TABLE OF CONTENTS

1.0. 2.0. 3.0. SCOPE ......................................................................... 2 REFERENCE ..................................................................... 3 National Aerospace Standard, Fluid cleanliness1CLEANLINESS ..................... 4 3.1. Cleaning of tubes during and after pre-fabrication - General guide: .... 4 3.1.1. Mechanical cleaning of tubes ........................................... 4 3.1.2. Chemical cleaning of tubes ............................................. 4 3.1.3. Alkaline degreasing .................................................... 4 3.1.4. Water rinsing .......................................................... 4 3.1.5. Pickling (only Carbon pipes and not to seamless cold drawn SS pipes) ... 4 3.1.6. Alternative pickling (suppliers request) .............................. 4 3.1.7. Phosphoric acid pickling ............................................... 4 3.1.8. Water rinsing .......................................................... 4 3.1.9. Neutralisation ......................................................... 5 3.1.10. Water rinsing .......................................................... 5 3.1.11. Drying ................................................................. 5 3.1.12. Surface treatment ...................................................... 5 3.1.13. Passivation of Stainless Steel Pipes ................................... 5 3.1.14. Storage of tubes and tube parts ........................................ 6 FLUSHING ...................................................................... 7 4.1. Preparation of a Flushing Plan ......................................... 7 4.2. Hydraulic Pipe Flushing ................................................ 7 4.2.1. Specification of Flushing Flow ......................................... 7 4.2.2. Equipment needed during flushing ....................................... 8 4.2.3. Eventual 250-ml sample bottle, which is cleaned and sealed of a certified supplier.Check List to be made up before flushing ............ 8 4.3. Water Pipe Flushing (Hydro flushing) ................................... 9 4.4. Air Pipe Flushing - Pressurised air shock blowing (PAS) ............... 10 4.5. Mud, Cement and Vent Pipe Flushing See NORSOK L-CR-004 ................ 10 4.6. Pneumatic flushing .................................................... 10 INSPECTION OF CLEANLINESS LEVEL .............................................. 11 5.1. OFF line automatic particle counter ................................... 11 5.2. Fluid sampling ........................................................ 11 5.3. ON line automatic particle counter .................................... 11 PRESERVATION ................................................................. 12 DOCUMENTATION ................................................................ 12 7.1. General ............................................................... 12 7.2. Completion Records .................................................... 12 7.3. Completion Record Sheet example ....................................... 12 QA & SAFETY .................................................................. 13 8.1. Quality Assurance ..................................................... 13 8.2. ISO 4406 SCALE NUMBERS - Basis of code ................................ 13 COMPLETION RECORD SHEET EXAMPLE .............................................. 14

4.0.

5.0.

6.0. 7.0.

8.0.

9.0.

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1.0. SCOPE
This Procedure regards the Flushing of: Hydraulic Piping Ring Line System and the corresponding Equipment Water Pipes for cooling of HPU, HP-washing and Utility Water Air Pipes for Utility an Instrument Air Mud - Cement - Vent Pipes In accordance with the Block Diagram V1000-D1006-H0001, 2 and 3 and the specifications referred to. This Specification, applies to the three categories: Equipment Packages, Cranes and Ring Line Reynolds factor requirement under 5.2.1 as well as the Ring Line System, Equipment Flushed with This Packages separate HPU Procedure Ring Line Flushed with This System separate Test HPU Procedure Systems below, applies to Equipment and Cranes Reynolds No. 4000 Reynolds No. 4000 Delivered Sealed Clean Commissioned according to this Procedure

Flushing of systems is based on a controlled start-up where the cleanliness level is achieved through continuously filtration and monitoring with a particle counter. This Flushing Procedure in the order of schedules: 1. Cleaning of Tubes and Pipes prior to assembly. 2. Assembling of fixed Ring Line pipe works. 3. Cleaning 4. Pressure Testing (SS Systems prior to Flushing - CS Systems after Flushing) 5. Flushing (This Procedure) 6. Preservation of fixed Ring Line pipe works. 7. Clean assembling of Equipment to the fixed Ring Line pipe works. 8. Ring Line Leak Testing at Working Pressure, of the complete system assembly 9. Leak Testing Repeat after Equipment Test & Trial. 10. Any unsuccessful part of the process requires repetition before proceeding.

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2.0. REFERENCE
The P.O specification and this Specification of the corresponding internal National Oilwell Varco practise are ruling to all Suppliers and Sub-Suppliers through all stages in the development of the System. Consequently any other Reference should be waived by the Client in due time. References for National Oilwell Varco guidance are: National Oilwell Hydraulic Hand Book Rev.2 10.08.99 National Oilwell HL/T-16 PreservationNORSOK L-002 National Oilwell ISO 4021 NORSOK L-CR-004 and ANNEX B: NORSOK Z-006 V1000-D1011-H0001, 2 & 3 NAS 1638 Piping Design, Layout and Stress Analysis Clean Mounting (Report Format) Oil Sampling Piping Fabrication, Installation, Flushing and Testing, Requirements for internal treatment of piping after prefab and installation before commissioning. Preservation of equipment and systems Hydraulic Block Diagrams

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3.0. National Aerospace Standard, Fluid cleanliness1CLEANLINESS

3.1. 3.1.1. Cleaning of tubes during and after pre-fabrication - General guide: Mechanical cleaning of tubes After mechanical cleaning, tubes and tube flanges shall be smooth and free from slag, welding beads, baking, pores and foreign particles. Sandblasting shall not take place. Chemical cleaning of tubes Tubes with scale and/or corrosion shall be treated according to the following procedure: Alkaline degreasing - Water rinsing - Pickling - Water rinsing - Neutralising - Water rinsing - Drying. Alkaline degreasing The tubes are to be cleaned with an approved degreasing agent oil and grease reduce the effect of the pickling process. An alkaline bath which removes most of the organic dirt (lacquer, oil, fat) may consist of 10% NaOH (caustic soda) and 90% water. Treatment time is approximately one hour at 90 degr.C. Certain types of fat are not removed by this procedure. Water rinsing The tubes are to be thoroughly washed with fresh water. Pickling (only Carbon pipes and not to seamless cold drawn SS pipes) The tubes are preferably pickled in a sulphuric acid bath consisting of: 10% 20% H2SO4 (sulphuric acid in water, 1 2 m/l Inhibitor (Hexamine). Maximum bath temperature, 80C. Alternatively the tubes are filled completely with pickling fluid. Always pour acid concentration into water, not vice versa. The acids must be treated carefully as they are highly corrosive. Protect skin and eyes and follow the recommendations of the acid supplier. Alternative pickling (suppliers request) Pickling in hydrochloric acid 50 % HCI (Hydrochloric acid in 35% concentration, non-arsenic) in water, 1 -2 ml/l Inhibitor (Hexamine). Maximum bath temperature: 35C, Pickling time: 10-60 min. Hydrochloric acid is very active and leads to immediate corrosion if neutralisation measures are not taken immediately after the pickling. However, pickling in hydrochloric acid may lead to hydrogen embrittlement in the steel if the inhibitor is not efficient enough. Phosphoric acid pickling Phosphoric acid pickling gives a small normally requires no neutralisation.

3.1.2.

3.1.3.

3.1.4.

3.1.5.

3.1.6.

3.1.7.

amount

of

corrosion

and

3.1.8.

Water rinsing The tubes are to be washed thoroughly with fresh water immediately after the acid pickling.

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5 3.1.9. Neutralisation The tubes are to be washed with an adequate neutralising liquid. An adequate neutralising liquid may consist of 2 % NasP04 (trinatrium phosphate) in water. Bath temperatures from 80 90C. Treatment times from 1 2 minutes. Water rinsing The tubes shall be washed thoroughly with fresh water to remove the neutralising liquid. Drying The tubes shall be dried with warm, dry air within 30 minutes after the water rinsing. Surface treatment To maintain the obtained until installation, the tubes shall be treated with a suitable protection liquid. The liquid used should give protection against corrosion at least for five months after the properties of the flushing fluid or system oil. Passivation of Stainless Steel Pipes Bare stainless steel will rust and corrode in the presence of iron particles or filings until a chromic oxide film develops on the surface when exposed to oxygen in the air The passivating process is used to hasten and enhance the creation of this oxide as well as to develop a thicker and tougher film. The surface should be cleaned first before passivating. Swabbing with the passivating solution will remove most loose solids. In extreme cases a preliminary acid wash may be used for cleaning if it is neutralised and rinsed away prior to passivation The following solutions are used passivating stainless steel (for 316L tube/pipe): Solution A: For series 200 and 300, and chromium grades containing 17% Cr. or more. 70% nitric acid (HN03) 6-15% (Vol.) Water, clean and fresh Remainder Operating temperature Room Contact time 10-30 minutes Solution B: For free-machining grades, polished surf, and series 400 with less than 17% Cr. 70% nitric acid (HNO3) 18-25% (Vol.) Sodium dichromate (Naz, Cr2Oi, ZH20) 2% (Wt.) Water, clean and fresh Remainder Operating temperature Room or 120F Contact time 10-30 minutes Passivating is accomplished as follows:

3.1.10.

3.1.11.

3.1.12.

3.1.13.

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Immerse, flush or swab with passivation solution. Flush the surface with clean fresh water (not sea water) to remove all traces of acid. Subsequent rust proofing by coating with oil or hydraulic fluid is unnecessary and undesirable since this film serves only to hold dust and dirt. It is important to close all pipe openings to carefully guard against the entry of dirt until final installation is complete.

Do not clean Stainless Steel Pipes with a wire brush as traces of iron because its may be left on the surface. 3.1.14. Storage of tubes and tube parts Cleaned and surface treated tubes and fittings have to be capped immediately and should be stored in a dry place.

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4.0. FLUSHING
4.1. Preparation of a Flushing Plan A Flushing Plan including Block Diagram for the specific system shall be prepared. Special equipment for the Flushing, like supporting equipment, loops, couplings, connectors etc. shall be listed and sketched at the diagrams. Cleaning shall be carried out prior to pressure testing and the Flushing thereafter. General requirements for Flushing for specific systems are listed in NORSOK L-CR-004 - table 1 in Annex B National Oilwell Varco shall approve the Flushing Plan. Hydraulic Pipe Flushing Flushing of the Ring Line Piping System shall be performed in accordance with the References noted and as a minimum satisfy: NAS 1638 class 8 ISO 4406 17/14. Specification of Flushing Flow During the flushing of the pipes, it is necessary to reach turbulent conditions in order to ensure efficient removal of and transport of particles with the flow. The Reynolds number defines turbulent conditions and is given by the equation 1: Q is the flow in the pipeline given in litre/minute D is the inner diameter given in millimetres vis cinematic viscosity given in centistokes The numerical value of Reynolds number defines all the different flow regimes: Laminar Flow Re < 2300 Transition between turbulent and laminar flow 2300 < Re < 4000 Fully turbulent flow Re > 4000 Re>3000 is defined as turbulent conditions during flushing. For long pipelines and especially pipes with diameter less than 15 mm, the pressure drop must be controlled according to the required flow with equation 2. Viscosity is the only parameter that both increases the flow and decreases the pressure drop. The flushing fluid should be compatible with the operating fluid, re. Equation 2: In the Alignment Chart below, practical combinations of flow, pipe diameters and viscosity at Reynolds number 3000 are given. If required to flush at higher Reynolds number, the equations referred to should calculate the flow.

4.2.

4.2.1.

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4.1 - Alignment Chart to find the required flow to achieve turbulent conditions. 4.2.2. Equipment needed during flushing 4.2.3. Flushing-unit, use another HPU with sufficient capacity (Yard). Thermometer Particle counter As per oil heater required, various hoses with couplings, caps and tools.

Eventual 250-ml sample bottle, which is cleaned and sealed of a certified supplier.Check List to be made up before flushing Check that the system is assembled with reference to the hydraulic design requirements and the Flushing Plan approved by National Oilwell Varco, including National Oilwell Varco approved report regarding CLEAN MOUNTING. 1. Check that all leaks are sealed/tightened as required. 2. Inspect the oil level in the Reservoir. The Reservoir shall be filled through filters of specified sizes up to normal level of the Reservoir. 3. Check that all manually operated (normally open) test valves are fully open (e.g. globe and gate valve). 4. Loop together all supply ports (pump and tank ports) In the Ring Line Main with hoses and valves in accordance with the Sketch below (Port Loop). 5. The ends of the Ring Main also looped together (End Loop). 6. Ensure that the system designer's Flushing Assembly Instructions are met and check out the Plan with a Yellow Marker and sign.

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1. 2. 3.

4. 5. 6. 7.

8.

Start the pumps and filtrate the oil internally in the HPU until NAS 1638 class 8 (ISO 4406 code 17/14) is achieved. Circulate the oil and bleed air until the system is filled with oil. Heat the oil during running to 5560C for VG 32 oil (6065C for VG 46 oil)1. The temperature shall be measured in the reservoir. If this temperature is not possible to achieve during normal running, a heater should be mounted and used. Run flow through the port loops one loop at a time. Open the valve with full effort for 3 minutes. Run through the rest of the port loops in the same way. Run the moving elements (actuator, hydraulic motor, etc.) one by one. Actuators are to be run with full effort at least 10 times in each direction. Hydraulic motors are to be run with full effort for 3 min. in each direction. Monitor the cleanliness level with a particle counter. Sample from the return line close to the return filter. Let at least 5 litres of oil circulate through the counter before sampling. If the sample has NAS class 8 (ISO 17/14) or better, two new samples shall be taken at once. If the target cleanliness level is not achieved and it is over NAS class 11 stop the pumps2. If the NAS class is between 8 and 11 repeat the procedure with running of the moving elements until target cleanliness level NAS class 8 is achieved. The responsible person shall sign the specific equipments test printouts from the particle counter which shall be attached to the complete report.

4.3.

Water Pipe Flushing (Hydro flushing) See NORSOK L-CR-004 chapter 8, item 8.2; quote: Chapter 8, item 8.2, Hydro flushing: Items of equipment which would be sensitive to damage during hydro flushing shall be removed, blocked or isolated. A list shall be prepared and be part of the flush & test procedure. Ball valves shall be flushed in fully open position. All piping systems shall be flushed using high pressure jet flushing equipment, such as rotating hose or rotating nozzle. Minimum pressure shall be 600 Bar. Below 4, High Velocity Water Flushing (HVWF) may be used. Water velocity shall be a minimum of 10m/s. On systems where high pressure jet flushing cannot be used due to complicated shapes and/or long runs HVWF may be used. The flushing medium shall in general be fresh water. When flushing stainless steel lines, the chloride ion content shall be less than 200ppm. After flushing, the piping systems shall be completely drained and protected against corrosion. Ball valves shall be flushed fully open. never should be lower then 16 cSt. The oil and at 72C for VG46 oil. These the flushing is to be contacted for be removed from the system and bypasses

Because of pump breakdown, the viscosity viscosity is 16 cSt at 62C for VG 32 temperatures must never be exceeded. The superior that is responsible for consultation. Proportional valves are to put on the valve block.

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10 4.4. Air Pipe Flushing - Pressurised air shock blowing (PAS) See NORSOK L-CR-004 chapter 8, item 8.3. We quote: Chapter 8, item 8.3, pressurised air shock blowing: This meted may be used as an initial cleaning method for instrument air, plant air and as an alternative method for initial cleaning of small bore pipe (less than 2). This method may also be used when there are problems removing trapped liquid in the circuit, or to verify cleanliness of small bore pipe where video inspection is impossible or inadequate due to pipe dimension or configuration. When using PAS method for cleaning or verification the procedure shall be repeated until cleanliness is acceptable. The air shocking pressure shall never exceed the working pressure of the system and shall never be more than 8 Bar. Safety precaution shall be taken when this method is used. Mud, Cement and Vent Pipe Flushing See NORSOK L-CR-004 See section 4.3. Water Pipe flushing Pneumatic flushing See NORSOK L-CR-004 chapter 8, item 8.4. We quote: Chapter 8, item 8.4, Pneumatic flushing: In cases where water is not desirable in the piping system (e.q. instrument / utility air), flushing by pressurised air or PAS shall be carried out. When pressurised air is used, the minimum velocity shall be 35 m/s. Procedure covering all safety aspects shall be established.

4.5.

4.6.

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11

5.0. INSPECTION OF CLEANLINESS LEVEL

The obtained cleanliness level shall be documented before a flushing operation may be considered as final. Use particle counter to control the solid particle level and a titration instrument to control the water content. 5.1. OFF line automatic particle counter This is the most common method. It is possible to use an external laboratory with a up to date instrument or to rent the equipment - with trained personnel - to analyse on site. The results shall be documented in a Cleanliness Print out Certificate and signed. Fluid sampling Fluid Sampling is often underestimated. The frequency and quality of the sampling is vital for the monitoring of the process and the documentation. The location of the sampling point is downstream (Return Line). Oil samples only to be taken as dynamic sampling There are several designs of samplings points, but very few to give a representative oil sample. One recommended system to follow is ISO 4021. The sampling bottles shall be special cleaned and prepared bottle of at least 100 ml, 250 ml is preferred. The supplier of the prepared bottles shall be able to document the cleanliness level of the prepared bottles. ON line automatic particle counter This is a very sensitive method that has to be handled with care. Only specially trained personnel are qualified to install and operate such equipment. The major advantage of this method is a full control with the cleanliness level at all times during the process. Equipment that can shut down the flushing station after having reached the recommended cleanness level and made print outs automatically, is available. Another advantage is the elimination of uncertainty caused by sample bottles and external handling of the samples. It is recommended, however, to always send one sample of each flushing operation to an external laboratory as a final documentation.

5.2.

5.3.

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12

6.0. PRESERVATION
Ring line system in derrick to be sealed off with blind flanges and solid caps/plugs after flushing.

7.0. DOCUMENTATION
7.1. General Documentation requirements are generally in accordance with: Technical Specification of Piping Installation. Pressure Testing for National Oilwell Varco Equipment. Completion Records Completion Record Sheets shall be developed by the Supplier in order to fulfil the requirements of the Client and National Oilwell Varco. National Oilwell Varco shall approve the lay-out of the Completion Records as a part of the Flushing Plan (see 5.1). Completion Record Sheet example Attached to this Specification is an example of Completion Record Sheet, suitable for Hydraulic Piping Service tests. Adequate Sheets shall be developed for other Service Codes.

7.2.

7.3.

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13

8.0. QA & SAFETY

8.1. Quality Assurance Quality Assurance requirements are generally in accordance with the Quality Plan. Safety requirements see Pressure Testing Procedure.CONTAMINATION CODES Comparison of Contamination Codes against other commonly used cleanliness classes are given in the following table: Table 8.1 - APPROXIMATE EQUIVALENTS OF CONTAMINATION CLASSES BS 5540/4 ISO/DIS 4406 CODE NAS 1638 CLASS SAE 749 CLASS 11/8 2 12/9 3 0 13/10 4 1 14/9 14/11 5 2 15/9 15/10 15/12 6 3 16/10 16/11 16/13 7 17/11 17/14 8 18/12 18/13 18/15 9 6 19/13 19/16 10 20/13 20/17 11 21/14 21/18 12 22/15 23/17 NOTE: The above comparisons relate to particle count data only. To conform to any particular standard, reference should be made to the recommended experimental procedure. 8.2. ISO 4406 SCALE NUMBERS - Basis of code The code number corresponding to a pollution level comprises two scale numbers, which permits the differentiation of the dimension and the distribution of the particles as follows: The first scale number is the number of particles > 5 um per milliliter of fluid. The second scale number is the number of particles > 15 um per milliliter of fluid.

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14 Allocation of scale numbers: The scale numbers are attributed according to the number of particles counted large than um and 15 um respectively, yielded in 1 ml. of fluid (see the table). Number of particles per milliliter More than Up to and including 80 000 160 000 40 000 80 000 20 000 40 000 10 000 20 000 5 000 10 000 2 500 5 000 1 300 2 500 640 1 300 320 640 160 320 80 160 40 80 20 40 10 20 5 10 2,5 5 1,3 2,5 Scale number 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8

9.0. COMPLETION RECORD SHEET EXAMPLE

Note: This completion record sheet and Hydraulic Block Diagram with the flushing loop marked and the result of the oil sample must be stored in a flushing record book as a final documentation of the flushing.

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