COMMISSIONING LUBRICATING OIL SYSTEMS

1. SCOPE

1.1. Although lubricating systems vary widely in size, design, and complexity, certain steps toward proper startup are
common to all. The minimum requirement is that lubricating and seal oil systems shall be cleaned and flushed in
accordance with the manufacturer's instructions. It is the intent of this procedure to outline these steps in general,
realising that the details must be modified to suit the specific situation. Where the manufacturer’s procedure fails to
meet the standards of this procedure it is strongly urged that the higher level be adopted.

2. INTRODUCTION
2.1. Hydrostatic testing. Interconnected pressure-containing oil piping, which has been field fabricated, must be
hydrostatically tested to 1.5 times the MAWP (API 614 requirement). As the presence of water in these lines may
pose serious problems in the subsequent flushing process, it is recommended that this test is done with the same oil
that is to be used for flushing of the system. Oil pipework and vessels on both the oil and equipment skids should
have been tested by the manufacturer, rendering a repetition of the hydro-test of these components unnecessary.

2.2. Proper commissioning of lubricating oil circuits is paramount to the successful start-up and continued trouble-free
operation of equipment served by the system. It should be noted from the outset that the commissioning of a lubricating
system is neither mysterious nor difficult, and that a systematic approach will ensure a clean, functional system in a
minimum of time. Two distinct and separate steps are involved, namely:

• Physical cleaning
• Flushing and testing

Obviously. the steps must take place in the order shown; it is a waste of time to attempt flushing and testing of a system
which is not properly cleaned. These two steps are briefly outlined below.

3. PHYSICAL CLEANING

3.1. The object of physical cleaning is to remove all foreign matter from the oil system. Shell-specified lubricating oil
circuits are nowadays always made of stainless steel, including the tank. Thus, the old requirement for chemical
cleaning for the removal of rust and millscale, mechanical cleaning for removal of weld and weld spatter, and general
elimination of debris such as welding rods, loose paint, sand, mud, grease, and rags has been largely superseded.
Conversely, smaller clearances, bearing materials with better fatigue resistance, finer filtration and higher speeds bring
with them an increased requirement for clean oil. While such cleaning is normally done by the manufacturer prior to
installation of the equipment at the site, it remains the responsibility of those commissioning the system to verify that the
system is clean just prior to flushing and testing, and to effect any additional or supplemental cleaning required.
Verification of cleanliness of the lubricating oil system can be made only by physical inspection of the components,
including oil storage tank, coolers, filters, pumps, supply headers and drain headers. Ball valves at dead ends of piping
systems require particular attention because debris accumulates in the narrow crevice between the ball and housing.
Additionally, components being served by the oil system, such as bearing and seal housings, gear boxes, coupling
covers, and turbine governor housings must be inspected and cleaned. Systems which have been cleaned prior to
installation, and which have been well maintained in the field, may require no more than solvent washing for removal of
preservatives. Conversely, a poorly prepared system, or a system that has deteriorated during installation, may require
more elaborate treatment such as chemical and/or mechanical cleaning.

3.2. Oil and process piping associated with rotating equipment may require chemical cleaning. If inspection of the
system indicates that chemical or mechanical cleaning is required, the elements involved must be removed from the
system for cleaning. It is impractical to chemically clean a system by circulating a pickling solution because of the
probability of damage to major equipment as well as to instruments, control valves and pumps. Likewise, grit-blasting
installed equipment is strictly forbidden because of the probability of system contamination. For further
recommendations reference is made to DEP 70.10.80.11-Gen. A particular problem may occur with the pipe coating
known as “Japanese black”. Search this name in the best practices section for more information.

• 3.3. Parts which have been removed from the system for cleaning must be given a protective coating after cleaning
to prevent deterioration before reinstallation. This protective coating must be compatible with the lubricant to be
 employed in the system. ENSIS OIL N can provide a suitable protective film, in outdoor sheltered conditions, for
up to 12 months. It contains no additives that will adversely affect lubricant properties.

Once cleaned and preserved, extreme care must be taken in reassembly to ensure that dirt is not re-introduced into the
system.

3.4. Cleaning of piping associated with or serving gas seals shall be carried out according to the requirements of the seal
manufacturer. Piping already installed and cleaned prior to shipment to site should be sealed off. Piping between filters
and seals should not be disturbed without the consent of the equipment manufacturer, in order not to violate the
warranty.

3.5. After the system has been physically cleaned, flushing and checking can be started.

4. FLUSHING AND CHECKING

4.1. The objective of flushing and checking is to prove the cleanliness and soundness of the lubrication system prior to
starting the equipment which it serves. Specific accomplishments of this operation are:

1. To flush any portions of the system which cannot be physically cleaned, such as internal passageways in bearing
housings.

2. To wash out any residue left in the system after physical cleaning.

3. To provide proof that the cleaning has been effective.

4. To check the operation of each component of the system including pumps, coolers, filters, valves, and
instrumentation.

5. To permit operation of the system under pressure to check for, and to repair leaks.

6. To permit observation of oil flow to every point served by the lubricating oil system.

4.2. Recommended flushing procedure. Note that the time taken for complete flushing is inversely dependent on the
flow rate. The absolute minimum acceptable flow rate is that provided by two pumps, typically of the order of 2
m/s. A preferable flow rate would be 8 m/s, for which an auxiliary pump is needed. The turbulence provided by
such a rate is of great benefit in removing deposits. The period required for thorough flushing with the installed
pumps, which can be measurable in weeks, may be reduced to 20% by the use of an additional pump.

The best results are obtained by progressively increasing the extent of flushing, checking screens for acceptable levels at
each stage. Initially circulate oil around the oil skid only, after replacing control valves with spool pieces. Progressively
add removed control valves, extend the range of flushing to the pipework supplying the machine, then to the machine
itself.

1. Have on hand a liberal supply of clean rags, solvent, oil-absorbing material, pipe gaskets, filter elements, test
screens, and lubricating oil.

2. The most widely used practice today is to bypass bearings and seals with hoses or pipework made up to fit. In
some circumstances it may be preferred to remove line bearings, thrust bearings and continuously lubricated
couplings. Remove mechanical seals on compressors where their design permits removal without flooding the
compressor casing with lubricating oil during circulation

3. Remove any restrictions in lubricating oil lines, such as orifices in lubricant and control oil lines to bearings, seals,
and turbine valves.

4. Remove any spray nozzles such as those serving continuously lubricated couplings and gears.

5. Disconnect the small oil lines to such items which would be damaged by minute amounts of dirt and through
which you do not wish to circulate oil until after the system is proven clean. Examples of such items are speed
transmitters, governors, and mechanical seals which cannot be removed without flooding the compressor casing. Be
extremely careful not to introduce dirt into these auxiliary units when removing the pipe and immediately blind or
plug the connections from which the pipe was removed. After the system has been flushed, these small lines are to
be thoroughly cleaned and reconnected.

6. Install temporary strainers at the suction of all lubricating oil pumps. It is important to note that positive
displacement pumps, unlike a centrifugal, will not pass foreign matter without damage. A weld bead, for example,
can ruin the pump.

7. Remove elements from the lubricating oil system filters for initial flushing, substituting 100 mesh screens. The
very large amounts of debris initially disturbed will quickly block the elements. Once debris levels deposited on the
screens have reduced to acceptable levels, the elements can be replaced.

8. Check operation of the lubricating oil tank level alarm.

9. Add the correct grade of lubricating oil to the oil tank. Note that flushing should not be carried out with an EP
grade and in this case special arrangements may need to be made. It is generally sufficient to fill to the minimum
alarm level.

10. Bleed air from the system and be sure the lubricating oil pumps are primed.

11. Rotate the lubricating oil pumps by hand at. least ten complete revolutions to ensure that they are free. Proceed
with a check of each pump to assure that it is operable. Important items to check are:

1. Direction of rotation.

2. Coupling alignment and lubrication.

3. Relief valve setting.

4. Operating speed of turbine-driven pumps.

5. Ability of electric-driven pumps to start up against full discharge pressure of steam-driven pump

6. General pump operation: bearing temperatures, vibration levels, noise, mechanical seals.

12. Check the operation of pressure control valves and pressure switches.

13. With the main and auxiliary lubricating oil pumps in operation, bleed low pressure steam into the water side of
the oil cooler to bring the oil temperature up to 82C to 87C. Check the nameplate of the exchanger for maximum
operating temperature and pressure, and do not exceed the manufacturer's limitations. Alternative heating methods
that may be employed include internal electrical tank heaters and external heating blankets.

14. On systems employing turbines with hydraulic dump valves or hydraulic overspeed trip valves, open these
valves to permit oil to circulate freely through the supply lines for at least two hours. After that time, close these
valves and operate the trip-throttle valve hydraulic cylinder over its entire travel a minimum of twenty times to flush
the cylinder and its supply lines.

15. Circulate the hot oil through the entire system for a minimum of twelve hours. During this time, make regular
checks on the following items (keep a log).

1. Check that oil commences and continues to flow through every line by monitoring inlet and exit
temperatures.

2. Check for leaks in piping and machines.

3. Check lubricating oil temperature.

4. Check the differential pressure across the filter.

 5. Check the operation of lubricating oil pumps and turbines.

16. During circulation, attempt to knock loose any foreign material which may be clinging to pipe walls. This may
be done by hammering the pipes with plastic hammers, especially field fabricated pipework, to assist in removal
of debris, or by cycling the oil temperature repeatedly between 27C and 82C, or by setting up pipe vibration by
introducing air into the lubricating oil supply lines just downstream of the lubricating oil pumps. As noted above,
the turbulence generated by high flow rates is most beneficial in this respect.

4.3 Procedure for checking

1. After twelve hours of continuous flushing with both pumps, install 100 mesh screens as specified in API 614,
Clause 4.3.3.7.1, at convenient flanges upstream of each bearing and seal of the machines being served by the
lubricating oil system. Restart the pumps and circulate the oil for another twelve hours at the highest possible
temperature and flow, but in any case not lower than 45 °C. During this period pumps shall be repeatedly stopped
and started.

2. Remove and inspect each test screen. If foreign material appearing on the screens is less than that specified in
API 614, it can be assumed that the system is clean, and you may continue with this procedure. If small amounts of
foreign matter are collected, remove the test screens and repeat Items 4.2.15 and 4.3.1. If gross amounts of residue
appear on the test screens, it is an indication that physical cleaning of the system was inadequate or ineffective, and it
is probably a waste of time to continue the flushing operation. Re-cleaning of all equipment downstream of the filter
elements should be considered.

3. After the system is proved to be clean, and the test screens have been removed, circulate oil for about one
additional hour to assure removal of any foreign material which may have been inadvertently introduced in removing
the screens.

4. Replace filter elements

5. Replace couplings, orifices, spray nozzles, and small headers. Be extremely careful not to introduce dirt into the
system as these items are replaced. Wash all items with solvent prior to replacement. Wash the outside of any
flanges with solvent before breaking the flanges. Dirt introduced into the system at this time can nullify the effect of
the previous cleaning and flushing..

6. With orifices replaced, check the operation of the trip and throttle valves, mechanical dump valves, and power
cylinders on steam turbines.

7. See that spray nozzles are properly installed and properly directed. Check that all deliver at the correct flow and
pressure.

8. Check the automatic start-up of the auxiliary oil pump by tripping the main pump. Observe the action of alarm
and shutdown switches. If the system is in proper working order, the only switch that will actuate is the one
indicating that the auxiliary pump is running. Low oil pressure alarm and shutdown switches should not operate if
the auxiliary pump comes on properly. Check that pressure is maintained in control oil circuits when pumps are
changed over.

9. Check proper operation of pressure control valves with the entire lubricating system in its normal operating
condition.

10. Various packaged units and lube oil or seal oil skids include positive displacement pumps which are equipped
with discharge relief valves for pump and/or piping protection. It is normal to test these valves once flushing
has been completed. Every effort should be made to avoid removing and replacing valves from a clean system
for testing. In most cases where measurement of the pressure upstream of the relief valve is possible, the
valves may be tested in-situ using calibrated pressure gauges. If removal for shop testing is unavoidable,
precautions should be taken to avoid the ingress of debris into clean systems.

11. Drain off flushing oil and either discard or prepare for further use as flushing oil by filtering to 5µm. Never
reuse flushing oil as a lubricating oil. Note that foaming problems may occur if corrosion inhibitors remain in
 circulation. Clean out the tanks/vessels, again taking maximum precautions to avoid the re-introduction of
dirt. Inspect for cleanliness and absence of any foreign matter.

12. Refill the system to the normal level with the correct grade of oil

Appendix 1. Seal systems

General procedures for seal oil systems are very similar to those used for lubricating oil circuits. Additional notes are
shown below.
1. The cleanliness requirements of the barrier liquid for Plan 54 seal systems are comparable to those of hydraulic
systems or lube/control oil systems. In order to avoid seal failures during start-up it is therefore imperative that
these lines are thoroughly cleaned. The stainless steel supply lines will need extensive flushing with gasoil (diesel
fuel) and any carbon steel return lines need to be chemically cleaned and passivated before they are incorporated in
the flushing process. At each machine the seals will have to be by-passed in the flushing process to avoid entry and
accumulation of debris in the intermediate seal chamber. The total flushing process has to be structured into a step
by step procedure, where first the main headers and later on the sub-headers and lines to and from pumps are
flushed.

2. Plan 53 seal systems are fitted with a supply line only to the various systems, and thus a flushing process by
means of circulation is impractical. Lines should be flushed and cleaned by detergent flushing followed by air
blowing, where cleanliness can be detected by means of a target at the end of the subject line sections. Here also the
system will need to be divided into sub-sections for cleaning in order to reassure an effective cleaning process