. . Cleanliness Acceptance Criteria: These coolers must meet the acceptance criteria of section 5.0 of this specification, 2. Shell and Tube Water to Oil Coolers Ona shell and tube cooler the oil flows through the baffles and not the tubes. The pressure created inside the cooler when trying to achieve a turbulent flow that is equivalent to a 4000 Reynolds, 6 Caterpillar: Confidential GREEN Solar Turbines Specification No. ES 2184 A Caterpillar Company number, may surpass the vessel's design pressure. Based on the above reasons, it is recommended that the shell and tube type water to oil coolers be flushed to the following conditions: ‘a. Flow: 1.5 times the design flow b, Temperature: 150 F cc. Duration: At least 1-hour before a fluid sample can be taken and the strainers or filter bags at the outlet of the flushing rig can be inspected 4. Direction: The direction of the oil low shall be both in the forward and reverse, starting with the reverse direction of flow first. @, Cleanliness Acceptance Criteria: These coolers must meet the acceptance criteria of section 5.0 of this specification, Dual coolers with transfer valves assemblies Every precaution shall be taken to ensure and maximize the cleanliness of the internal sections of the transfer valve and interconnect piping assembly prior to assembly. Doing this will reduce the total flushing time required to achieve the Cleanliness Acceptance Criteria. The complete dual water to oil cooler and transfer valve assembly shall meet the same cleanliness acceptance criteria of section 5.0 of this specification prior to shipment. 8.0 PUMP ASSEMBLIES ‘Apump assembly is defined as an integrated assembly comprising pump(s), manifolds and valves. The assembly process can inject mill scale and liquid sealant, which must be removed by flushing with clean cll to meet the following criteria: (See Figure 2). ‘a, Flow: 1.0 times design flow. b. Temperature: 150 . cc. Duration: Atleast 1-hour before the strainers or filter bags at the outlet of the pump assembly can be inspected. d. Cleanliness Acceptance Criteria: Must meet the acceptance criteria of section 5.2 of this specification, 7 Caterpillar: Confidential GREEN Solar Turbines Specification No. ES 2184 ‘A Caterpillar Company ™ FSS FS1— Strainer, Pump Suction TI — Temperature indicator FS3 — Inspection Screen or Filter Bag P2_— Pump, Kidney Loop FSS — Filter, Kidney Loop Figure 2. Typical Pump Assembly Flushing System 8 Caterpillar: Confidential GREEN Solar Turbines Specification No. ES 2184 A Caterpillar Company 10 20 3.0 APPENDIX A CLEANING OF OIL TANK INTERNAL SURFACES AND TANK VENT PIPING Surface Preparation ‘A. Abrasive blast to produce a grayish metallic near white surface with 1 mil minimum profile depth. B. Steel plugs shall be used tor 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. C. 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. D. _Allpipe assemblies that will become part of the base assembly must be blasted internally and swabbed clean before being installed E. Lube oil tank covers are to be painted to Solar system "E” unless otherwise specified by ‘engineering drawing. F. Manifolds which are welded into oll tank covers shall be unpainted on the section that is, internal to the tank G. _ Tank associated vent piping is to be mechanically cleaned per section 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 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 manufacturer’ instructions. ® Caterpillar: Confidential GREEN Solar Turbines Specification No. ES 2184 A Caterpillar Company 1.0 APPENDIX B PICKLING AND PASSIVATION OF PIPEWORK AND EQUIPMENT All carbon steel piping shall be pickled to the following minimum requirements: 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 non- ferrous components to avaid damage. Piping shall be dismantled in suitable sections to ensure sutticient 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 195 F 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 150 F) 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/tlushing 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 175 F for an adequate duration. ‘The piping shall be thoroughly rinsed after passivation with potable water. Alter rinsing the piping shall be drained of water and air dried with hol, dry, filtered air at 150 to 170 F, 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. 10 Caterpillar: Confidential GREEN DOCUMENT TITLE : OPERATION & MAINTENACE MANUAL, ITEM NO. ITEM DESCRIPTION DOCUMENT NO. : _ SNO-M-4500122555-MA-032 REQUISITION NO. MGT 210 PURCHASE ORDER NO. 4500122555 SNO-ST-4023 Steam Turbine Generator (STG) Oarprovep Owirn COMMENT OREVIEWED OREsupMir This approval or review does not relieve the vendor subcontractor of his responsibilities to meet all requirements of the purchase order oriaiNaL | cuekep | APpp(rRs) SIGN DATE SAMSUNG ENGINEERING CO. 25.06.2014 Tit issue Barsik Rib Rib REV DATE DESCRIPTION | PREPARED BY | CHECKED BY ‘APPROVED BY SENORO GAS DEVELOPMENT PROJECT PROJECT NO. : SU2873 & a TRIPATRA-SAMSUNG CONSORTIUM. TRIPATRA sausunc excacennc ‘TRIPATRA-SAMSUNG CONSORTIUM SIEMENS | siemens Turbomac ery Equipment GmbH ‘A Operating manual SIEMENS. 6 Assembly and disassembly 6.3.9 6.3.10 6.3.11 68 Flushing of lube oil lines The oil system is supplied in clean and flushed condition. If no work is performed on the oil system, repeated flushing of the oil system is not nec- essary. Contamination of the oil system with foreign substances is to be avoided. Lube oil lines that are installed on the construction site must be flushed with lube oil. © _ notice Not flushed lube oil pipes It lube oll pipes are not tlushea, dit particles may cause damage to important machine and ac- cessory components + Flush the pipes. Separate lube oil ines from the bearing housing or gearbox. Lead separated lube oil lines into the return lines via a bypass line (e.g. tube). Fill the oll tank with lube oil at least up to the minimum oil level mark. Switch on oil supply u © Dirt particles will accumulate in the filter. Flush lines until no more dirt particles accumulate in the filter, 6. Clean oil filter after flushing. 7. Reconnect the lube oil lines. aes Assemble accessories "Rocumentation an accessories" Filling the oil tank with lube oil * Oil tank and filling opening must be clean * Fill in lube oil through a filling filter + Fill oil tank up to maximum oil level mark ~ (In case of initial filing, lube oil must be refilled after initial commissi + Plug filing opening + Record type of lube oil used ng) ils must not be mixed Oils by different manufacturers and of different types or qualities must not be mixed. In case of initial filling, the oil must be refilled after commissioning. EQUUI9086621 Vers.0 DOCUMENT TITLE : OPERATION MANUAL DOCUMENT NO. REQUISITION NO, PURCHASE ORDER NO. SNO-M-45001 2030 MGCi10 4500120300-0 ITEM NO, SNO=PK-5101/5201 ITEM DESCRIPTION PROPANE REFRIGERANT PACKAGE MATERIAL CLASSIFICATION : ea APPROVED O WITH COMMENT ISSUED OOREVIEWED OResusmir JUN. 16, 204 la [riPtis approval or review does not relieve the vendor subcontractor of his responsibilities to meet all requirements The purchase order FOR FINAL p ORIGINAL | CHEKED | APPD(PRI) SIGN DATE SAMSUNG ENGINEERING CO., LTD. c TUN.162014 FOR FINAL DILEE TH HWANG SSLEE m2 TUN05.2014 FOR APPROVAL DILEE TH HWANG SSLEE BI ‘APR29.2014| FOR APPROVAL, DILEE TH HWANG: SSLEE B MAR312014 FOR APPROVAT DALE TH HWANG SS LEE REV DATE DESCRIPTION | PREPAREDBY | CHECKED BY | APPROVED BY SENORO GAS DEVELOPMENT PROJECT PROJECT NO. : SU2573 TROL, inated TRIPATRA-SAMSUNG CONSORTIUM, TRIPATRA-GAMSUNG CONSORTIUM AUNew Bos NEWTEMS CO., LTD. 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OU} JO SQUDWWIOJIEd OU} UO JOeYe JOeJIP D spy >0M Bulysn|s lO . aM Sie WEN 8 ¢ repre po nmRoe nc el Ayye}odg jroweBeueyy ABroug jog moly Sia WON'S "NOA yueYUL oPH Set HENS Senoro LNG Project Acid Gas Removal Design OASE® Operating Guidelines Project No : 3924 Project : Senoro LNG Project Location : Indonesia Owner : JOB Pertamina — Medco E & P Contractor : Samsung Engineering Revision A Revision Date : 19 Nov 2012 CONFIDENTIAL ‘The information contained in this document is confidential and may not be disclosed to others or reproduced or used for any purpose whatever, without the written consent of BASF East Asia Regional Headquarters Ltd Table of Contents 1 Cleaning procedure. 1.1 General Aspects 12 Pre-leaning 1.3 Preparation for flushing by water circulation, 1.4 Flushing with 3% (wt) potash solution 1.5 First condensate / demineralized water flush 1.6 Second condensate / demineralized water flush 2 OASE" solution - Preparation and Activator system, 2.1 Absorption mechanism 2.2 Solution strength 23 Activator content 2.4 Water quality 25 Chloride level 2.6 Solvent make-up 2.7 Solvent storage of OASE” Premix, 2.8 Storage of used OASE" Solution 2.9 Minimum solution temperature 3° Start-up procedure 3.1 Measures prior to start-up. 3.2 Preparing the OASE" solution 3.3. Passivation step prior to the very first startup 3.4 Regular start-up 3.5 Time required for start-up 4 Operating instructions 41 Copslip 4.2 Adjustment of solution flow rate 4.3 Foaming problems 4.4 Antifoam agent, 4.4.1 General recommendations for antifoam dosage 44.2 Amere!™ 1500 443° Other antifoam agents, 4.5 Filter operation, 4.6 Regular Solvent Analyses 4.7 Gas Analyses. eevaoreuvey 10 10 10 a 2 2 B B 15 15 15 16 v7 18 19 19 2 2 2 2 23 23 24 24 25 CONFIDENTIAL The information contained in this document is confidential and may not be disclosed to others or reproduced or used for any purpose whatever, without the written consent of BASF East Asia Regional Headquarters Ltd, 48 49 4.0 aan 4az Reduced load operation Pressure drop in columns Corrosion inhibitor Heat tracing Environmental Aspects 5 _ Effects of a variation of operating parameters sa 52 53 84 55 56 57 58 59 General Aspects Solvent circulation rate Lean solution temperature Feed gas temperature Feed gas pressure Stripper overhead pressure Reboiler duty Solution strength Concentration of activator system 6 — Shut-down and de-inventorying procedure 6a 62 63 64 Measures p 3 to an inspection Change-out of packing when H,Sis present in the feed gas Storing the solution in the storage tank Heating the stored solution 2 2s 26 26 26 28 2 2 2 2 29 2 30 30 at 32 32 34 34 35 CONFIDENTIAL The information contained in this document is confidential and may not be disclosed to others or reproduced or used for any purpose whatever, without the written consent of BASF East Asia Regional Headquarters Ltd, OASE® Process Technology Projet Soro NGAGRU O:= BASF Owner 428 Pertamina - Medco E & P The Chemical Company Dee. OASE Operating Guidelines Page 3 of 36 Project No, 3924 Rev. A 1 Cleaning procedure 4.4 General Aspects The cleaning procedure prior to the start-up of an OASE® unit consists of the following steps: + Pre-cleaning ‘+ Preparation for flushing by circulation + Potash solution flush + First condensate / demineralized water flush + Second condensate / demineralized water flush For new plants, all five cleaning steps above are usually required. For revamps and solution swaps, the scope of cleaning work has to be decided individually, based on the actual condition of the system. According to BASF's experience, the following rules of thumb can be given Anytime a new piece of equipment is installed into an operating OASE® acid gas removal unit, it needs to be degreased by a potash solution flush even when the flushing can be limited to the affected parts. Note that new packing is usually oily due to the manufacturing process. Even so called "degreased" packing, which can be ordered from the manufacturers, typically contains more oil than can be tolerated in the OASE® process. Hence, a potash cleaning step is also required in this case. A Cleaning of the packing outside the columns is also possible. 1.2 Pre-cleaning The pre-cleaning of the unit is done by air or steam-blasting and by water-flushing using fire or plant water hoses, Thereby, coarse grime which may have been introduced during construction is removed. The vortex breaking packing should not yet have been installed at this stage of the cleaning procedure. * open manholes and bottom drains of the columns and tanks * remove orifice meters in the liquid lines and, in advance, close the taps in the impulse pressure line connections * plate and frame heat exchangers should be disconnected or bypassed during the initial cleaning steps until the plant is sufficiently clean. Otherwise, they could get plugged rapidly. CONFIDENTIAL The information contained in this document is confidential and may not be disclosed to others or reproduced or used for any purpose whatever, without the written consent of BASF East Asia Regional Headquarters Ltd OASE® Process Technology Projet Soro NGAGRU O:= BASF Owner 428 Pertamina - Medco E & P The Chemical Company Dee. OASE Operating Guidelines Page 4 of 36 Project No, 3924 Rev. A ‘+ flush the equipment with water using fire or plant water hoses ‘+ clean lines in sections in the same manner It is recommended to remove the grease and oil from the vortex-breaking packing outside the columns. The reason for this recommendation is that during the caustic flushing step, sludge and debris usually gathers in the bottoms of the columns, which can only be removed when the vortex breaking packing is not yet installed. On the other hand, the oil from this packing needs to be removed, which can be done effectively by using a caustic or potash solution. In general the same chemicals, temperatures, procedures, etc. as for the cleaning of the plant can be applied. The cleaning can eventually be carried out in a pit or in a container, which can be heated up using steam, The cleaning can then be done by submerging big bags with the packing in the solution and leaving them there for some time. Afterwards, the caustic solution shalll be flushed away. Appropriate safety measures are required. The vortex-breaking packing should not be installed before the first condensate / demineralized water flush (see section 1.5 of this handbook) to allow for easy removal of solids and sludge. 1.3. Preparation for flushing by water circulation The following steps should be taken to prepare the system for flushing by circulating aliquid: ‘+ Install strainers on the suction side of the pumps ‘+ Check that the pumps are not mechanically blocked by coarse grime ‘+ Check operation of all remote-controlled actuators and control valves ‘+ Check operation of all equipment activated by the safety shutdown system (simulate shutdown conditions) + Leak test by pressurizing the system with nitrogen, e.g. to 1 barg. Check the flanges and cover seals on the columns and tanks, which were opened for the water flush for gas leakage using a suitable indicator (e.g. soap solution), 1.4 Flushing with 3 % (wt) potash solution Before any alkaline flush is carried out, some operators prefer to have an acid flush first to remove some scale and rust. If an acid flush step (using citric acid or similar) CONFIDENTIAL The information contained in this document is confidential and may not be disclosed to others or reproduced or used for any purpose whatever, without the written consent of BASF East Asia Regional Headquarters Ltd OASE® Process Technology Sena UNG AGRU O:= BASF Project Owner Location Dee. Project No, JOB Pertamina - Medco E & P The Chemical Company Indonesia OASE Operating Guidelines Page 5 of 36 3924 Rev. A is carried out, a water flush has to follow, before flushing with 3% (wt) potash solution starts, The following steps should be taken to prepare the system for flushing with a 3% (wt) potash solution: Prepare the solution from condensate or demineralized water and potash (K2CO3). The pH value of this solution is about 12. A technical quality of potash can be used, It is recommended to keep the chloride content of the potash solution below 100 to 500 ppmwt. This corresponds to a chloride content of the water-free potash of 0.34 to 1.65 %wt., calculated as CI. Higher chloride contents should be avoided due to corrosion concems. Instead of potassium carbonate, tri-sodium-phosphate (NasPO.), sodium carbonate, sodium hydroxide or potassium hydroxide can be applied. The pH value is higher in these cases (pH 13 and 14, respectively). Therefore, it is not recommended to exceed the maximum temperature of 70°C (158°F) to prevent corrosion damage of the equipment. A higher concentration than 3% (wt) is possible and might be recommended for plants with very dirty equipment. In practice, NaOH solution with a concentration of up to 5% (wt) has been applied successfully. Introduce the solution into the plant at a suitable location, e.g. at the bottom of LP flash vessel Pressurize the absorber to approximately 3 to 5 barg with nitrogen. In the regenerator and LP flash, a pressure of 0.1 to 0.5 barg might be maintained by means of the pressure controller in the CO2 off-gas line. Circulate the solution through the system for about 8 hours at a temperature of 50 to 70°C (122 to 158°F) at full flow rate. For this purpose the solvent circulation pumps have to be taken in operation according to the vendor's instructions. As soon as steady conditions are achieved, check the circulation rate by means of the FIC valve positions. Simultaneously, the level indicators should be checked. Flushing of the regenerator overhead lines and condenser can be done by overflowing the level to the reflux vessel and returning to the regenerator system. An alternative is to clean the overhead condenser with potash and water before installation then flush the overhead lines with steam after installation of the condenser. CONFIDENTIAL The information contained in this document is confidential and may not be disclosed to others or reproduced or used for any purpose whatever, without the written consent of BASF East Asia Regional Headquarters Ltd OASE® Process Technology Sena UNG AGRU O:= BASF Project Owner Location Dee. Project No, JOB Pertamina - Medco E & P The Chemical Company Indonesia OASE Operating Guidelines Page 6 of 36 3924 Rev. A Full flow rate means 100 % of design flow rate. Pumps and spare pumps should be taken into service and cleaned one after the other, Do not operate all pumps simultaneously in order to avoid an extremely high flow rate, which could exceed the hydraulic limits of the plant Empty the entire system. Take liquid samples. If the potash solution after flushing is extremely dirty, the potash or caustic flushing step will have to be repeated, eventually several times. This applies especially to plants which are very dirty or rusty, ¢.g. new plants in hot and humid climate zones. In most cases, two potash or caustic flushing steps is enough. Remove and clean strainers in the pump suction lines, Re-install the suction side strainers of the pumps. In case the waste water has to be neutralized prior to disposal, the neutralization must be carried out outside the CO2 removal unit. 1.5 First condensate / demineralized water flush The following steps should be taken for the first flushing with condensate / demineralized water: Install the carefully cleaned additional packing for the bottom section (vortex breaking packing) into the bottom of the absorber (and hp flash, as applicable). Reinstall orifice meters. Plate and frame heat exchangers can be taken on line, They should be protected by strainers in order to prevent plugging. The first water flush is carried out as described in section 1.4. The water is, initially heated to about 70 °C (158 °F) and the system is flushed for about 5 hours at full flow rate. The flow rate can be indicated by means of the reinstalled orifice meter. Full flow rate means 100 % of design flow rate. Pumps and spare pumps should be taken into service and cleaned one after the other, Do not operate all pumps simultaneously in order to avoid an extremely high flow rate, which could exceed the hydraulic limits of the plant CONFIDENTIAL The information contained in this document is confidential and may not be disclosed to others or reproduced or used for any purpose whatever, without the written consent of BASF East Asia Regional Headquarters Ltd OASE® Process Technology Project Owner Location Dee. Project No, SerroTNS ASAD O= BASF JOB Pertamina - Medco E & P The Chemical Company Indonesia OASE Operating Guidelines Page 7 of 36 3924 Rev. A 1.6 Second condensate / deminer: Take a liquid sample from the water used for flushing and add about the same volume of OASE® to the sample so that the specified amine ‘concentration is approximately met, Check this diluted amine solution for foaming activity (see separate manual: "Analysis Manual for the BASF OASE® Process"), The foaming tendency is considered low when the foam volume is not higher than 300 mL and the collapse time 30s or less. However, a somewhat higher foaming tendency during operation can be ‘compensated by an increased antifoam dosage rate. Compare the result of the foam test with a foam test carried out with a mixture of OASE® and demineralized water. This blind test gives you the baseline for the foam tests carried out with samples from the system. Check the pH value of the solution. The pH value should be < 9. A higher pH value indicates too high a potassium carbonate content. Drain the water and check the suction strainers for dirt If the flushing water is clean, the foaming tendency is low (foam volume < 300 mi and collapse time < 30s) and the pH value is not too high, the second condensate / demineralized water flush can be omitted. ed water flush The following steps should be taken for the second flushing with condensate / demineralized water: The flush is carried out as described for the potash solution in section 4 Circulate the water through the system for about 6 hours at full flow rate and simultaneously raise the temperature to the operating temperature. Take a liquid sample from the water used for flushing and add about the same volume of OASE® to the sample so that the specified amine concentration is approximately met. Check this diluted amine solution for foaming activity. If foaming activity exceeds the guidelines, a repeat of the caustic flushing with 3 % (wt) potash solution according to section 1.4 , followed by condensate / demineralized water flushes according to section 1.5 and 1.6 as described above should be considered. Check pH of the solution. The pH value should be < 9. A higher pH value indicates too high a potassium carbonate content. CONFIDENTIAL The information contained in this document is confidential and may not be disclosed to others or reproduced or used for any purpose whatever, without the written consent of BASF East Asia Regional Headquarters Ltd OASE® Process Technology Project Senoro LNG AGRU Owner JOB Pertamina - Medco E & P Location —_ Indonesia Dee. OASE Operating Guidelines Project No. 3924 O- BASF The Chemical Company Page 8 of 36 Rev. A ‘+ Ifthe flush water is clean, the foaming tendency is low (foam volume < 300 ml and collapse time < 30 s) and the pH value is not too high, the OASE® can be charged. Otherwise, flushing with 3 %(wt) potash solution and/or the demineralized water flush has to be repeated. A foam volume not higher than 300 mi and a collapse time of 30 s or less are required for a low foaming tendency. + However, these figures still have to be compared with the results of a blind test (foam test with a mixture of pure OASE® and demineralized water), Which defines the baseline for the foaming tendency. Better values than in the blind test can usually not be achieved. After the final water flush, the content of particles in the wash water should be small ‘As a rule of thumb, the solid content can be judged as follows: <10 ppm (wt.) solids: excellent <50 ppm (wt.) solids: good <100 ppm (wt.) solids: acceptable A higher content of solids usually leads to an excessive foaming tendency. In this case, further flushing is required. CONFIDENTIAL The information contained in this document is confidential and may not be disclosed to others or reproduced or used for any purpose whatever, without the written consent of BASF East Asia Regional Headquarters Ltd ‘Senoro Gas Development Project Joint Operating Body Pertamina HALDOR TopsoE [7 Job $-03284 Doc. P47001 Rev. 0 Medco E &P Tomori Sulawesi 1185 JOB NO. DOC. NO. REV. Joint Operating Body 9608 Peramioamwicoeae tener | 9608 | swo.nasnotootsa- | 0 awe 80-001 & | a CONTRACT NO.: | Ko498R/JOBT/MDP TRIPATRA ‘SAMSUNG ENGINEERING TRIPATRA-SAMSUNG CONSURTIUM __| SENORO GAS DEVELOPMENT PROJECT Operating guidelines close sa pars witout writen approval of Hada Tapeae NS r Approved Senoro Gas Development Project HALDOR TopsoE fF) Joint Operating Body Pertamina Job $-03284 Doc. P47001 Rev. 0 Medco E &P Tomori Sulawesi 17/85 + Open the continuous blow-down valve, BDV-4024 B, and the manual valve, BDV-4024 C, positioned in bypass around the intermittent blow-down valve®, BDV-4024 A and let the water drain out completely once the clarity of the drained condensate is acceptable. 27 Boil-out of steam system The boil-out, also referred to as alkaline cleaning”, should be conducted in accordance with standard/local/clientienduser procedures or in accordance with the procedure described below. It must, however, be noted, that the boil-out of the boilers must be conducted in accordance with recommendations issued by the manufacturer of the specific boilers (refer to Supplier's documentation). in principle, alkaline cleaning is executed with a solution of sodium triphosphate (NasPO,) and sodium hydroxide (NaOH), using the method commonly known as the “breathing method’, ie. the pressure of the system is increased and decreased repeatedly and in a stepwise manner. The fluctuations in pressure will loosen the rust and scale, which is subsequently removed by draining, The boitout is usually done in steps until the normal operating pressure is reached or limited to the pressure of the steam available for heating. The boil-out procedure is divided into two steps: = Atmospheric boil-out + Pressure boil-out 274 Atmospheric boil-out Atmospheric boil-out is performed at low pressure, close to atmospheric pressure. Preconditions: + Flushing of the steam system has been conducted (refer to section 2.6). + All instruments, which are not needed during the boikout, should be blocked off or removed during the boi-out process. Actions: = Inactivate all active trip signals to interlock I1 and reset interlock 1 = Inactivate all active trip signals to interlock I:3 and reset interlock 3 = Inactivate all active trip signals to interlock 5 and reset interlock 5. + Activate trip signal to interlock I-6 and ensure SDV 4013 A is closed = Ensure that all valves in the start-up steam import lines are closed * The intermittent blow-down valve is operated with a hand lever with a spring return and therefore itis recommended to use the mechanical valve positioned in the bypass around the blow-down valve when empiying the steam drum This is to avoid having to hold the hand lever while emptying the steam drum. Itis important that the valve in the bypass is only used when there is litle or no pressure in the steam drum as the high pressure drop over the valve can damage the valve. " alkaline cleaning: a combination of fushing and boil-out, ‘declone oid pares witout writen approval ot Haldar Tapsae NS Senoro Gas Development Project HALDOR TopsoE fF) Joint Operating Body Pertamina Job $-03284 Doc. P47001 Rev. 0 Medco E &P Tomori Sulawesi 18/85 + Chemicals corresponding to a concentration of 0.3 wt.% NasPOs (approx 167 Ib) and 0.025, wL% NaOH (approximately 14 Ib) ate added through the manhole into the steam drum, SNO-V-4024. + The manhole of the steam drum, SNO-V-4024, is closed. + The steam drum, SNO-V-4024, is filled with boiler feed water until minimum level" is reached (similarly to the procedure described in section 2.6), = Alter filing, partially open the steam drum vent and open fully the vent valve in the steam to steam turbine, SNO-ST-4023 line, PV-4013 A. + Start steam generator, SNO-H-4045, follow the vendor instructions to start. + Start heating by importing start-up steam = When the pressure in the steam drum, SNO-V-4024, is 30 psig, start the blow-down operation + Blow down the steam drum, SNO-V-4024, continuously through the continuous blow-down valve, BDV-4024 B. * Blow down the waste heat boiler, SNO-E-4012, and the steam drum, SNO-V-4024, intermittently through the intermittent blow-down valve, BDV-4024 A, every hour. = After each blow-down, gradually close the vent on the steam drum SNO-V-4024, to raise the pressure to 30 psig = Subsequently open the steam drum vent to depressurize to 0.0 psig + After 24 hours, close the steam drum vent and raise the pressure to 37 psig, stop the heating and blow down the steam system under pressure. + After the atmospheric boil-out, flush the system at least twice (refer to section 2.6). = When the steam system has cooled down, carry out inspection to ensure that the system has been adequately cleaned. 272 Pressure boil-out Pressure boil-out is performed at high pressure, closest possible to normal operating pressure (refer to Appendix 11). Note: if found advantageous, the pressure boil-out procedure can be performed at the same. time as the first heating-up (refer to section 3,2) in order to attain a higher boil-out pressure. Preconditions: = Atmospheric boil-out has been performed (refer to section 2.7.1). + All instruments, which are not needed during the boil-out, should be blocked off or removed during the boi-out process. Actions: + Inactivate all active trip signals to interlock |-1 and reset interlock I-1. + Inactivate all active trip signals to interlock |-3 and reset interlock I-3. + Inactivate all active trip signals to interlock |-5 and reset interlock I-5. "Filing to only minimum level is recommended in order to ensure sufficient void volume in the steam drum for the condensing steam at these intial conditions. ‘declone oid pares witout writen approval ot Haldar Tapsae NS Senoro Gas Development Project HALDOR TopsoE fF) Joint Operating Body Pertamina Job $-03284 Doc. P47001 Rev. 0 Medco E &P Tomori Sulawesi 19/85 = Activate trip signal to interlock 1-6 and ensure SDV 4013 A is closed + Ensure that all valves in the startup steam import lines are closed = Chemicals corresponding to a concentration of 0.3 wt.% NasPOs (approx 167 Ib) and 0.025 wt.% NaOH (approximately 14 Ib) are added through the manhole into the steam drum, SNO-V-4024. + The manhole of the steam drum, SNO-V-4024, is closed. + The steam drum, SNO-V-4024, is filled with water (BFW) until minimum level”? is reached (similarly to the procedure described in section 2.6). * After filing, close the steam drum vent and open fully the vent in the steam to steam turbine, SNO-ST-4023 line"?, PV-4013 A. + Start steam generator, SNO-H-4045, follow the vendor instructions to start. + Start heating by importing start-up steam. = Raise the pressure in the steam drum, SNO-V-4024, to 45 psig by adjusting the steam drum pressure controller, PIC-4024 A. + When reaching 45 psig, partially open the steam drum vent and allow the pressure to drop by 30 psig = Close the steam drum vent again and raise the pressure to 90 psig (by PIC-4024 A) and subsequently allow the pressure to drop by 30 psig (by the steam drum vent valve). * Continue this procedure up to as close as possible to the normal operating pressure (refer to ‘Appendix 11) as possible". Each step (pressurising and depressurising) should last at least 2 hours. The rate of depressurising should be significantly higher than for pressurisation. + Maintain the pressure at the highest possible level for at least 4 hours, controlling the pressure by venting if required. * Maintain the liquid level in the steam drum, SNO-V-4024; at the normal operating level (refer to Appendix 11). If required, lower the liquid level by using the intermittent blow-down valve, BDV-04024 A. * Finally, slowly vent out the steam to safe location through the vent valve in the steam to steam turbine, SNO-ST-4023 line, PV-4013 A = After the pressure boil-out has been completed, drain the water from the steam system through the intermittent blow-down bypass valve", BDV-4024 C. + Flush out the boiler system, ie. fill the steam drum, SNO-V-4024, with water, pressurise to about 7.0 psig by start-up steam generator, SNO-H-4045, and drain subsequently. = If the final inspection leads to any doubt about the cleanliness of the boiler system, the pressure boil-out must be repeated Filing to only minimum level is recommended in order to ensure sufficient void volume in the steam drum for the condensing steam at these intial conditions. "At this stage, steam from the WSA plant can not be sent to steam turbine, SNO-ST-4023 as neither pressure nor temperature is acceptable. The higher limit of the achievable pressure is determined by the available pressure of the start-up steam. * The intermittent blow-down valve is operated with a hand lever with a spring retum and therefore its recommended to-use the mechanical valve positioned in the bypass around the blow-down valve when emptying the steam drum. ‘This is to avoid having to hold the hand lever while emplying the steam drum. Itis important that the valve in the bypass is only used when there is tle or no pressure in the steam drum as the high pressure drop over the valve can damage the valve. ‘declone oid pares witout writen approval ot Haldar Tapsae NS Senoro Gas Development Project HALDOR TopsoE fF) Joint Operating Body Pertamina Job $-03284 Doc. P47001 Rev. 0 Medco E &P Tomori Sulawesi 20/85 2.8 Deaerator Before the deaerator, SNO-V-4027 is set into operation it is boiled out using the same procedure as indicated for the steam system (refer to section 2.7 ), After boil out packing materials are installed and the Deaerator, SNO-V-4027 is ready to be taken into operation. 29 Conservation of steam system If the boilers are not put into operation immediately (i.e. in a manner of days) after the boil-out has been completed, they should be preserved. It is recommended to use a dry preservation method (refer to section 2.9), but other preferred standard preservation procedure can be used instead, if found advantageous. The dry preservation method is based on the fact, that even in the presence of air, no corrosion can take place inside the boilers, provided the relative humidity of the air is always below 50%. Actions: + The system is completely drained of water through the continuous and intermittent blow- down and the drain valves. = The remaining water vapour is completely purged out through the steam drum vent and the vent valve in the steam to steam turbine, SNO-ST-4023 line, PV-4013 A + The dryness of the system is ensured by blocking in the boiler system and providing a low, but permanent flow of nitrogen or dry, oifree air, e.g. instrument air, through the system while maintaining a small positive pressure ‘declone oid pares witout writen approval ot Haldar Tapsae NS