Our High Velocity Hot Oil (HVOF) Flushing and Chemical Flushing services help you meet or exceed ISO cleanliness requirements (16/13/10) and protect critical equipment. We have performed flushing services in plants across the US and the world, and our team ensures all flushed meet API 614 standards.
The RIG team provides turnkey flushing services to remove contaminates, correct moisture levels, eliminate varnish and fully degrease equipment. Our team completes a thorough walk-down of your facility and provides a comprehensive flushing plan, equipment setups, piping diagrams and full documentation for your review prior to beginning work. Our certified technicians take full responsibility for the entire flush, including providing equipment (flanges, filters, jumpers, etc.)
Our engineering and field technician team provides the following flushing services:
- Heat transfer system flushing
- High velocity hot oil flushes for Gas & Steam Turbines, Compressors, Stationary Engines, Piping, Heat Exchangers, Reservoirs and Tanks, Etc.
- Chemical flushing services
- Debris and build up removal including: turbulent flow piping decontamination, metal working debris, and built up dirt contamination
- Utility piping pigging
Overview of Managed Flushing Services Steps
- Perform an onsite walk down of your facility
- Develop a flushing plan with recommendations for improved equipment reliability
- Establish inspection requirements for lubricant performance and QA verification
- Perform onsite services, including:
- Verify flush paths and jumper installation
- Set up flushing equipment
- Complete system flushing and related elements
- Inspect flush screens‚ filters and bags
- Gather key baseline and related performance data for documentation
- Monitor system improvements
- Document the service summary and ROI management review
- Daily communication with key stakeholders on-site and off-site
- Executing the pre-determined Inspection Test Plan (ITP) and communicating results
Our service summaries always include the following information:
- Details the steps completed
- Documents performance improvement
- ISO cleanliness levels before and after flushing
- Additional engineering recommendations to enhance system reliability
- Outlines recommended maintenance routines to enhance preventative maintenance measures (such as oil change schedules)
High Velocity Hot Oil Flushing (HVOF) Projects
Chemical Plant Commissioning project that provided High Velocity Oil Flushing on multiple units during maintenance turnarounds including – LDCU, Wet Gas Compressor and Coker Jet Cutter.
LyondellBasell, Channelview, TX – 2018 OP2 – Turnaround – Provided a combined service consisting of Varnish Mitigation and High Velocity Oil Flushing on the Methane, Charge Gas and Refrigerant Compressors.
Provided High Velocity Oil Flushing on Dresser Rand Recip compressors, and Pressure Testing and High Pressure Flushing of the Tiger West Rail Hydraulics.
Chevron Pascagoula, AL – Provided High Velocity Oil Flushing Services on multiple compressors including (3) Kobelco Units, Plant 24 Aromax Compressor, K95 80 and Dresser Rand 8105-C Compressor.
High Velocity Hot Oil Flushing (HVOF) Projects
Air Products Baytown, TX – New SMR Hydrogen Plant: Chemical cleaned the Amine system and continuous steam blow the headers to the users
Coal Fired Boilers- Performed chemical cleaning of the boilers, fuel oil piping and condensers. Hydrolazing on Steam, CCW, BFW and Condensate piping. Oilflushing of 2 SKODA STG’s. Impulse steam blows.
Koch Fertilizer – Fort Dodge, IA, Beatrice, NE., Enid, OK, and Dodge City, KS. Providing emergency response and scheduled turnaround services including chemical cleaning and High Velocity Oil Flushing.
Citric acid chemical cleaning of the HRSG, Gas Line air blow to the Duct Burners and CT. Oilflushing of the CT and Kobelco Compressor. Steam blows to the header.
How do you know or prove you are achieving the high velocity during lube oil flushing?
The velocity of each flush is based on a pre-generated Reynolds Number (Re). Piping diameter, fluid temperature, linear footage, piping schedule, and viscosity are factored to ensure proper turbulent flow is achieved in each section of piping. At a minimum, a Reynolds Number of >4000 will be generated. After the onsite system walk down, we will create a detailed process that ensures sufficient Reynolds numbers are achieved, and it will be submitted for your review beforehand.
What is high velocity hot oil flushing?
Lube oil flushing is a plant maintenance service that flushes the oil lines of plant equipment and turbines to clean the oil used in these processes. The purpose is to reduce contaminates in oil and extend the life of critical equipment like turbines and hydraulic equipment. By reducing the contaminate levels back to OEM recommended levels, equipment internals are protected from wear and tear caused by degraded oil quality.
What ISO particle count do you qualify as “clean” for a standard lube oil system ISO 32 lube oil operating at 100-PSI?
ISO standards are solely based on OEM standards and customer requirements. If these are not available, our internal standard for lube oil systems is 16/14/11. The primary goal when performing a high velocity hot oil flush is piping cleanliness, so we incorporate the use of API 614 visual standards alongside the ISO cleanliness specifications.
Do you operate the lube oil flush around the clock? Is it ever unattended?
We provide manpower 24 hrs per day until project completion. We structure our schedule to ensure our equipment is monitored during day and night shifts, along with shift changes and lunch breaks.
What do you require from in-plant personnel—what level of interaction?
Our goal is to offer a full turnkey solution for our customers. After coordinating with our onsite contact, once onsite, our goal is to provide everything needed to get the job done. One of our top priorities is good communication, and you will receive constant updates on our progress. We do require “approval” signatures for certain phases and scope changes of the project to ensure your expectations are met. However, unless otherwise required, we will take care of staging, electrical setup to generator, pipe-fitting/millwright phases, circulation, and breakdown.
What are your lube systems power requirements?
Our power requirements are typically 480 3-Phase, 70 Amps–125 Amps.
Do you initially “muck-out” the lube oil reservoir prior to starting the flush?
Based on customer requirements, the system reservoir is cleaned by means of confined space entry. New or used flush fluid is then filtered back into the reservoir to begin the circulation phase.
Do you use your own lube oil or the plant’s?
Typically, the customer provides the flushing oil; however, if requested, we could supply, if agreed upon within the planning stages.
How much lube oil (normally/average) is required?
The lube oil flush is generally done with the in-service oil that is already in the reservoir. If new lubricant is being added to the reservoir for flushing, it is recommended that we have enough oil to fill all hard piping and our equipment with an addition of 200 gallons or less to maintain a positive head suction on our equipment to prevent aeration and cavitation of equipment during the flush.
Can you “cleanup” an existing lube system; cleanup by means of particulate filtration and water removal?
Yes, RIG offers custom side stream filtration for in-service units. We have a fleet of filter carts and dehydration units that will reduce particle count to better than 16/14/11 and water less than 100 ppm by Karl Fischer.
Does your flushing process align with equipment manufacturers requirements?
The RIG team has worked with many OEM’s domestically and abroad. Our technical expertise takes into account the unit and OEM’s requirements while building the process and procedure. The process is submitted in writing and agreed upon prior to starting flushing activities. Many times, this includes the OEM’s sign off. Particularly with commissioning and warranty activities.