HARADH AND HAWIYAH GAS COMPRESSION PROJECT
DOCUMENT No.:
REV :
0
Contractor Transmittal No:
Company Transmittal No:
Date:
No
Status: Status:
CLIENT comments
1
The item "REFERENCES" in order to below the INDEX
2
Define measurement of deposit solubility for treatment selction
3
Prior to commencing rupture disc internal cleaning for big bore pipe
to be verified that disc have full bore contact with pipe diameter
4
Error on the word to be corrected "DISINFECTION"
Page No.
Answer by:
BCG
Comments by:
Contractor reply
Index
gopalasx
8.5
gopalasx
8.3.2.1
gopalasx
8.4
gopalasx
Reference (if applicable)
In all our procedures the item "REFERENCES" is at
the end of the document.
According to the material of the lube oil system, SAEP-1028, Para 10.2
acid/EDTA cleaning and passivation are not required,
only hot alkaline treatment. The selection of a
removal treatment depends on the degree of
contamination as appear in section 8.5 of the
procedure
Fixed in the procedure.
No rupture discs are going to be used.
Several layers of plastic bag or adequate plastic
material will be used depending on the activity
pressure.
Accepted and corrected
Status
(Open/closed)
CLOSED
CLOSED
CLOSED
CLOSED
5
6
7
8
9
Status:
1. Approved / Reviewed / Accepted
2. Reviewed with Comments
3. Rejected with comments
4. For COMPANY information
Aramco Overseas Company: Company General Use
1 of 1
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INDEX
1.
PURPOSE ....................................................................................................................... 4
2.
SCOPE ............................................................................................................................ 4
3.
DEFINITIONS .................................................................................................................. 5
4.
SAFETY CONSIDERATIONS ......................................................................................... 5
4.1
4.2
5.
ROLES AND RESPONSIBILITIES.................................................................................. 9
5.1
5.2
5.3
5.4
5.5
5.6
5.7
6.
HEALTH, SAFETY AND ENVIRONMENT ................................................................ 6
PRECAUTIONS ........................................................................................................ 7
PRE-COMMISSIONING MANAGER ......................................................................... 9
PRE-COMMISSIONING SUPERINTENDENT ........................................................... 9
PRE-COMMISSIONING SUPERVISOR .................................................................... 9
HSE MANAGER ...................................................................................................... 10
HSE SUPERINTENDENT........................................................................................ 10
HSE SUPERVISOR ................................................................................................. 12
COMPANY WITNESS ............................................................................................. 13
PREPARATION BEFORE THE CLEANING ................................................................. 13
6.1
6.2
6.3
PREPARATION OF PIPING.................................................................................... 13
PROTECTION OF INSTRUMENTS IN PIPING ....................................................... 14
PROTECTION OF EXISTING EQUIPMENT ............................................................ 15
7.
REQUIREMENTS TO CLEAN EXISTING EQUIPMENT ............................................... 15
8.
CLEANING METHODS ................................................................................................. 16
8.1 MECHANICAL CLEANING ..................................................................................... 17
8.1.1 Brushing ........................................................................................................... 17
8.1.2 High pressure water jet cleaning .................................................................... 17
8.1.3 Hydromilling or Aqualazing ............................................................................. 18
8.2 WATER FLUSHING ................................................................................................ 18
8.2.1 Water quality considerations .......................................................................... 18
8.3 AIR BLOWING ........................................................................................................ 21
8.3.1 Air accumulation/Quick decompression method .......................................... 21
8.3.2 Direct blowing method..................................................................................... 21
8.4 DISINFECTION ....................................................................................................... 24
8.5 HOT ALKALINE TREATMENT ............................................................................... 25
8.5.1 Alkaline degreasing with Soda Ash. ............................................................... 26
8.5.2 Caustic Degreasing .......................................................................................... 27
8.5.3 Permanganate Degreasing .............................................................................. 28
8.6 LUBE OIL FLUSHING............................................................................................. 29
8.7 PIGGING ................................................................................................................. 31
9.
ACCEPTANCE CRITERIA ............................................................................................ 31
9.1
AIR BLOWING ........................................................................................................ 31
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9.2 WATER FLUSHING ................................................................................................ 31
9.3 CHEMICAL CLEANING .......................................................................................... 32
9.4 LUBE OIL FLUSHING............................................................................................. 32
9.4.1 Acceptance after Cleaning and Flushing ....................................................... 32
9.4.2 Acceptance for Service.................................................................................... 32
10. POSTWORK ................................................................................................................. 33
10.1
10.2
10.3
10.4
10.5
REINSTATEMENT .................................................................................................. 33
DRYING .................................................................................................................. 33
INERTIZATION ....................................................................................................... 34
INSPECTION OF CLEANING PERFORMANCE ..................................................... 34
EQUIPMENT LAY-UP ............................................................................................. 34
11. REFERENCES .............................................................................................................. 35
11.1 COMPANY DOCUMENTS ...................................................................................... 35
11.2 PROJECT MANAGEMENT SYSTEM PROCEDURES ........................................... 36
12. ATTACHMENTS ........................................................................................................... 36
12.1 ATT01. SYSTEM CLEANING METHODS ............................................................... 36
12.2 ATT02. CLEANING MATRIX .................................................................................. 37
12.3 ATT03. DETAILED PRE/COMMISSIONING PROCEDURES LIST......................... 38
13. TEMPLATES ................................................................................................................. 39
13.1 TMP01. SATR-A-2008. INTERNAL CLEANLINESS REPORT (PIPING
SYSTEMS & EQUIPMENT) .................................................................................... 39
13.2 TMP02. SAIC-L-2017. PIPING / EQUIPMENT INTERNAL CLEANING
INSPECTION .......................................................................................................... 40
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1. PURPOSE
The object of this document is to specify the cleaning and safety requirements for the piping
systems and equipment (but not limited) in order to remove contaminants such as mill scale,
corrosion products, deposits, nuts bolts and welding rods and other solids left behind during
their transportation, storage and erection. These contaminants would otherwise restrict flow,
impair heat transfer, plug orifice plates and damage equipment such as pumps, compressor
and valves and result in costly shutdowns.
This document neither abrogates nor modifies the contractual agreements between the
Company and Contractor but provides the mechanism for carrying out the normal working
relationship between the parties during the Project execution.
2. SCOPE
The guidelines contained in this document apply to all parties involved into the Project.
This document specifies the procedure - as general methodology - to be adopted for cleaning
all equipment and piping systems of the Units in Haradh and Hawiyah Field Gas Compression
Project, during Mechanical Completion phase, before hydrotest.
Therefore, in case of special cleaning or chemical cleaning, a specialized Subcontractor with a
large experience in management of chemicals and hazardous substances, could be required
to execute the work. This type of cleaning will be carried out after hydrotest and only in those
subsystems that required chemical cleaning.
Due to the huge environmental costs involved in the use of large amounts of water, the use of
air will be preferable for cleaning. In the irremediable case of using water, it must be of an
adequate quality to avoid corrosion problems in the pipe material and must dispose of an
appropriate management and recycling method.
CONTRACTOR shall develop generic Pre-Commissioning Procedures detailing the method
and specific requirements of all types of Pre-Commissioning activity undertaken during the
Pre-Commissioning of the Facilities. These will form the basis of the detailed, step by step
Pre-Commissioning Procedures for each task within a subsystem.
Cleaning detailed procedures should include as minimum but not limited to the correspondent:
subsystem definition and boundaries or limits (set P&IDs), safety recommendations, cleaning
method and fluid, temporary connections and post work. A detailed Pre-Commissioning list of
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activities per subsystem are included in the following Attachment (10130-00-161-PD-0004Att03) as an example.
3. DEFINITIONS
COMPANY:
ARAMCO OVERSEAS COMPANY B.V. (OOK)
Saudi Arabian Oil Company (Saudi Aramco) (IK)
CONTRACTOR:
UTE TR HARADH Gas Compression Project (OOK)
Técnicas Reunidas Saudia for Services and Contracting Co
Ltd. (IK)
PROJECT:
Haradh and Hawiyah Field Gas Compression Project.
•
Package 1: North Gas Compression Plants (NGCP).
•
Package 2: Satellite Gas Compression Plants
(SaGCP).
•
Package 3: South Gas Compression Plants (SGCP).
MOC:
Madrid Operation Centre.
HOC:
Haradh Operation Centre.
VENDOR:
Any person, firm, partnership, company, corporation or
combination thereof with whom CONTRACTOR has sent the
REQUEST FOR QUOTATION or placed the PURCHASE
ORDER
PRE-COMMISSIONING:
Achieved when the facility defined in the approved scope,
construction documentation, drawings, specifications and
material requisitions has been installed and tested (Precommissioned) and is available for commissioning and startup.
4. SAFETY CONSIDERATIONS
Safety precautions during the piping & equipment cleaning shall be in accordance with the
following aspects:
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4.1 HEALTH, SAFETY AND ENVIRONMENT
•
Ensure that permit to work has been issued before proceeding with work.
•
Proper formal communication-coordination protocol between Construction and PreCommissioning will be used.
•
SUBCONTRACTOR team should be managed by experienced and trained personnel.
•
All workforce either TR personnel, Subcontractor and Vendor shall undergo Specific
TR HSE Pre-Commissioning training. HSE Competency Card will issued to all
workforces assigned and/or involved in Pre-Commissioning activities.
•
Ensure that all required Personal Protection Equipment (hardhat, safety glasses, safety
shoes, safety gloves, etc.) are provided and worn by personnel involved in the activity.
•
Air blowing area will be clearly delimited and signposted to prevent unauthorized
personnel.
•
Ensure that correct materials (plastic bag, adequate plastic material, or klingerit joints)
are used to prevent accident or injury to personnel.
•
Specific tools and equipment shall be identified to make and perform tests in the field
with instructions for their use, calibration and storage. Valid inspection and calibration
shall be ensured.
•
For works at height, safe work platform will be provided an all safety rules followed as
per the standards.
•
Access to operating points must allow safety movements.
•
Portable eye washer should be available (if not available operative safety showers/eye
washer in working area); either temporary or permanent, prior to initiation of chemical
cleaning as per SAES-B-069.
•
SDS’s must be available and Personal Protection Equipment will be provided according
to SDS’s specifications, when required (typically used at.: Chemical cleaning, lube oil
flushing, and the like).
•
Provide adequate lighting at all operating points, if required.
•
A detailed and specific JSA and check list will be developed for every type of cleaning
activity.
This document is property of UTE TR Haradh Gas Compression Project and TR Saudia for Services and Contracting Co Ltd.
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During chemical cleaning, specific JSA shall be developed and approved prior work
commence, in addition SDS safety requirements shall be follow, Construction Safety
Manual of Aramco I-10 Hazardous Material Safety Requirements shall be follow but not
limited, other related Saudi Aramco G.I. Shall be followed if applicable. During
Chemical Cleaning, special attention shall be gave to PPE´s, for that CSM I-3 Personal
Protection PPE chapter shall be follow.
•
During any cleaning methodology where is need to be use equipment such as Air
compressor, pumps, electrical power generator, etc., CSM III-2 Mechanical and Heavy
Equipment safety requirements shall be follow.
•
No hands and power tools handmade, damaged, defected shall be used at any case,
those above mentioned shall be removed form site immediately. CSM I-11 Hands tools
and Power tools safety requirements shall be follow
4.2 PRECAUTIONS
•
Check that line supports and temporary accessories near flow outlet are adequate to
avoid line movements.
•
Before removing any line accessories, it must be checked that line is depressurized
and empty.
•
Safe access to all operation points to be provided.
•
Any equipment opening facing to air discharge point shall be covered to prevent foreign
materials from entering and damaging the equipment.
•
Air blowing is not carry out through control valves, exchangers or vessels, unless the
line to such a device has been cleaned first.
•
Air pressure shall never exceed 80 psig.
•
The execution of flushing works shall include the necessary measures for safety,
cleaning of area and disposal of the waste water.
•
Ensure that water outlet points are properly barricaded. “Water Flushing/Air
Blowing/Chemical Cleaning on going. Keep out” signs shall be clearly displayed on
the barricade.
•
Ensure that appropriate hoses, fittings and connections are used to prevent accidents
or injuries to personnel. Temporary fittings and spools shall be approved and tested.
This document is property of UTE TR Haradh Gas Compression Project and TR Saudia for Services and Contracting Co Ltd.
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A suitable communication method (e.g. two-way radio) shall be available and operative
among personnel in the activity.
•
During flushing, design pressure of the system cannot be exceeded.
•
During water filling and/or drainage of lines and equipment, vents should be maintained
fully open in order to avoid overpressures or vacuum in lines and equipment.
•
Water used for flushing should be with normal operation quality: raw water, utility water,
potable water or demineralized water. In order to avoid stress corrosion cracking,
allowable chlorine ion concentration in water should be below 50 ppm for austenitic
stainless-steel pipes and piping components in contact with water.
•
All lines or systems to be subject to water flushing shall be properly supported.
Dragging forces produced during flushing could cause the line is displaced.
•
All electric equipment which can be affected during flushing water drainage (motors,
junction boxes, etc.) should be protected with plastic covers.
•
The suction side of temporary pumps to be used for flushing, must be equipped with a
strainer to catch foreign materials.
•
Whenever a vessel full of water has to be emptied, a special note will be issued to state
that a vent will have to be opened previously in order not to create a vacuum in the
vessel.
•
Take suitable measures to prevent that dirty water enters any permanent equipment,
specially pumps, compressors, and heat exchangers.
•
System to be cleaned must be isolated from the other adjoining systems.
•
Drain/vent points should never be cleared with sticks and/or other manual tools if line is
not completely depressurized.
•
For Chemical Cleaning, store all chemicals needed for the procedure on-site prior to
commencing cleaning, including emergency neutralizing agents and nitrogen.
•
For Chemical Cleaning ensure that the system heater or an external heat source is
available to maintain the cleaning fluid temperature, within the limits specified.
This document is property of UTE TR Haradh Gas Compression Project and TR Saudia for Services and Contracting Co Ltd.
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5. ROLES AND RESPONSIBILITIES
5.1 PRE-COMMISSIONING MANAGER
•
- Leading and coordinating CONTRACTOR's Pre-commissioning activities.
•
- Directly report to the Site Manager.
•
- Coordinates and follow up meetings with the CLIENT's Pre-Commissioning Manager,
in order to meet contractual and project requirements.
•
- Coordinates and manages the Pre-Commissioning activities with the rest of
CONTRACTOR's Managers, regarding to work with the same flow and meeting project
schedules.
5.2 PRE-COMMISSIONING SUPERINTENDENT
•
Prepare a planning/schedule for the cleaning activities.
•
Follow up site activities.
•
Prepare monthly progress report of activities performed by pre-commissioning group.
•
Organize with pre-commissioning manager daily activities and select the equipment to
be cleaned.
•
Coordinate together with pre-commissioning supervisors all safety activities at site.
•
Prepare P&IDs pre-commissioning “as built” copy to be sent to home office for final
issue.
•
Assist and co-work with pre-commissioning manager to manage and plan all activities
required for achieving the Mechanical Completion Certificate in full accordance with
plans, specifications and terms of contract.
5.3 PRE-COMMISSIONING SUPERVISOR
•
Organize and guide sub-contractor personnel at site during the execution of piping
equipment cleaning activities.
•
Check that sub-contractor personnel follow up the detailed procedures for the
preparation of circuits for the execution of pre-commissioning works.
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Check that sub-contractor has enough man power, equipment and tools to perform the
works within the scheduled time.
•
Coordinate with sub-contractors for inspections of the executed works with the
attendance of COMPANY personnel.
•
Coordinate safety aspects of the work.
•
Monitoring subcontractor supervision is present during the pre-com activities to ensure
the proper safety precautions and work instructions are being implemented.
5.4 HSE MANAGER
•
Ensure SUBCONTRACTORS compliance with, understanding and implementation with
of HSE Requirements stated in all HSE plans and procedures.
•
In the event of an accident/ incident prepare accident/ incident reports and
investigations,
both
for
site
and
governmental
bodies
in
conjunction
with
SUBCONTRACTOR.
•
Promote, plan and schedule motivation activities to increase Health, Safety and
Environmental awareness on Site.
•
Establish, follow up and update all Safety, Health and Environmental record-keeping
systems, including the Environmental log as established in the Construction
Environmental Management Plan.
•
Distribute 24 hours in advance as minimum, notices communicating all interested
parties of tests that are being performed or warning them about possible new risk
conditions.
•
Follow up and update environmental aspects and objectives as required in the
Construction Environmental Management Plan.
5.5 HSE SUPERINTENDENT
HSE Superintendent will coordinate all safety, health, environmental and precommissioning
activities
in
the
area
to
which
they
are
assigned
and
will
be
in
continuous
communication with HSE Area Manager. He will be assisted by area HSE Supervisors and
SUBCONTRACTOR HSE team. The HSE Superintendent main responsibilities for their
area of responsibility will be:
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•
Assist the Site HSE Manager in any duty he shall perform.
•
Sign permits to work and have available copies of all work permits required in order to
guarantee compliance with their conditions and regulations.
•
Daily inspect the Work Site in cooperation with Sub-CONTRACTORs, HSE and
supervisors.
•
Identify and report on a daily basis unsafe situations and unsafe acts.
•
Take immediate action to correct unsafe situations or initiate corrective measures.
•
Maintaining all HSE related record and files associated with the projects.
•
Attend periodical or special HSE meetings as required.
•
Assist in the performance of risk assessment.
•
Participate in CONTRACTOR or COMPANY scheduled work area audits or inspections
and implement and document required corrective actions.
•
Check that the field equipment inspection program has been implemented and tags/
labels have been provided.
•
Check that personal protection equipment is suitable for the use for which it is
intended.
•
Carry out inspections to ensure compliance with SUBCONTRACTOR Project Site
Safety
Program,
CONTRACTOR
Project
Site
Safety
Program,
COMPANY
requirements and National and local regulations.
•
Arrange HSE publicity and coordination of safety incentive, recognition, and personal
contact programs.
•
Advise on safety, health and environmental regulations, inspections, and activities of
government that require compliance.
•
Provide HSE coordination, leadership, and HSE advice to line management and
organization of training programs requested.
•
Immediately visit the site of serious injuries to view evidence, conduct investigation,
prepare a report and institute corrective action.
•
Ensure workers’ welfare is maintained.
•
Establish and maintain site emergency response team.
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Request the proper installation of an adequate number and type of firefighting
equipment, according to the Site HSE Plan.
5.6 HSE SUPERVISOR
CONTRACTOR HSE Supervisor’s main responsibilities are:
•
Assist the Site HSE Superintendent and HSE Area Manger in any duty they shall
perform.
•
Identify and report on a daily basis unsafe acts and conditions.
•
Take immediate action to correct unsafe scenarios or initiate corrective measures,
stopping the works if necessary.
•
Prepare layout clearly indicating firefighting equipment location.
•
Ensure documentation and equipment certificates are available and valid before
entering the site.
•
Attend periodical or special HSE meetings as required.
•
Assist in the performance of risk assessment and JSA.
•
Take part in CONTRACTOR or COMPANY scheduled work area audits or inspections
and implement and document required corrective actions.
•
Check that the field equipment inspection program has been implemented and tags/
stickers have been provided.
•
Check that personal protection equipment and collective means are suitable for the use
for which they are intended.
•
Distribute to SUBCONTRACTOR standards, procedures or any other document that
may be required to organize works safely.
•
Carry out inspections to ensure compliance with SUBCONTRACTOR Site Safety
Program, CONTRACTOR Site Safety Program, COMPANY requirements and National
and local regulations.
•
Support CONTRACTOR HSE Manager to prepare periodic Safety reports, ensuring
their distribution in a timely manner.
•
Ensure workers’ welfare is maintained at all times.
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5.7 COMPANY WITNESS
COMPANY personnel must witness all the pre-commissioning activities as per Division of
Responsibilities for Turnover SA GI-2.710-5. COMPANY responsibilities should follow section
4 from SAEP-1662.
6. PREPARATION BEFORE THE CLEANING
The following pre-cleaning is required:
6.1 PREPARATION OF PIPING
•
Cleaning shall be carried out before hydrostatic pressure testing of the installed
pipework.
•
During flushing the spring supports and spring hangers shall be blocked.
•
For large diameter pipe temporary supports may be required if the line is designed to
carry gases instead of liquids.
•
Isolate equipment such as pumps and vessels that not need cleaning.
•
Fabricate and install bypasses around equipment to be isolated as required.
•
Block valves shall be left fully open during cleaning.
•
Check valves (in case of welded check valves which cannot be removed, they shall
be set in fully open position by means of internals removal)
•
Ejector nozzles and Traps shall be removed.
•
Internal of filters and strainers shall be installed after cleaning activities.
•
Process limitations regarding over pressure or creating vacuum of any vessels and
tanks to be taken into account.
•
All equipment that may be subject to damage by the line cleaning procedure must be
protected with appropriate barriers.
•
The diameter of the outlet pipe shall be at least 2/3 of the line to be cleaned.
•
When a couple of flanges has to be opened to allow the flow to flush out, the
distance between the two flanges shall be at least 1/6 (one sixth) of the pipe
diameter.
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Drains not designed for such large flows should not be used to evacuate water since
they might be flooded.
•
Where piping is not isolated from mechanical equipment, the specific cleaning
requirements prescribed by the equipment vendor must be reviewed to ensure pipe
cleaning methods do not void with mechanical equipment guarantees.
6.2 PROTECTION OF INSTRUMENTS IN PIPING
The following instruments shall be not installed or shall be removed to protect them from
damage during cleaning:
•
Temperature Gauges (with thermowells).
•
Pressure Safety Relief Valves (PSV).
•
Pressure Safety Elements or Rupture Disk.
•
Pressure Regulators.
•
Flow Meters (positive displacement, mass flow turbine and vortex type).
•
Flow Indicating Switches (bellows type).
•
Control Valves and regulators.
The following instruments shall be blocked and vented during cleaning (if no block and vent
valve is available the instrument shall be removed):
•
Pressure Gauges.
•
Pressure Instruments (all types).
•
Pressure Switches.
•
Level Switches- float type (if applicable).
•
Level Instrument (differential pressure cell and bellows type).
•
Glasses.
•
Flow Instruments (differential pressure cell and bellows type).
•
Level Instruments (displacer type).
•
Flow switches (vane type).
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Any other specific instrument or equipment identified shall be removed or blocked during
cleaning operation.
6.3 PROTECTION OF EXISTING EQUIPMENT
•
During blowing of lines the exhaust must be directed toward a safe location and
toward a shield resistant plate.
•
All equipment that could be damaged by the cleaning processes shall be properly
protected. Cover motors with a tarpaulin, insulation, instruments near the flow outlet,
etc.
•
The cleaning fluid shall never flow through pumps or compressors: the line shall be
disconnected before the equipment or a “jumper” shall be installed.
7. REQUIREMENTS TO CLEAN EXISTING EQUIPMENT
• Do not use existing process drain to evacuate large quantities of cleaning fluid exhaust.
• Do not contact equipment containing austenitic material with the following materials:
o
Chlorinated solvents.
o
Cleaning compounds/solutions containing Sulphur.
o
Acid cleaning solutions.
• Contractor to make sure acid solutions containing halides or chemicals such as
hydrochloric acid does not come in contact with pipes and equipment containing
austenitic steel material (Water shall content less than 50 ppm chloride to be acceptable).
• Do not introduce chemical solution into equipment unless high point vents and low point
drains are available to ensure proper filling and complete removal of solutions.
• Heat is not to be applied directly to equipment containing acid solutions.
• Instrument and equipment removed during cleaning shall be protected from damage
including the flange faces.
• Cleaning shall preferentially be done along the designed flow direction only.
• Cleaning shall preferentially be done starting from top to bottom.
• Main header shall be cleaned first.
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• Cleaning shall remove all loose non-adherent materials which could break away during
operation of the piping system and equipment.
• Removal of weld slag, flux, debris, grease, oil and any foreign matter on the internal
surfaces of piping systems shall be performed by using cleaning methods.
• All Cleaned surfaces are to be protected by methods consistent with industry standard
practices.
• If any clean surface that is previously cleaned is contaminated it shall be re-cleaned.
• Blankets to be installed on platforms to protect equipment and people close to the
cleaning area.
• Whenever a vessel, full of water, has to be emptied, special care to be taken that vents
are previously opened in order not to create vacuum conditions in the vessel.
• The cleaning fluid shall not flow through any exchanger unless the upstream pipes have
been cleaned (use the by-pass, if any, or “break” the line before the exchanger).
• The flushing is generally not carried through columns or drums.
• If a vessel is used as an air reservoir, all internals, such as demisters, have to be
dismantled prior to starting the flushing, to avoid damage on them.
• Any column or drum to be used as an air reservoir must have its associated relief valve(s)
in normal operation before starting any pressurization.
8. CLEANING METHODS
The cleaning methods to be used shall be selected based on the piping service, the
constituent materials and the particular pipework arrangement (diameter and length).
Manufacturer recommended procedure for cleaning shall be followed in addition to this
procedure.
In next paragraphs are described all cleaning methods to be used in this project, according to
SAES-L-350.
For further information, see attachments 10130-00-161-PD-0004-Att01 and Att02 of this
procedure, with detailed Cleaning Methods and Matrix.
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8.1 MECHANICAL CLEANING
•
When a technician can access to the network (i.e. vessels and large diameter pipes),
the most efficient way to clean the surfaces consists of manual brushing and removing
the rust fallen down with a vacuum cleaner and/or a final blowing. If reachable,
surfaces to be cleaned can be brushed or air hosed from outside.
•
Scraping, brushing, drilling or blasting with abrasives are conventional mechanical
cleaning methods in which the cleaning effect is obtained by abrasion of the deposits.
•
In using any of these methods great care shall be taken not to damage the equipment
being cleaned.
•
Brushing can be applied for the removal of relatively soft deposits. For the cleaning of
the inside of heat exchanger tubes, special cleaning brushes with extension rod
assemblies are available. Care shall be taken to avoid mechanical damage to the tubes
due to bending of the extension rods.
•
High-pressure water jetting is a common method for cleaning exchangers and furnace
tubes.
•
Specific Permit to Work for Confined Spaces shall be raised and proper safety
measures shall be implemented, Permit to Work Procedure (10130-00-091-PD-0013).
8.1.1 Brushing
When a technician can access to the network (i.e. vessels and large diameter pipes), the
most efficient way to clean the surfaces consists of manual brushing and removing the
rust fallen down with a vacuum cleaner and/or a final blowing. If reachable, surfaces to
be cleaned can be brushed or air hosed from outside.
8.1.2 High pressure water jet cleaning
HP water jet cleaning is the most common method of conventional mechanical cleaning
for many applications (cleaning of exchangers and furnace tubes, large diameter lines,
etc.). It is also often used to complete a chemical cleaning process.
•
This operation requires to be carried out a specialized Contractor and high pressure
water jet equipment:
•
Equipment with a capacity of 130 litres of water per minute and a pump pressure of
14500 psi max. are normally used, mainly for the cleaning of heat exchanger tubes.
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However, effective cleaning of other types of equipment and piping with hard
deposits, requires higher pressures and greater volumes of water.
•
To obtain optimum results, adequate water pressure and water flow shall be
established for each cleaning operation. Especially careful must be maintained to
avoid damage to non-metallic pipes.
8.1.3 Hydromilling or Aqualazing
This is an advance high-pressure water jetting process, including on the mechanical
cleaning types, which can effectively clean piping systems of mill-scale, construction
debris, and process deposits. In addition to piping systems, Aqualazing can be used to
clean other critical plant components which can become contaminated with water or
process deposits.
Following SAES-K-402 (“Centrifugal compressors”) and SIC00007 (“Process Piping
Cleanliness Requirement for Centrifugal Compressors”) recommendations the suction
piping of the centrifugal compressor’s trains are going to be cleaned by this method. If it
is necessary, a third-party service will be contracted to carry out these activities with the
appropriate equipment (HP pump, flexible and rigid lances, cleaning nozzles, and the
like).
Disposal of water after cleaning shall follow recommendations and criteria from SAEP327.
8.2 WATER FLUSHING
Water flushing is one cleaning method that cleans with kinetic energy of a water flow.
Foreign materials such as sand, rust and weld slag located inside pipes will be removed by
the kinetic energy of the water flow.
During the pre-commissioning stage water flushing is carried out with pumped water by the
pumps installed permanently or with temporally pump facility.
8.2.1 Water quality considerations
Material Specifications should indicate type of water to be used to prevent corrosion
problems.
Pipe Material
Carbon steel
Flushing water to be used
Raw water / Fire water
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Pipe Material
Flushing water to be used
Copper Tubbing
Raw water / Fire water
S.S. AISI 304 L
Demineralised water (<50ppm Cl)
Monel
Raw water / Fire water
Glass lined C.S.
Raw water / Fire water
Sanicro
Raw water / Fire water
Duplex
Demineralised water (<50ppm Cl)
Potable water lines
Potable water
Fiber Glass Reinforced
Plastic
Raw water / Fire water
8.2.1.1 Planning
Big bore piping are not recommended to be water flushed because of the big
amount of water and pumping capacity to be required.
Water flushing route shall be defined and marked up on the P&IDs in the
system’s detailed water flushing procedure.
The following items shall be indicated on the P&IDs:
• Water supply point and water supply source.
• Water discharge points.
• Valves to be operated.
• Temporary piping, spool and blind spectacles, if any.
• Pipe accessories and instruments to be isolated or removed.
The diameter of the outlet pipe shall be at least 2/3 of the diameter of the line to
be cleaned, and at least as large as the inlet pipe.
Provision of an air connection is recommended to enhance drain out by air
sweeping after water flushing.
8.2.1.2 Preparation
Prior to the commencement of flushing, the route shall be checked (walked
down) at site by the Pre-commissioning Team in charge of this system using
the prepared detailed procedure.
Following items, if any, shall be isolated or removed:
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• Safety valves
• Check valves, as required
• Self-activated valves except ball/gate type ones
• Emergency shut off valves except ball/gate type ones
• Rupture disks
• Spargers
• Orifice plates or turbines flowmeters, and other flowmeter elements
• In-line mixers, strainers and filter elements
• Spray nozzles
• Control valves except ball/gate type ones
8.2.1.3 Material resources
The following items should be available for water flushing execution:
• Water hoses
• Hose arrestors (hose safety whip checks)
• Water hose connection flanges. (Tested and certified)
• Temporary ball valves screwed and flanged. (Tested and certified)
• Temporary Klinger Gaskets
• Portable diesel pumps and portable tank
• Temporary flanged connections. (Tested and certified)
• Calibrated Pressure indicators
• Temporary spools (Tested and certified)
8.2.1.4 Execution
• Water is introduced to the pipes to be flushed at available maximum flow
within the limit of draining capacity of the pipe.
• Whenever possible, the cleaning fluid shall flow from top to bottom.
• First, flush the main headers/lines and then proceed to clean the branches.
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• During flushing, it is very important to get as much water velocity as
possible in order to remove from line all the foreign material and particles.
8.3 AIR BLOWING
Air blowing is one cleaning method that cleans with the kinetic energy of an air flow.
Foreign materials such as sand, debris, rust and weld slag located inside pipes are
removed due to the effect of the air flow. Since the specific gravity of air is small, high
velocity is required to obtain large kinetic energy.
Air for blowing will be supplied from Utility air header or temporary portable dry and oil
free air compressor(s) shall be used in case the permanent air supply compressor(s) are
not ready.
During the air blowing, larger lines or headers are blown first, followed by smaller lines,
branches or sub-headers.
Air blowing may be developed by one of the following methods described here bellow.
8.3.1 Air accumulation/Quick decompression method
Compressed air is accumulated in a suitable reservoir such as column/drum/vessel/big
bore piping associated with the piping to be blown. A valve should be located as close
to the reservoir as possible to produce maximum velocity in the pipe. Then, the piping
connected is blown by opening the valve and breaking the selected plastic bag or the
adequate plastic material. Temporary or permanent equipment can be utilised as a
reservoir. Caution should be taken to ensure air is blown / vented to a safe location.
8.3.2 Direct blowing method
The pipe to be air blown to atmosphere is directly connected to the air supply source via
temporary pipe or air hose.
This method is typically applied to small bore pipe and vessels. A suitable air supply
source is required, either from the utility air supply header or from a temporary
compressor.
8.3.2.1 Planning
Air blowing route shall be defined and marked up on the P&IDs in the detailed air
blowing procedure.
The following items shall be indicated on the P&IDs:
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• Air inlet points
• Air discharge points
• Valves to be operated
• Temporary piping, spools and blinds, if any
•
Pipe accessories and instruments to be removed
If a rupture disk (bursting disc) is to be installed on a large diameter pipe, the set
pressure of the disc shall be carefully calculated in order to limit the energy
released when bursting occurs to an acceptable level (In particular with regard to
recoil effect). Supports shall be always verified.
When plastic sheets are used as bursting accessory, trial and error method is used
to achieve the desired bursting pressure.
8.3.2.2 Preparation
Prior to the commencement of blowing, the air-blowing route shall be checked
(walked down) at site by the Pre-commissioning Team in charge of this system
using the prepared detailed procedure.
Following items, if any, shall be isolated or removed:
• Safety valves
• Check valves, as required
• Self-activated valves except ball/gate type ones
• Emergency shut off valves except ball/gate type ones
• Rupture disks
• Spargers
• Orifice plates or turbines flowmeters, and other flowmeter elements
• In-line mixers, strainers and filter elements
• Spray nozzles
• Control valves except ball type
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8.3.2.3 Material resources
Pre-Commissioning Team shall ensure traceability in management and inspection of
temporary elements (material, equipment, where they come from, service, hours,
condition).
Following items shall be available for air blowing execution as temporally facilities:
• Air hoses
• Hose arrestors (hose safety whip checks)
• Air hose connection flanges. (Tested and certified)
• Temporary ball valves screwed and flanged. (Tested and certified)
o
Temporary Klinger Gaskets
o
Portable oil free air compressors
o
Temporary flanged connections. (Tested and certified)
o
Calibrated Pressure indicators
o
Temporary spools (Tested and certified)
8.3.2.4 Execution
8.3.2.4.1
Air accumulation/Quick decompression method
• Check that the circuit is isolated.
• Check that all safety measures have been adhered to.
• If a quick opening valve is used, allow the air to enter the circuit and carefully
check that pressure in the system never exceeds the maximum allowable
pressure. When the required pressure is reached, quickly open the valve. This
operation shall be repeated as many times as needed. First, blow the main
headers/lines and then proceed to their branches.
• If a rupture disk is used, allow compressed air to enter the circuit; check
continuously the pressure rise, and when the rupture disk blows out, stop the
air inlet in the circuit. This operation shall be repeated as many times as
needed.
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8.3.2.4.2
Direct blowing method
• Start the air compressor (when used).
• Open the valves on the main header to be air flushed.
• Allow the air flow to enter the network.
• If the valve between the compressor and the network to be flushed is a globe
valve, and if the compressor allows for quick increases of flow rates, changes
of flow rates in the line may be made. By changing the air velocity, a more
effective removal of rust and scales from surfaces can be achieved. For loose
dirtiness, a continuous blowing at a constant speed should be sufficient.
8.4 DISINFECTION
This section is applied to potable water systems. RO membranes and safety showers
systems.
The purpose of this method is to disinfect installed potable water piping system by removal
of biological contaminants harmful to human health. This shall be done in compliance with
all laws and regulations.
To do it, is necessary to perform internal chemical cleaning of the installed piping system by
disinfectant solution. The flushing agent shall be potable water and the chemical that can
be use shall be:
•
Liquid chlorine packaged in steel cylinders in conjunction with a chlorinator.
•
Sodium Hypochlorite
•
Calcium Hydrochloride
Prior to start disinfecting pipes, CONTRACTOR shall ensure all showers and facets are
closed, also block valves shall be left fully open during cleaning. Personnel, who are
working disinfecting the pipes, shall wear PPE equipment and may require special mask.
•
Flush all pipe lines with potable water before disinfecting. Minimum flushing velocity
should be 0.75 m/s for water mains.
•
Flushing shall continue until water discharges are clear and free from turbidity and
extraneous materials.
•
Fill the pipes with potable water and the solution of concentrated chlorine.
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During the chlorine is inside the pipes, all valves in the system shall be cycled on and
off a minimum of 5 times.
•
Chlorinated water shall be flushed from the system after the applicable contact period
with potable water till this water is chlorine free. Then all safety showers and faucets
shall be closed.
•
Outlet pipes or nozzles at flushing discharges shall be directed to a safe location where
chance of damage from disposal of flushing water is minimal.
•
Wastes shall be disposed of in an environmentally acceptable manner.
8.5 HOT ALKALINE TREATMENT
According to the material of the new lube oil system fabricated all from stainless steel
components (318/316 SS Dual), acid/EDTA cleaning and passivation are not required; only
hot alkaline treatment.
Following the requirements of the SAEP-1028 selection of a removal treatment depends on
the degree of contamination:
TREATMENT
Degree of organic
contamination (wt. %)
Hot steam or condensate or demineralized
water at 95ºC (with or without surfactant)
>5
Soda ash
5-10
Caustic (NaOH) degreasing
10-25
Permanganate (KMnO4) degreasing
<25
General preparation:
•
Ensure all safety precautions and precleaning (if required) are complete. Note that prior
to initiation of hot alkaline treatment it is required:
Eye wash fountains and/or safety showers (SAES-B-069).
Work permit procedures:
- “Release of flammable gas” work permit is required when flammable
chemicals are going to be used.
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- Hot work permit to operate pumps.
Equipment necessary for the containment and clean-up of small chemical spills.
Available plan to route any runoff or spills that cannot be contained or absorbed
to a segregated containment pit or if required to the plant general slops system.
Cordon off the area and post it with “DANGER” and “NO ENTRY TO
UNAUTHORIZED PERSONNEL” signs.
Chemical Hazard bulletins for each chemical or material to be used shall be
continuously available on site. If they are not available, the Safety Data Sheet
(SDS) are required from the manufacturer.
All personnel handling chemicals shall wear the personal protective equipment
(PPE) specified by the Chemical Hazard Bulletin or SDS for the materials
involved.
•
Ensure lube oil and fluid power system instrument leads are isolated for protection,
unless required for the cleaning operation.
•
Inspect all pressure parts for obstructions (lines, drains and vents), to be certain that
they are clear.
•
Commercial grade quality chemicals will be adequate for use according to SAEP-1028.
Hot alkaline methods:
8.5.1 Alkaline degreasing with Soda Ash.
Control Parameters:
Chemical
Concentration
Sodium carbonate
0.5 to 1.0% by weight
Sodium metasilicate
0.5 to 1.0% by weight
Trisodium phosphate
0.5 to 1.0% by weight
Surfactant
0.1 to 0.2% by volume
Anti-foam (if required)
0.05 to 0.1% by volume
Temperature Limit
95°C maximum
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Circulation rate
150 to 250 L/minute
Residence Time
4 to 6 hours
Corrosion Rates
< 2 mpy for carbon steel
Safety Hazards:
The solution can react violently with acids.
Procedure:
•
Dissolve the chemicals externally and blend fill through the chemical feed
connection. Fill the lube/seal oil and fluid power systems to ensure adequate
alkaline solution contact with the contaminated metal surfaces. Vent air, as
required, from high point vents to allow complete liquid filling of the system.
•
Heat the solution with steam to 95°C and circulate for 4 to 6 hours after the
required temperature is reached.
•
Drain the system into a holding tank.
•
Following complete draining of alkaline solution, fill the system with steam
condensate or demineralized water heated to 77°C for a rinse.
•
Drain the system and the repeat rinse.
•
The lube and seal oil system will be inspected by Operations and Operations
Engineering. If the inspection indicates unsatisfactory removal of oil and grease,
repeat the entire procedure.
Testing:
Immediately after the system has been filled and once each hour thereafter during
circulation, determine the phosphate values. If the phosphate concentrations drop to half
the original values, add additional chemicals to restore the original concentrations.
8.5.2 Caustic Degreasing
Control Parameters:
Chemical
Concentration
Sodium hydroxide
1.0 to 2.0% by weight
Trisodium phosphate
0.5 to 1.0% by weight
Surfactant
0.1 to 0.3% by volume
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Anti-foam (if required)
0.05 to 0.1% by volume
Temperature Limit
95°C maximum
Circulation Rate
150 to 250 L/minute
Residence Time
4 to 6 hours
Corrosion Rates
< 2 mpy for carbon steel
Safety Hazards:
Sodium hydroxide reacts exothermically with water and must never be added to hot
water. All dilution of sodium hydroxide, either liquid or solid, should be carried out slowly
with constant stirring.
Procedure:
The procedure steps are the same as in Section 8.5.1.
Testing:
Immediately after the system has been filled and once each hour thereafter during
circulation, determine the phosphate values. If the phosphate concentrations drop to half
the original value, add additional chemicals to restore the original concentration.
8.5.3 Permanganate Degreasing
Chemical
Concentration
Sodium hydroxide
1.0 to 3.0% by weight
Potassium
permanganate
1.0 to 3.0% by weight
Temperature Limit
95°C maximum
Circulation Rate
120 to 150 L/minute
Residence Time
4 to 6 hours
Corrosion Rates
< 2 mpy for carbon steel
Safety Hazards:
Handle potassium permanganate with care, as it is a strong oxidizing agent. Add slowly
with constant stirring to dilute sodium hydroxide in water.
Precautions:
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Do not use any antifoam or surfactant as they will react with permanganate and deplete
its strength. This treatment frequently results in the deposition of manganese dioxide.
Procedure:
•
Dissolve the chemicals externally and fill the lube/seal oil and fluid power systems
to contact with contaminated metal surfaces.
•
Heat the solution with steam to bring to desired temperature range. Circulate, using
chemical cleaning pumps for 4 to 6 hours. Monitor permanganate concentration
until concentration stabilizes.
•
Drain the solution into a holding tank.
•
Following complete draining of alkaline solution, fill the system with steam
condensate or demineralized water heated to 77°C to rinse.
•
Drain the system and repeat rinse.
•
The lube and seal oil system will be inspected by Operations and Operations
Engineering. If the inspection indicates unsatisfactory removal of oil and grease,
repeat the entire procedure.
Testing:
Immediately after the system has been filled and once each hour thereafter during
circulation, determine the permanganate concentration. If permanganate strength drops
below 1.0% do not add permanganate to increase its concentration. Drain the system
into a holding tank, add fresh degreasing solution and continue circulation.
8.6 LUBE OIL FLUSHING
Cleaning applied to Lube Oil and Seal Oil piping systems of compressors and pumps with
their drivers and gear box.
•
Before commencing oil flushing, the lube oil and seal oil piping systems will be cleaned
by air blowing in order to remove all dirt and debris. Blowing will be performed jointly
with hammering of piping for removal of particles. Air blowing will also remove water or
moisture present in the piping system.
Prior to charging the system with flushing oil it is recommended to confirm the cleanliness
of the tank and the piping by inspecting all accessible areas where possible.
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A jumper spool should be installed to bypass the machine bearings, couplings, gear
boxes and other areas where lube oil is supplied. If it is not practical to flush the feed
lines in situ, they can be removed, thoroughly cleaned, sealed and finally reinstated
after the cleaning.
•
To avoid compatibility problems, the system shall be flushed with the same operating
oil unless otherwise specified by vendor. Temporary stainless-steel screens of a mesh
number defined by the vendor backed up by perforated steel plates should be installed
on the return side of the jumpers for collecting dirt during the flushing. A large fine
mesh screen should be installed on the main oil return line at the flange on the lube oil
tank. The screen will be regularly inspected for cleanliness with a frequency depending
on the quantity and nature of dirt found.
•
The amount of dirt collected in the fine mesh screen will indicate the cleanliness of the
system. The screen will be regularly inspected for cleanliness with a frequency
depending on the quantity and nature of dirt found. But on initial flushing a check will be
done after a few time as per commissioning personnel criteria at site.
•
Flushing oil will be circulated into the whole system by using its own lube oil pumps and
heated up to 158ºF (70 ºC) - 176ºF (80 ºC) by means of tank heater or by a temporary
heat exchanger connected to the circulation system. It is preferred to circulate the oil
with the two lube oil pumps to increase the velocity through the pipes. To avoid
dirtiness from entering the pumps, temporary filters will be used.
•
A thermal shock of the system, obtained allowing the oil temperature to drop
temporarily to approx. 122ºF (50ºC), may be found effective for loosening adherent
particles that may have adhered to the piping surfaces should be accelerated by
vibrating or hammering oil lines.
Note: It shall be noted that if the permanent pumps and heaters are used, CONTRACTOR
will ensure that pumps will be available, and the lube oil pumps control are working to avoid
any delay in starting the flushing. If not, a generator will be provided to energize the pumps
from the proportional MCCs and in this case the flushing process will be monitored 24
hours to trip the pump manually in case of losing the oil or any other reason that will require
shutting down the lube oil pump.
The use of Lube Oil system pumps is allowed during the lube oil flushing activities, fulfilling
with the SAEP-1028 and VENDOR (V-10130-10-510-0100-0051, drawing SIC00006)
requirements.
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10130
PIPING & EQUIPMENT CLEANING PROCEDURE
PAGE 31
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REV.: 05
8.7 PIGGING
Blowing of long lines (e.g. offsite lines > 400 meters) is impractical and in most cases
ineffective. Good results will be obtained by scraping critical lines (feed/product lines) with
scraper pigs. This method is slightly more expensive, but the risk of contaminated feed or
product can thus be eliminated.
9. ACCEPTANCE CRITERIA
The procedure should be approved by the Materials Engineering & Corrosion Operations
Division/ Consulting Services Department (ME&COD/CSD), according to SAEP-1662, section
4.7.
9.1 AIR BLOWING
Cleanliness criteria: The color of the air at the exit point will indicate whether or not rust and
dirt remain in the piping. This is usually sufficient for the majority of process and utilities
piping.
When the cleaning criteria is more restrictive, install a white fabric or cardboard in front of
the air blowing exit for checking air cleanliness by observing the presence of particles
impacting on the white surface. The fabric or cardboard must be fixed to the pipe or well
supported to avoid it to blow or move by the exiting air flow. It will never be supported by
hand in front of the air flow.
Cleaning results shall be recorded in your corresponding check list.
9.2 WATER FLUSHING
The flushing is deemed completed when foreign materials that will interfere with system
normal operation are no longer visualized in flushed water and the effluent water is clear.
For plant water flushing, acceptance criteria should be that the color of the outlet water
must be similar to the quality of the inlet water. The color should be checked by taking a
water samples in a plastic or glass transparent bottle. It should be noted that in Carbon
Steel lines, color of water at the outlet point will be always yellowish.
Cleaning results shall be recorded in your corresponding check list.
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PIPING & EQUIPMENT CLEANING PROCEDURE
PAGE 32
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REV.: 05
9.3 CHEMICAL CLEANING
The chemically cleaned pipes shall be examined at accessible points. The internal surface
of pipe shall be uniform and free of rust and deposits. If the inspections show imperfect
treatment, the operations of chemical cleaning shall be repeated.
Depending on the phase and product used for chemical cleaning, the following parameters
can be controlled: turbidity, pH, total iron (Fe3+), conductivity, and any other parameter as
defined in Specific Procedures.
Cleaning results shall be recorded in your corresponding check list.
9.4 LUBE OIL FLUSHING
9.4.1 Acceptance after Cleaning and Flushing
After a minimum of 24 hours continuous flushing, a final cleanliness check shall be
made. The inspection screens shall be cleaned and reinstalled and the flushing oil shall
be circulated for an additional period of 12 hours. The system is clean if:
•
No visible accumulation of dirt/foreign material is found on the screens after 12
hours of circulation.
•
Moisture cannot be detected using the Lube Oil Condition Monitoring Program
Laboratories’ hot plate crackle test method.
•
All surfaces in contact with oil shall have a uniform clean metallic color. Accessible
surfaces, when viewed without magnification, shall be free of visible metal deposit,
preservatives, welding slag, rust, corrosion, oxides, paint or other foreign material.
•
The cleanliness of the system is acceptable to the Saudi Aramco proponent
organization’s Operations personnel.
9.4.2 Acceptance for Service
•
After flushing is completed per SAEP-1028, fill the system with clean unused
service oil.
•
Establish normal lube, seal oil and fluid power system flows in preparation for
equipment start-up.
•
Circulate for two hours and collect a composite two liter sample from different
drains. Send the sample to Southern Area Laboratories Division at Abqaiq for
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PIPING & EQUIPMENT CLEANING PROCEDURE
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chemical and physical analyses listed in paragraph 6.2. The system oil will be
considered acceptable for service, by CSD Lubrication Engineer, when:
−
The particle count, in accordance with ISO 4406, is 17/16/13 or less. If tworange ISO codes are used, the particle count shall be 16/13 or less.
−
The moisture content, in accordance with ASTM D1744, is 200 ppm or less.
−
The rest of physical and chemical analyses are within the acceptable levels
for new oil.
The sample bottle must be clearly labeled “Final Fill Sample for the attention of the
CSD Lubrication Engineers”
10. POSTWORK
10.1 REINSTATEMENT
Contractor shall reinstall all equipment and instrumentation which had been removed for
cleaning. Instrument, equipment and piping shall be returned to the pre-flush condition
integrity as per relevant project drawings and specifications.
10.2 DRYING
Drying of piping systems shall be performed as last phase after water flushing or hydrotest.
Exceptions can be made in cases where water flushing is directly followed by water
batching or steam blowing. In such cases intermediate drying is not required.
The objective is to remove free water out of the cleaned piping systems and equipment by
means of blowing with plant air, instrument air or nitrogen. It is crucial that systems shall be
100% drained and dried (unless otherwise agreed) prior to preservation/Hand-over. In
many cases start-up disturbances are caused by incomplete draining and drying activities
(e.g. product contamination, or blockage of burners).
Drying can be distinguished into two different categories depending on the acceptance
criteria:
•
Simple drying: performed until free water is eliminated from system.
Checking of water content at low point. No drops, condensate or moisture in valve and
headers outlet (a dew point of -4 is recommended).
•
Critical drying: performed up to a specific dew point value.
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10130-00-161-PD-0004
REV.: 05
Dew point of -20 oC in three different points (low points and vents) of the dried system.
Dew point will be measured with a calibrated hygrometer. It is recommended in
Nitrogen, Instrument air and Lube Oil Systems.
For further information see Piping and Equipment Drying procedure 10130-00-161-PD0005.
10.3 INERTIZATION
When
system
requires
inertization
after
drying,
installation
of
inertization
equipment/connections shall be done in such a way that prevents air ingress (humidity
ingress) from atmosphere to the system.
Positive pressure of nitrogen (0’2-0’3 bar g) shall be maintained in the system to avoid
ingress of humidity.
If the startup of the equipment after cleaning (i.e.: after Water Running Test) circulation is
likely to be delayed by more than five days, dry it with nitrogen to a dew point of -1ºC or
less and store it under a positive pressure of nitrogen of 5 psig for corrosion protection
10.4 INSPECTION OF CLEANING PERFORMANCE
Plant Inspection, Operations, Operations Engineering and the cleaning contractor are to
inspect after the cleaning, to ascertain that the job has been successfully completed. Visual
inspections are carried out to determine the effectiveness of cleaning. No visible traces of
water, loose or adherent deposits inside the equipment are acceptable.
10.5 EQUIPMENT LAY-UP
According to what it is needed, during Mechanical Completion stage, equipment lay-up will
be done following one of these cases:
•
If the startup of the equipment after cleaning is likely to be delayed by more than 5
days, dry it with nitrogen to a dew point of -1°C or less and store it under a positive
pressure of nitrogen of 5 psig for corrosion protection.
Further details in SAEP-1662.
•
In the other hand, equipment must be laid-up after hydrotesting unless it can be
ensured that it will be returned to service within 30 days from the first introduction of
hydrotest water to the system.
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10130
HARADH AND HAWIYAH FIELD GAS COMPRESSION PROJECT
PIPING & EQUIPMENT CLEANING PROCEDURE
PAGE 35
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10130-00-161-PD-0004
REV.: 05
Further details in SAES-A-007.
These activities are in accordance with the “Piping Lay-Up Procedure” (10130-00-161-PD0021).
11. REFERENCES
11.1 COMPANY DOCUMENTS
•
Haradh
and
Hawiyah
Field
Gas
Compression Project (Package 1– North
Gas Compression Plants (NGCP)
•
Haradh
and
Hawiyah
Field
Gas
Compression Project (Package 2 –
Satellite
Gas
Compression
Plants
(SaGCP)
•
Haradh
and
Hawiyah
Field
Gas
Compression Project (Package 3 – South
Gas Compression Plants (SGCP)
SAES-L-350
•
Construction of Plant Piping
•
SAES-K-402
•
Centrifugal Compressors
•
SAEP-32
•
Environmental Performance Assessment
(EPA) Program
•
SAEP-1028
•
Chemical Cleaning and Flushing of LubeSeal Oil and Fluid Power Systems
•
•
SAEP-327
Disposal of Wastewater from Cleaning,
Flushing and Dewatering Pipelines and
Vessels
•
•
SAEP-348
Chemical Cleaning, Disinfection, Post
Treatment and Storage of Reverse
Osmosis Membrandes
•
SAEP-388
•
Cleaning of Pipelines
•
SAEP-1662
•
Cleaning of Heat Exchangers and Unfired
Plant Equipment
•
SAES-A-007
•
Hydrostatic Testing Fluids and Lay-Up
Procedures
•
SAES-B-069
•
Emergency Eyewashes and Showers
•
SAES-G-116
•
Cleanliness Standard for Lube/Seal Oil
and Fluid Power Systems
•
SAES-S-040
•
Saudi Aramco Water Systems
•
SAES-J-901
•
Instrument Air Supply Systems
•
SAES-S-070
•
Installation of Utility Piping Systems
•
Contract IK (6600040668) & Contract
OOK (6600040667)
•
Contract IK (6600040670) & Contract
OOK (6600040669)
•
Contract IK (6600040672) & Contract
OOK (6600040671)
•
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10130
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PIPING & EQUIPMENT CLEANING PROCEDURE
PAGE 36
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10130-00-161-PD-0004
REV.: 05
•
SAIC-L-2017
•
Piping/Equipment
Inspection
•
SATR-A-2008
•
Internal Cleanliness
Systems & Equipment)
•
01-SAMSS-017
•
Auxiliary Piping for Mechanical Equipment
•
PP-311652
•
Producing Facilities Chemical Cleaning
(Project Specification)
Internal
Report
Cleaning
(Piping
11.2 PROJECT MANAGEMENT SYSTEM PROCEDURES
•
10130-00-091-PD-0006
• HAZARD IDENTIFICATION PLAN
•
10130-00-091-PD-0013
• PERMIT TO WORK PROCEDURE
•
10130-00-161-PD-0001
• PRE-COMMISSIONING AND MECHANICAL
COMPLETION PLAN
•
10130-00-161-PD-0002
• START UP EXECUTION PLAN
•
10130-00-161-PD-0003
• PRESERVATION OF ELEMENTS
EQUIPMENT PROCEDURE
•
10130-00-161-PD-0005
• PIPING
AND
PROCEDURE
•
10130-00-161-PD-0006
• REINSTATEMENT PROCEDURE
•
10130-00-161-PD-0021
• PIPING LAY-UP PROCEDURE
EQUIPMENT
AND
DRYING
NOTE: “References are made for General Procedures already issued to Client. In many
cases these procedures are already Approved. Specific Procedures per package might be
issued if required. For traceability purpose the package specific procedures will maintain
the same code/number: 10130-XX-YYY-PD-NNNN, but using instead of -00- for the two
digits -XX- a -01- for package 1 “North Gas Compression Plants”, -02- for package 2
“Satellite Gas Compression Plants” and -03- for package 3 South Gas Compression
Plants”.
12. ATTACHMENTS
12.1 ATT01. SYSTEM CLEANING METHODS
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PIPING & EQUIPMENT CLEANING PROCEDURE
PAGE 1 OF 3
10130-00-161-PD-0004-Att01
REV.: 05
Clarification Tables
Depending on the “fluid service”, a Cleaning Matrix for each kind of pipe has been prepared
in the Attachment 02.
Factors such as the diameter or length of the pipeline have not been taken into account in
the matrix, therefore, the cleaning method and acceptance criteria could be changed to
others more appropriated due to the actual conditions in site.
Details to understand the matrix (10130-00-161-PD-0004-Att02) are shown below:
CLEANING METHOD
METHOD
DESCRIPTION
1
2
3
MECHANICAL
CLEANING
(diameters
greater than 24”
or equipment
provided with
manways of 24”)
AIR BLOWING
(all diameters)
WATER / OIL
FLUSHING
(diameters less
than 12”)
DETAILS
1A
Brushing or scraping.
1B
HP water jetting or Hydromilling: use a high pressure jet of
water or a mixture water-abrasive to remove debris by
erosion (Compressor’s suction pipes).
1C
Pig from source to destination. Generally used on headers
and long laterals only.
2A
Continuous Air Blowing (small diameters).
2B
Depressurization by quick opening valve: pressurization with
air and subsequent sudden release (normally lines greater
than 8").
2C
Air Blasting: pressurization with air until disc ruptures. Disc
specifications and rupture pressure to be calculated and
verified to be within the piping line specs.
3A
Low velocity water flushing: typically flushing once through
the system, to remove gross debris.
3B
Pulse water flushing: External Water Slug Generator
Equipment required with Air Receiver as delivery system.
The traveling pulse water is filtered with a 40 micron filter.
3C
Circulate fluid with temporary pumps to minimum of 125% of
normal operating velocity. System is filtered to a system a
determined filter size.
3D
Circulate fluid with permanent system pumps. System is
filtered to a system determined filter size. High speed
circulation flush with water.
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PIPING & EQUIPMENT CLEANING PROCEDURE
PAGE 2 OF 3
10130-00-161-PD-0004-Att01
REV.: 05
CHEMICAL
CLEANING
(special
services)
4
3E
Circulate fluid with permanent system pumps. System is
filtered to a system determined filter size. High speed
circulation flush with oil.
4A
Chemical cleaning (Compressor’s suction pipes)
4B
Degreasing (for lube/seal oil systems)
4D
Passivation (for cooling water services)
4E
Chemical Disinfection (for potable water services).
LUBE OIL
FLUSHING
5
5
Circulate fluid with permanent system pumps. System is
filtered to a system determined filter size. High speed
circulation flush with oil.
CLEANING CRITERIA
CRITERIA
DESCRIPTION
1
2
DETAILS
Visual inspection.
Cleaning fluid is not discoloured and contains no visible
debris.
40 micron mesh filter in
line for particle removal.
No visible accumulation of dirt/foreign material is found on the
screen mesh after system circulation (for a specified size
(microns)).
No visible accumulation of dirt/foreign material is found and
the acceptance criteria depends on the positive result of a
cleaning fluid sample: chemical analysis or particle count.
3
Titration analysis or
millipore sample.
*For chemical cleaning the sample shall be analyzed:
• Degreasing
pH
Alcalinity P and M
Oil content of solution
• Acid treatment
Acid concentration
pH
Ferric ( +++) Ions (ppm)
Total Iron (ppm)
Inhibitor Efficiency
• Temporary Passivation
pH
Ammonia concentration
Passivating agent concentration
Conductivity
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PIPING & EQUIPMENT CLEANING PROCEDURE
PAGE 3 OF 3
10130-00-161-PD-0004-Att01
REV.: 05
Nitrito (NO2)
Total Iron Fe
TSS
Microbio (Aerobic count/ml)
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REV.: 05
12.2 ATT02. CLEANING MATRIX
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PAGE 1 OF 1
10130-00-161-PD-0004-Att02
REV.: 05
CLEANING MATRIX
SERVICE
CLEANING METHOD
CLEANING CRITERIA
Sour Gas
1A, 1B, 1C, 2B
1
Sweet Gas
1A, 1B, 1C, 2B
1
Flash Gas
Motive Gas
Seal Gas
Pilot Gas
Ignition Gas
Purge Gas
To HP Flare
2A, 2B, 2C
2A, 2B, 2C
2A, 2B, 2C
2A, 2B, 2C
2A, 2B, 2C
2A, 2B, 2C
2A, 2B, 2C
1
1
1
1
1
1
1
Blodown to HP Flare
2A, 2B, 2C
1
Nitrogen
Nitrogen/Steam
Instrument Air
Plant Air
Drain
Produced Water
Condensate & Water
HC Liquids
HC Liquids & Solids
Condesate
Lube Oil
Corrosion Inhibitor
Well Water
Hipoclorite
Utility Water
Fire Water
2A, 2B, 2C
2A, 2B, 2C
2A, 2B, 2C
2A, 2B, 2C
2A, 2B, 2C
2A, 2B, 2C
2A, 2B, 2C
2A, 2B, 2C
2A, 2B, 2C
2A, 2B, 2C
2A, 4B, 5A
2A, 2B, 2C
3B
2A, 2B, 2C
3B
3B
1
1
3
1
1
1
1
1
1
1
2,3
1
1
1,3
1
1
Potable Water
3B, 4E
3
Scraping Liquid
3B
1
3B
1
2A, 2B, 2C
1
Oxigen Scavenger
and Scale Inhibitor
Diesel
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10130-00-161-PD-0004
REV.: 05
12.3 ATT03. DETAILED PRE/COMMISSIONING PROCEDURES LIST
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DETAILED PRE/COMMISSIONING PROCEDURES LIST
FOR HAWIYAH GAS COMPRESSION PLANT-1 UNIT 510
10130
REV.: 03
System Code
System Description
Subsystem Code
Subsystem Description
Discipline
CLEANING
U10-P01
U10-P02
U10-P03
U10-P04
U10-P05
U10-P06
U10-P07
U10-P08
U10-P09
U10-U02
U10-U04
U10-U04
U10-U04
U10-U04
U10-U04
U10-U05
U10-U09
U10-U09
U10-P10
U10-U11
U10-U11
U10-U12
U10-U13
U10-U14
U10-U15
U10-U15
U10-U15
U10-U16
U10-U16
U10-U17
U10-U18
U10-U19
U10-U20
SOUR GAS CATCHER
PRODUCED WATER/ SAND JET
CONDENSATE SEPARATOR
SOUR GAS COMPRESSOR T1
SOUR GAS COMPRESSOR T2
SOUR GAS COMPRESSOR T3
SWEET GAS CATCHER
SWEET GAS COMPRESSOR
GAS JET COMPRESSOR
NITROGEN/LP STEAM TEMPORARY
AIR SYSTEM
AIR SYSTEM
AIR SYSTEM
AIR SYSTEM
AIR SYSTEM
PILOT GAS
HP FLARE
HP FLARE
CLOSE DRAIN SYSTEM
CHEMICAL PACKAGE
CHEMICAL PACKAGE
NITROGEN
SEAL GAS
LUBE OIL
FIRE WATER
FIRE WATER
FIRE WATER
FIRE WATER
UTILITY WATER
DIESEL
POTABLE WATER
OILY WATER SEWER
SANITARY WASTE WATER
U10-P01-01
U10-P02-01
U10-P03-01
U10-P04-01
U10-P05-01
U10-P06-01
U10-P07-01
U10-P08-01
U10-P09-01
U10-U02-01
U10-U04-01
U10-U04-02
U10-U04-03
U10-U04-04
U10-U04-05
U10-U05-01
U10-U09-01
U10-U09-02
U10-P10-01
U10-U11-01
U10-U11-02
U10-U12-01
U10-U13-01
U10-U14-01
U10-U15-01
U10-U15-02
U10-U15-03
U10-U15-04
U10-U16-01
U10-U17-01
U10-U18-01
U10-U19-01
U10-U20-01
SOUR GAS CATCHER
PRODUCED WATER/ SAND JET
CONDENSATE SEPARATOR
SOUR GAS COMPRESSOR T1
SOUR GAS COMPRESSOR T2
SOUR GAS COMPRESSOR T3
SWEET GAS CATCHER
SWEET GAS COMPRESSOR
GAS JET COMPRESSOR
NITROGEN/LP STEAM TEMPORARY
INSTRUMENT AIR
PLANT AIR
AIR COMPRESSOR
AIR COMPRESSOR ACCUMULATOR
AIR DRYERS
PILOT GAS
HP FLARE HEADER
HP FLARE STACK
CLOSE DRAIN SYSTEM
CORROSION INHIBITOR
HYPOCHLORITE INJECTION
NITROGEN
SEAL GAS
LUBE OIL
FIRE WATER DISTRIBUTION
WELL WATER
FIRE WATER TANKS/PUMPS
FIRE WATER ABOVEGROUND 510
UTILITY WATER
DIESEL STORAGE TANK
POTABLE WATER
OILY WATER SEWER
SANITARY WASTE WATER
Process
Process
Process
Process
Process
Process
Process
Process
Process
Utilities
Utilities
Utilities
Utilities
Utilities
Utilities
Utilities
Utilities
Utilities
Process
Utilities
Utilities
Utilities
Utilities
Utilities
Utilities
Utilities
Utilities
Utilities
Utilities
Utilities
Utilities
Utilities
Utilities
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
NOTE:
TR CONTRACTOR will develop a Detailed Pre/Commissioning Procedure per Subsystem with specific activities as it is shown in the above schedule, for COMPANY
approval.
These specific activities will be done according to ARAMCO standards, VENDOR recommendations and TR experience in other projects.
This schedule is only a reference meaning that each Gas Compression Plant (GCP) will have the correspondent list of Detailed Pre/Commissioning Procedures per
Subsystem.
Furthermore this list will be updated as the Haradh & Hawiyah Project progresses, with the approval for the COMPANY.
CHEMICAL
CLEANING
LUBE OIL
FLUSHING
DISINFECTION
DRYING
X
X
MOTOR SOLO RUN
TEST
X
X
X
X
X
X
X
X
X
X
WATER RUN-IN
TEST
CATALYST /
CHEMICAL
LOADING
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
BOX UP/FINAL
ALINGMENT
LEAK TEST &
INERTING
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
LOOP TEST
X
X
X
X
X
X
X
X
X
SERVICE TEST
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
SIS LOOP TEST
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
PERFORMANCE TEST
FUNCIONAL TEST
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
PAGE 1 of 3
OTHERS
DETAILED PRE/COMMISSIONING PROCEDURES LIST
FOR HAWIYAH LIQUID SEPARATIONT STATION UNIT 510-008
10130
REV.: 03
System Code
System Description
Subsystem Code
Subsystem Description
Discipline
CLEANING
U13-P02
U13-P10
U13-U11
SEPARATOR
CLOSE DRAIN SYSTEM
CHEMICAL PACKAGE
U13-P02-01
U13-P10-01
U13-U11-01
HWYH LIQUID SEPARATOR
CLOSE DRAIN SYSTEM
CORROSION INHIBITOR
Process
Process
Utilities
X
X
X
NOTE:
TR CONTRACTOR will develop a Detailed Pre/Commissioning Procedure per Subsystem with specific activities as it is shown in the above schedule, for COMPANY
approval.
These specific activities will be done according to ARAMCO standards, VENDOR recommendations and TR experience in other projects.
This schedule is only a reference meaning that each Liquid Separation Station (LSS) will have the correspondent list of Detailed Pre/Commissioning Procedures per
Subsystem.
Furthermore this list will be updated as the Haradh & Hawiyah Project progresses, with the approval for the COMPANY.
CHEMICAL
CLEANING
LUBE OIL FLUSHING
DISINFECTION
DRYING
X
MOTOR SOLO RUN
TEST
X
WATER RUN-IN
TEST
X
CATALYST /
CHEMICAL
LOADING
X
LOOP TEST
BOX UP/FINAL
ALINGMENT
LEAK TEST &
INERTING
X
X
X
X
X
X
X
X
X
SERVICE TEST
SIS LOOP TEST
PERFORMANCE TEST
X
X
X
X
FUNCIONAL TEST
PAGE 2 of 3
OTHERS
DETAILED PRE/COMMISSIONING PROCEDURES LIST
FOR NORTH ADMINISTRATION AREA 511-512
10130
REV.: 03
System Code
System Description
Subsystem Code
Subsystem Description
Discipline
CLEANING
U14-U11
U14-U15
U14-U15
U14-U15
U14-U15
U14-U16
U14-U17
U14-U18
U14-U19
CHEMICAL PACKAGE
FIRE WATER
FIRE WATER
FIRE WATER
FIRE WATER
UTILITY WATER
DIESEL
POTABLE WATER
OILY WATER SEWER
U14-U11-02
U14-U15-01
U14-U15-02
U14-U15-03
U14-U15-04
U14-U16-01
U14-U17-01
U14-U18-01
U14-U19-01
HYPOCLORITE INJECTION PACKAGE
FIRE WATER DISTRIBUTION
WELL WATER
FIRE WATER TANKS/PUMPS
FIRE WATER ABOVEGROUND 511
UTILITY WATER
DIESEL STORAGE TANK
POTABLE WATER
OILY WATER SEWER
Utilities
Utilities
Utilities
Utilities
Utilities
Utilities
Utilities
Utilities
Utilities
X
X
X
X
X
X
X
X
X
NOTE:
TR CONTRACTOR will develop a Detailed Pre/Commissioning Procedure per Subsystem with specific activities as it is shown in the above schedule, for COMPANY
approval.
These specific activities will be done according to ARAMCO standards, VENDOR recommendations and TR experience in other projects.
This schedule is only a reference meaning that each Administration Area (AA) will have the correspondent list of Detailed Pre/Commissioning Procedures per
Subsystem.
Furthermore this list will be updated as the Haradh & Hawiyah Project progresses, with the approval for the COMPANY.
CHEMICAL
CLEANING
LUBE OIL FLUSHING
DISINFECTION
X
X
DRYING
MOTOR SOLO RUN
TEST
WATER RUN-IN
TEST
CATALYST /
CHEMICAL
LOADING
LOOP TEST
BOX UP/FINAL
ALINGMENT
LEAK TEST &
INERTING
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
SERVICE TEST
X
X
X
X
X
X
X
SIS LOOP TEST
PERFORMANCE TEST
X
X
X
X
X
X
X
X
X
X
FUNCIONAL TEST
X
X
X
X
PAGE 3 of 3
OTHERS
HARADH AND HAWIYAH FIELD GAS COMPRESSION PROJECT
10130
PIPING & EQUIPMENT CLEANING PROCEDURE
PAGE 39
OF 40
10130-00-161-PD-0004
REV.: 05
13. TEMPLATES
13.1 Tmp01. SATR-A-2008. INTERNAL CLEANLINESS REPORT (PIPING SYSTEMS &
EQUIPMENT)
This document is property of UTE TR Haradh Gas Compression Project and TR Saudia for Services and Contracting Co Ltd.
Its reproduction without previous permission in writing is strictly forbidden.
SAUDI ARAMCO ID/PIEU - 15-Nov-2017 - REV. 2016.06.00 (Standards Cutoff -June 30, 2016)
Rev. 2016.06.00
30-Jun-16
SAIC NUMBER
DATE APPROVED
QR NUMBER
SAUDI ARAMCO TEST REPORT
Internal Cleanliness Report (Piping Systems & Equip)
SATR-A-2008
PROJECT TITLE
WBS / BI / JO NUMBER
15-Nov-17
MECH
CONTRACTOR / SUBCONTRACTOR
EQUIPMENT ID NUMBER(S)
EQUIPMENT DESCRIPTION
TEST SYSTEM No./Test Pack No.
PLANT NO.
DRAWING NUMBER (P&ID/ISO) / REV. No.
PIPE CLEANING DIAGRAM (If applicable)
LOCATION
WORK PERMIT REQD?
SCHEDULED TEST DATE & TIME
ACTUAL TEST DATE & TIME
SAUDI ARAMCO TIP (SATIP) NUMBER
SATIP Activity No.
TEST IN ACCORDANCE WITH:
a) Procedure No.
b) Supporting SAIC No.
System Description:
Service Fluid:
MAOP:
System Material Type:
Internal Cleanliness Report for On-Plot Piping & Equipment (See Remarks)
Method of internal cleaning
(For piping systems and equipment)
Limits of internal cleaning
(State Partial or Full and terminating ends)
Type Of Debris
(sand, mill scale, electrodes, debris, etc.)
Valve Cavities & Other Low Point
System Components
Internal Cleanliness Report for Pipelines (Note 2)
Pipeline Description : ____________________________________________ Pipe Internal Diameter(s): _________________
Drawing No:
Location / Date
Section No:
Test No:
From KM:
To KM:
Scraper Type
RUN 1
DATE
RUN 2
TIME
DATE
RUN 3
TIME
DATE
REMARKS
TIME
Cleaning Start
Cleaning End
Cleaning Duration
OBSERVATIONS:
1. Indicate Amount
and/or type of debris
2. Scraper
RESULT (ACC/REJ)
REMARKS: Note 1: Items in italics above are for guidance in completion of forms prior to pressure testing.
N ote 2: Valves should be installed in systems after pressure testing whenever possible during system reinstatement. Code fabricated test implements can easily
replace valves during system hydrotests. Cavities & other low points in the line where debris can accumulate require special attention during cleaning. Typical flushing
with air or water is inadequate in the removal of debris from valve cavities and low points. This accumulated debris (sand, scale, metal shavings, slag, etc) creates
serious corrosion and operational problems for COMPANY. Cleaning methods shall demonstrate adequate cleaning for all piping system components and equipment.
Where items such as valve cavities exhibit an inadequate level of cleanliness, adequate cleaning & inspection shall be performed at earliest opportunity and addressed
no later than immediately after hydrotest. Avoid flushing lines through valves & install field hydrotested valves "after" system testing where possible.
Contractor / Third-Party
Construction Representative*
Name, Initials and Date:
Saudi Aramco
PMT Representative
Work is Complete and Ready for Inspection:
QC Inspector
Name, Initials and Date:
T&I Witnessed
QC Record Reviewed
Work Verified
T&I Witnessed
QC Record Reviewed
Work Verified
T&I Witnessed
QC Record Reviewed
Work Verified
PID Representative
Performed Inspection
Work / Rework May Proceed
Name, Initials and Date:
Name, Initials and Date:
QC Supervisor
Proponent and Others
Quality Record Approved:
Name, Sign and Date:
Name, Organization,
Initials and Date:
*Person Responsible for Completion of Quality Work / Test
Saudi Aramco: Company General Use
Y = YES
N = NO F = FAILED
HARADH AND HAWIYAH FIELD GAS COMPRESSION PROJECT
10130
PIPING & EQUIPMENT CLEANING PROCEDURE
PAGE 40
OF 40
10130-00-161-PD-0004
REV.: 05
13.2 Tmp02. SAIC-L-2017. PIPING / EQUIPMENT INTERNAL CLEANING INSPECTION
This document is property of UTE TR Haradh Gas Compression Project and TR Saudia for Services and Contracting Co Ltd.
Its reproduction without previous permission in writing is strictly forbidden.
SAUDI ARAMCO ID/PIEU - 15-Nov-2017 - REV. 2016.06.00 (Standards Cutoff -June 30, 2016)
SAUDI ARAMCO INSPECTION CHECKLIST
Piping / Equipment Internal Cleaning Inspection
PROJECT TITLE
Rev. 2016.06.00
SAIC NUMBER
SAIC-L-2017
WBS / BI / JO NUMBER
EQUIPMENT ID NUMBER(S)
EQUIPMENT DESCRIPTION
LAYOUT DRAWING NUMBER
REV. NO.
SCHEDULED INSPECTION DATE & TIME
ACTUAL INSPECTION DATE & TIME
30-Jun-16
DATE APPROVED
15-Nov-17
QR NUMBER
MECH-
CONTRACTOR / SUBCONTRACTOR
EQPT CODE
SYSTEM ID.
PURCHASE ORDER NUMBER
PLANT NO.
EC / PMCC / MCC NO.
QUANTITY INSP.
MH's SPENT
TRAVEL TIME
SAUDI ARAMCO USE ONLY
SAUDI ARAMCO TIP NUMBER
SAUDI ARAMCO ACTIVITY NUMBER
SAUDI ARAMCO INSPECTION LEVEL
CONTRACTOR INSPECTION LEVEL
ITEM
REFERENCE
ACCEPTANCE CRITERIA
No.
General
Requirements
(Note:
Use
SATR-A-2008
to
document
findings
using
this checklist )
A
A1
Method of cleaning & flushing of piping spools & systems applicable for
every individual system category was approved/agreed upon by PMT,
Proponent and Inspection.
SAES-L-350,
Para. 15.1
A2
Visual verification of end limits covered by this inspection conformed with
the QR (Quality Request for inspection)
SAES-L-350,
Para. 15.3
B
Progressive Internal inspection (DURING ASSEMBLY)
B1
Spools are visually inspected for internal cleanliness (no presence of
loose particles/flakes or debris) prior to welding/bolting to the preceeding
and/or succeeding spools. (Follow Notes Below)
A) Visual inspection includes use of video inspection techniques, visual,
scraping & positioning in vertical position.
B) Fine dusts are acceptable, unless specified for critical systems
B2
Ends of Piping spools or partially completed piping system passed visual
inspection for internal cleanliness, were covered & sealed to prevent
entry of debris (moisture, water or other foreign materials).
Note: Each section of cleaned spools or system shall be recorded
B3
All sensitive equipments to damage during cleaning and flushing of the
piping system shall not be installed and shall be removed if installed
prior to commencing the cleaning process. The list of these equipments
shall be established during early stages of the execution of the project.
Examples of sensitive equipments are: rotating machinery, orifices,
control valves, flow-elements, soft-seated valves, globe valves, etc.
B4
Partial cleanliness inspection certificates for each section of a completed
system are accounted for.
BEST PRACTICE
Note: Where cleanliness cannot be fully verified, systems shall be
cleaned by Method 2 or 3, whichever is applicable.)
C
Internal Cleaning by Water Flushing
C1
Equipment sensitive to damage during water flushing are identified and
shall be removed, blocked off or isolated. (Ex: Flow meter, sight glass,
soft-seated valves )
SAES-L-350,
Appendix A
C2
Components in new piping systems which interfere with filling, venting,
draining or flushing shall not be installed until after line flushing and
pressure testing are completed. These include orifice plates, flow
nozzles, sight glasses, venturies, positive displacement and turbine
meters and other in-line equipment.
SAES-A-004,
Para. 5.12.4
C3
Ball valves shall be flushed in fully open position.
SAES-L-350,
Appendix A
C4
Flushing medium used are any of the following:
A) Plant/process water
B) Raw water (Fire water OK when process water is not available)
Note: Sea water is not acceptable
SAES-L-350,
Appendix A
SAES-L-350,
Para. 15.3.2
SAES-L-350,
Para 15.2.3
SAES-L-350,
para. 14.1
Saudi Aramco: Company General Use
WORK PERMIT REQUIRED?
PASS
FAIL
N/A
RE-INSP DATE
SAUDI ARAMCO ID/PIEU - 15-Nov-2017 - REV. 2016.06.00 (Standards Cutoff -June 30, 2016)
SAUDI ARAMCO INSPECTION CHECKLIST
Piping / Equipment Internal Cleaning Inspection
PROJECT TITLE
ITEM
No.
Rev. 2016.06.00
SAIC NUMBER
SAIC-L-2017
WBS / BI / JO NUMBER
ACCEPTANCE CRITERIA
REFERENCE
C5
For stainless steel lines, flushing medium chloride ion content is less
than 50 mg/L. (NOTE: After flushing, the piping systems shall be
completely drained, dried to a dew point below -1°C ) and protected
against corrosion.
SAES-L-350,
Appendix A
C6
For lines below 4" dia., minimum velocity of water fushing is 3 m/s.
SAES-L-350,
Appendix A
C7
For lines 4" dia. and above, high pressure jet (rotating hose or nozzle)
at a minimum pressure of 60.8 mPa (8.8 psi) is used.
SAES-L-350,
Appendix A
D
Pneumatic Flushing
D1
Medium used for pneumatic flushing is dry air (dew point -1°C or less)
or steam with a minimum exit velocity of 15 m/s.
SAES-L-350,
Appendix A
D2
Flushing is repeated until cleanliness is verified by observing the
absence of any solids impact on a polished metal target at the exit.
SAES-L-350,
Appendix A
E
Pressurized Air Shock Blowing (PASB)
E1
PASB method is used for the following conditions:
a. For initial cleaning of instrument air, plant air
b. As an alternative method for initial cleaning of small bore pipe
(less than 2 inch).
c. Presence of trapped liquid in the piping, or if verification of
cleanliness using video inspection is not possible.
SAES-L-350,
Appendix A
E2
The air shocking pressure shall never exceed the working pressure of
the system and shall never be more than 810 kPa (115 psi).
SAES-L-350,
Appendix A
E3
Safety precautions are considered in consultation with Area Loss
Prevention Division.
SAES-L-350,
Appendix A
E4
PASB is repeated until cleanliness is verified by observing the absence
of any solids impact on a polished metal target at the exit.
SAES-L-350,
Appendix A
F
Mechanical Scrapers
F1
Mechanical scrapers are used on piping system that will not cause
damage to the pipe interior surface (ie: piping with internal coating).
SAES-L-350,
Appendix A
F2
Degree of cleanliness conforms with the approved internal cleaning
procedure.
SAES-L-450,
Para. 18.2
F3
Internal scrapers have full bore contact with the pipe inside diameter.
Procedure detail
F4
Additional checkpoints or Acceptance Criteria shall be added upon
approval of Piping Internal Cleaning Procedure by scraping.
Procedure detail
30-Jun-16
DATE APPROVED
15-Nov-17
QR NUMBER
MECH-
CONTRACTOR / SUBCONTRACTOR
PASS
FAIL
N/A
RE-INSP DATE
REMARKS:
ATTACHMENT:
1. SATR-A-2008, Piping / Equipment Internal Cleaning Inspection
NOTES FOR SATR-A-2008 USE:
Note 1: Method of internal cleaning states in detail the cleaning methods used (reference Company approved procedure)
Note 2: Limits of internal cleaning state whether cleaning was full or partial and details the system limits for cleaning
(specific line #) and/or equipment details/limits "as inspected"
Note 3: Type of Debris found states what was found during cleaning and any other unusual findings that could affect
system integrity "as inspected"
Note 4: Valve Cavity & other system low point component cleaning states exactly how low points remaining in line or the
equipment were cleaned. methods are adequate for removal of debris (sample selected by Company to witness shall
demonstrate this). See Explanation below.
Explanation: Valves should be installed in systems AFTER pressure testing when possible during system reinstatement.
THE ABOVE STATEMENT IS CLEARLY STATED AND INTENDED IN SAUDI ARAMCO STDS TO PREVENT VALVE SEAT DAMAGE.
Code fabricated test implements can easily replace valves during system hydrotests. Cavities & other low points in the
line where debris can accumulate require special attention during cleaning. Typical flushing with air or water is
inadequate in the removal of debris from valve cavities and low points. This accumulated debris (sand, scale, metal
Saudi Aramco: Company General Use
SAUDI ARAMCO ID/PIEU - 15-Nov-2017 - REV. 2016.06.00 (Standards Cutoff -June 30, 2016)
SAUDI ARAMCO INSPECTION CHECKLIST
Piping / Equipment Internal Cleaning Inspection
PROJECT TITLE
Rev. 2016.06.00
SAIC NUMBER
30-Jun-16
DATE APPROVED
SAIC-L-2017
15-Nov-17
WBS / BI / JO NUMBER
QR NUMBER
MECH-
CONTRACTOR / SUBCONTRACTOR
ITEM
PASS
FAIL
N/A
ACCEPTANCE CRITERIA
REFERENCE
No.
shavings, slag, etc) creates serious corrosion and operational problems for COMPANY. Cleaning methods shall
demonstrate adequate cleaning for all piping system components and equipment. Where items such as valve cavities
exhibit an inadequate level of cleanliness, adequate cleaning & inspection shall be performed at earliest opportunity and
addressed no later than immediately after hydrotest. Avoid flushing lines through valves & install field hydrotested valves
"after" system testing where possible. Preservation checks of valves utilizing "AMBIENT" Lay-up methods is required.
RE-INSP DATE
REFERENCE DOCUMENTS:
1. SAES-A-004, General Requirements for Pressure Testing, (7 Jan 2016)
2. SAES-L-350, Construction of Plant Piping, (22 April, 2009)
3. SAES-L-450, Construction of On-Land and Near-Shore Pipelines, (12 October 2015)
Contractor / Third-Party
Saudi Aramco
Construction Representative*
Name, Initials and Date:
PMT Representative
Work is Complete and Ready for Inspection:
QC Inspector
T&I Witnessed
QC Record Reviewed
Work Verified
T&I Witnessed
QC Record Reviewed
Work Verified
QC Record Reviewed
Work Verified
PID Representative
Performed Inspection
Work / Rework May Proceed
Name, Initials and Date:
Name, Initials and Date:
QC Supervisor
Name, Sign and Date:
Name, Initials and Date:
Proponent and Others
Quality Record Approved:
Name, Organization,
Initials and Date:
T&I Witnessed
*Person Responsible for Completion of Quality Work / Test
Y = YES
Saudi Aramco: Company General Use
N = NO F = FAILED