Cleaning and Flushing.pdf

PRE-COMMISSIONING FOR CLEANING AND FLUSHING PROCEDURE BANUWATI-K GAS COMPRESSOR PLATFORM

CONTRACT NO. 332003115

DATE

COSIGN DISCIPLINE SIGNATURE

PIPING

PAGE 1 OF 7 B3 23-12-2013 B2 16-12-2013 B1 25-08-2013 REV.

DATE

ISSUED FOR REVIEW ISSUED FOR REVIEW ISSUED FOR REVIEW DESCRIPTION

RIZKY

HAFID

RUSAEFUL

PRAWOTO B.HARI W RUSAEFUL

RIZKY

HAFID

RUSAEFUL

BY

CHECK.

REVIEW.

EXAM.

CLIENT CNOOC SES LTD. CERTIFI. NO.

A112002816

PRE-COMMISSIONING FOR CLEANING AND FLUSHING PROCEDURE

DOCUMENT NO.

3115-BWK-PRQ – 021.4

APPRO.

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PRE COMMISSIONING FOR CLEANING AND FLUSHING PROCEDURE CONTENTS Description

Page No.

1. INTRODUCTION

2

2. REFERENCES

2

3. GENERAL REQUIREMENTS

3

3.1 Piping Network to be Flushed

3

3.2 Safety Requirements

3

3.3 Safety Plan

4

3.4 Cleaning & Flushing Requirements

7

3.5 Cleaning & Flushing Equipment

8

3.6 Equipment and Instrument Protection

9

3.7 Personnel Requirement

9

4. CLEANNESS CRITERIA

10

5. CLEANING & FLUSHING

10

5.1 Cleaning & Flushing Preparation

10

5.2 Cleaning & Flushing Execution

11

5.3 After Cleaning & Flushing

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INTRODUCTION

This procedure describes the requirement for cleaning & flushing phase starting from preparation, execution, and acceptance. This procedure outlines requirement for cleaning & flushing at the yard for lines of piping system for Banowati K Project under coordination of Engineering Department, inspection by QA/QC, witness and approval by Contractor / Company. The purpose of the flushing is to ensure that systems to be handed over are clean and free from debris which may damage system equipment.

2.

REFERENCE

-

P&ID and TEST PACK ISOMETRIC

-

ASME/ANSI B.31.3

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ASME/ANSI B.31.8

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API RP 14E MECHANICAL – PIPE TESTING

3.

3.1

GENERAL REQUIREMENT

Piping Network to be Cleaned & Flushed The piping network to be cleaned & flushed can be found from a test pack consisting of line list, color-marked-up P&ID, and the network lay out. This shall be compiled from P&ID system and subsystem. Such guidance shall be issued by Engineering Department for Contractor / Company approval. Then it shall be distributed as coordination to other Contractor parties such as Pre-commissioning Team, QC Department, and Fabrication Department.

3.2

Safety Requirements The Yard Manager will be responsible for safety of all personnel involved in the work, however it will be the responsibility of each individual to ensure that each

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activity is safely performed. The following measure will be taken to effect safe operation: a. Job Safety Analysis (JSA) and a work permit shall be issued prior to each cleaning & flushing operation according to the Sub-Contractor’s safety procedures. b. Cleaning & Flushing schedule and location to be notified to all concern person to ensure adequate safety management in place for the work scope. c. Cleaning & Flushing shall be performed outdoor in good weather condition. d. Safety man shall constantly monitor the discharge area and the whole Cleaning & flushing activity to allow any immediate corrective action. e. Additional protection is required for flushing with rupture disk such as blinds barriers, Protection from thrown material to be on flushing outlet and around flushing area. f. Sufficient warning signs respectively in English and Indonesian shall be posted around the area which detailing: g. People close to the cleaning & flushing area shall use sufficient earplug. 3.3 Safety Plan Detail of safety plan shall be issued by the safety department prior to commencing any hydrostatic test. Hydrostatic test shall be covered by permit. This to include to filling the checklist inspection. 3.3.1 Communication Tool 

Two way Radio, Handy -Talkie



Cellular phone



Clinic standby radio

3.3.2 Personnel In charge for The Hydrostatic Test a.

Coordinator responsible : 

Coordinate the manpower involved during hydrostatic test.



Monitoring the process of work.



Stop the work if any accidental happens. Page 4 of 11 3115-BWK-PRQ – 021.4

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

Stop the work when hydrostatic test completed.



Ensure that calibration certificates still valid.

Supervisor responsible : 

Monitoring the process of work before, during and after hydrostatic test.



Make sure that personnel in charge to work is capable.



Inform to coordinator if there is any problem during hydrostatic test.



Inform to coordinator when hydrostatic test completed.

Safety Officer ; responsible : 

Audit the equipment refer to inspection checklist and monitoring the safety aspect before, during and after hydrostatic test.

 d.

Stop the work if the dangerous will happen.

Safety man responsible : 

Take the precaution and monitor the safety aspect before, during and after hydrostatic test.

 e.

Inform to safety officer if the dangerous will happen.

Medical Team responsible : 

Prepare the first aid kit and ambulance.



Ready for calling if any accident happen and take the first aid to the victim.



Bring the victim to the hospital :

3.3.3 Safety Precaution a.

Safety officer and hydrostatic test coordinator or supervisor check the equipment using inspection check list and sign-off among them and the result shall be distributed to : 

Yard Manager.



Safety Manager.



Production Superintendent.



COMPANY Representative.

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Safety Officer put barricades the area by safety line and display any safety board required and at least at two languages : English and Indonesia.

c.

Supervisor or Safety Officer performs meeting before commencement of the pressure test to the personnel involves. The meeting shall describes :

d.



Explain the task and responsibility to every personnel.



The dangerous that may happen and preventive action.



Necessary action when the accident happen during pressure test.



Explaining the emergency procedure if accident happen during pressure test.

Safety Officer re-checking the border area and safety sign before pressure test commencement.

3.3.4 Safety Action a.

Personnel involve shall use the proper personal protection equipment such: safety helm, safety glass, earplug, hand glove, etc.

b.

Coordinator or Supervisor shall control the personnel involve and make sure that every body on the position and standby on the agreed radio frequency.

c.

Scaffolding and associated attachment to the high point of vessel must be checked and approved before be used.

d.

Pressurizing shall be performed gradually as per mention in par.5.3.1

e.

If a test can create a danger the person in charge shall inform the coordinator.

f.

Coordinator or Supervisor stop the pressure test and solve the problem.

g.

Ambulance and medical team standby and prepare the first aid, etc.

3.3.5

Medical Evacuation Procedure.

If there is any accident during hydrostatic test, the following procedure shall be executed: a.

Call to the safety officer or safety man by radio or verbally.

b.

Safety officer contact the medical team to give the first aid. If there is serious problem the victim shall be sent to hospital by ambulance and accompanied by one personnel officer to handle any administrative requirements.

c.

Personnel officer reports to Yard Manager about victims condition. Page 6 of 11 3115-BWK-PRQ – 021.4

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Personnel officer inform the victim’s family.

Cleaning & Flushing Requirements The requirement for cleaning and flushing at the yard for all lines of piping system use air for medium and apply quick decompression method. a.

Record of flushing should be maintained by color marking of P&ID’s to define the system flushing circuits, direction of flow, volume scope, equipment isolation and prime mover used.

b. Pre-commissioning test sheet for flushing is to be prepared prior to the starting of the operation and approved by Contractor / Company. Notice to the precommissioning team shall be sent together with test sheet and marked-up P&ID. c. Conformity line check shall be performed to the piping network as per as-built isometric and marked-up P&ID. All doubler plates and/or pipe supports shall be checked to ensure that they are properly installed. d. It shall also be notified where the location of permanent support hangers or supplementary supports needed in order to withstand stress due to flushing. e. During flushing the spring supports and spring hangers shall be blocked / locked (See manufacturer’s instruction). f. Any sensitive instrumentation (flow instrumentation, probes, orifices) to be fully protected. All control valves shall be removed prior to flushing and then replaced by appropriate spool piece or if possible to joint the connection directly. g. Flushing outlet nozzle area should be at largest nozzle at the low point. h. Flushing pressure shall not exceed the piping design pressure, but flush rates and flow must be high enough to remove heavy debris (below 7 bars) i. Flushing of interconnecting pipe work should be in the direction of fall and from smaller pipe work into larger pipe work ensuring no debris is left trapped in dead legs. (Refer to GOC Mechanical - Pipe Testing).

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j. Mechanical cleaning may be applied for system or part of system with large pipe diameter (24” or more) using either rotary (i.e. air driven) or hand held steel wire brushes made of stainless steel.

3.5 Cleaning & Flushing Equipment The following equipment should be available as minimum: a. One (1) pressure gauge with range from 0 to 200 psig. The gauge must be mounted on compressor discharge b. Air filter with maximum mesh size of 120 microns c. One (1) variable air compressor with discharge pressure up to 100 psig d. One (1) air tank receiver completed with fitting and check valve. e. Flexible hoses f. Hose Clamps g. Temporary flushing outlet with NPS equal to pipe’s inlet size complete h. Additional spool piece, gasket, G-lock seal ring, stud bolt, blind hub / flanges, and test spade i. A material catcher of steel for use of rupture disk. j. Safety protective equipment Maintenance and calibration equipment shall be carried out in accordance Calibration Procedure 3.6 Equipment and Instrument Protection All instruments mounting in the system shall be excluded from flushing. a. During flushing all fragile internal equipment should be removed or disconnected. The following instrumentation and equipment is considered as being fragile: -

Pressure safety valve

-

Control valve

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Choke valve

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Check valve Page 8 of 11 3115-BWK-PRQ – 021.4

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Nozzle of chemical injector internals

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Internals of corrosion probe, corrosion coupon, and thermo wells

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Process instruments

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Orifice plate

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Flow glass

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Level glass and level switch.

All the valve which left in the piping during flushing shall be in open position and not be operated. b. Process impulse or injection to the lines should be disconnected. c. Control valves will be dismantled. d. All vessel or equipment shall be blinded. e. All rotating equipment such as process pumps, gas turbines, compressors and others shall be disconnected and blinded from the flushing network.

3.7 Personnel Requirement The pre-commissioning team shall at least consist of: 1 Lead Test Engineer, 1 Supervisor, 1 QC inspector, 1 Instrument Technician, 1 Safety Man, and Necessary Helpers The necessary helpers should be in proportional number to the volume of lines to be tested.

4.

CLEANNESS CRITERIA

Color of discharge shall indicate whether dust or debris remains in the piping, flushing to be repeated several times until the discharge air seems to be clean. Target plate is installed in front of air outlet to comprehensively check piping internal cleanliness.

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White cloth / paper may be used on target plate that indicates pipe internal is already clean. All pipeline shall be free from all foreign materials (e.g. as dirt, grease, oxide scale, weld deposits and temporary protective coating)

5.

CLEANING & FLUSHING 5.1 Cleaning & Flushing Preparation a. Install flushing outlet as shown in the test pack consisting isometric drawing and marked-up P&ID. b. Ensure that all relevant changes or modification as indicated on the P&ID or isometrics have been completed. c. External connections must be disconnected. d. Spool piece shall be installed instead of fragile valves and instrumentation. e. Check valves shall be removed from the line. f. In all cases the line should be isolated from network under test. g. Install discharge area protection and safety precaution, wood cover to be allocated in front of discharged point. h. Ensure that all restraints, clamps, and supports have been attached to the system properly. i. Flexible hoses use for the air blow shall be strong enough to withstand the operating pressure from supply air compressor. j. Install flushing area protection by using barricade and safety precaution. Main attention shall be drawn to fluid area. k. Flushing may be done partially if necessary.

5.2 Cleaning & Flushing Execution a. The temperature should be in the ambient temperature. b. Ensure that preparation proceeding has been followed accordingly. c. Use same size of pipe for outlet discharge valve for connecting air compressor outlet to the piping system combined with 3/4” nozzle hose for inlet pressure. Page 10 of 11 3115-BWK-PRQ – 021.4

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d. Close outlet valve and open inlet valve during pressurization. e. Pressurize the piping system up to required pressure (2.75 - 7 Barg / 40 – 101 Psig). f. Air should be injected into the system from point that easy to reach. g. When pressure reach the required pressure to break alumunium sheet on flushing outlet, observe any foreign material if any dust and debris on target plate. For flushing use rupture disk / alumunium sheet (for dia 6” and larger), observe any foreign material, dust and debris after pressure breaks. For flushing use temporary ball valve (for dia 1” thru 3”) close and open the valve several time until cleanness are reached. h. Repeat above steps until cleanness criteria are reached and witnessed by Company / Contractor. 5.3 After Cleaning & Flushing a. Clean up the temporary equipment. b. When relevant piping has been cleaned, seal the system at inlet and outlet for preparation of hydro test c. After flushing is finished and met the satisfaction of the Company, the flushing report shall be fully completed and then incorporated to pre commissioning dossier.

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