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Disouq Field Development Project

Specification for chemical cleaning of piping

Changes List
Date
Rev. prepared Prepared by Description
(DD.MM.YYYY)
0 03.12.2012 A.H. First Issue for Client Review
1 14.03.2013 A.Y. Approval for Construction
2 25.08.2013 A.Y. Approval for Construction

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Disouq Field Development Project

Specification for chemical cleaning of piping

Contents

INTRODUCTION..........................................................................................................................................4
1 GENERAL.............................................................................................................................................5
1.1 SCOPE..................................................................................................................................................5
1.2 PURPOSE.............................................................................................................................................5
2 RESPONSIBILITIES.............................................................................................................................5
2.1 OWNER................................................................................................................................................5
2.2 CHEMICAL CLEANING CONTRACTOR..........................................................................................6
2.3 REFERENCES......................................................................................................................................6
3 CLEANING...........................................................................................................................................6
3.1 REQUIREMENTS................................................................................................................................6
3.2 PROCEDURE.......................................................................................................................................6
3.3 MATERIALS........................................................................................................................................6
3.4 IN-PLACE CLEANING........................................................................................................................7
3.5 EQUIPMENT ISOLATION..................................................................................................................7
3.6 GENERAL CONDITIONS FOR CHEMICAL CLEANING..................................................................7
3.7 INSPECTION.......................................................................................................................................8
3.8 ACCEPTANCE.....................................................................................................................................8
4 CHEMICAL CLEANING SOLUTIONS...............................................................................................9
5 PROTECTION......................................................................................................................................9
5.1 GENERAL............................................................................................................................................9
5.2 DRYING...............................................................................................................................................9
5.3 RUST PREVENTION...........................................................................................................................9
5.4 SEALING.............................................................................................................................................9
5.5 TEMPORARY PROTECTION...........................................................................................................10
5.6 PERMANENT PROTECTION...........................................................................................................10
5.7 LUBE AND SEAL OIL SYSTEM.......................................................................................................10
6 DISPOSAL OF CHEMICALS.............................................................................................................10
7 GUARANTEE......................................................................................................................................10

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Disouq Field
F Develo
opment Pro
oject

Spe
ecification for
f chemic
cal cleaning
g of piping

INTRRODUCTION N
RWE Dea Egypt has h discovereed seven natuural gas reserrves in the Disouq
D Conceession withinn the onshoree
Nile D
Delta, startinng in 2008, as shown on the conccession mapp below. Fu urther explorration in thee
concesssion is ongooing. RWE Dea
D Egypt is the operatorr of the Conccession with EGAS as a partner.
p

The sselected deveelopment coomprises a central


c gas treatment siite near NS SG-1x, where the gas iss
collectted, treated by means of
o Low Tem mperature Seeparation utiilizing the Joule
J Thomsson effect too
achievve gas qualitty, and comppressed for export.
e Treatted gas is trransferred via a 16 pipeeline directlyy
into thhe GASCO NTSN pipelinee.
The wwell fluids arre gathered and
a fed to a common innlet separatoor at the cenntral plant. All
A gases andd
liquidss will be separated
s annd processedd on the ceentral treatm
ment site innto sales gaas, stabilizedd
condennsate, and frree productioon water.
Treatmment of gas is carried ouut in two traiins, while trreatment of condensate
c is in a singlee train. Threee
trains of sales gas compressionn are installed. Fuel gas ffor the gas enngine drives is taken fromm the suctionn
of the sales gas commpressors.

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Disouq Field Development Project

Specification for chemical cleaning of piping

1 GENERAL

1.1 SCOPE

This specification covers the requirements for field chemical cleaning in a new process unit. This
specification is general and sets forth the basic guidelines; however the cleaning contractor has the
responsibility of developing a detailed procedure Piping covered by this specification includes:

Carbon steel suction lines for all compressors


Field fabricated carbon steel lube oil, seal and hydraulic oil piping.
Degreasing flushing of stainless steel compressor piping.

1.2 PURPOSE
Certain piping must be chemically cleaned to remove mill scale, dirt, greases used as rust
preventatives and other foreign materials that could result in operating and maintenance problems
and/corrosion due to the reaction of scale with the process environment.
It is the intent of this specification to explain and describe how to remove all foreign matters from
the piping, which could dislodge during process operation and damage the machinery.

2 RESPONSIBILITIES

2.1 OWNER

2.1.1 Shall present to the cleaner contractor a list of metals and alloys in the section to be cleaned,
including valve trim, gaskets, bolts, nuts as well as major piping.

2.1.2 Shall provide the safe operating pressure of all components in the section to be cleaned.

2.1.3 Shall obtain from the cleaning contractor satisfactory evidence and / or guarantee that the cleaning
agent, inhibitor, detergent, neutralizer and passive to be used will not be injurious to these materials

2.1.4 Shall approve the cleaning procedure and chemicals used for all cleaning steps.

2.1.5 Shall witness the test and accept each step of the cleaning activity before proceeding to the next
step.

2.1.6 Shall accept the completion of the cleaning activity after inspection.

2.1.7 Shall be responsible of providing power, potable water, and personnel shall be from the contractor
to operate the contractor equipment.

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Disouq Field Development Project

Specification for chemical cleaning of piping

2.2 CHEMICAL CLEANING CONTRACTOR

2.2.1 Shall accept the responsibility of proposing and carrying out an acceptable proven procedure for
the entire cleaning operation. This shall cover all applicable steps in detail, such as flushing,
degreasing, chemical cleaning, neutralizing, passivation, clean water flushing, draining and safety.

2.2.2 Shall use inhibitor, detergent, emulsifier, or other additives in accordance with accepted practice
and experience and to suit the metallurgy of piping.

2.2.3 Shall establish, inform and get approval of the owner for the chemicals used for all chemical
cleaning steps: cleaning, degreasing, neutralizing, inhibiting and passivation agents (also the
nitrogen to be used for agitation and blanketing).

2.2.4 Shall dispose of or recover all spent acids, degreasers and neutralizers or shall advise the owner of
any special requirements for the safe disposal or recovery of these materials according to the
EGYPTIAN laws and regulations.

2.3 REFERENCES
Piping requiring cleaning is specified in the remarks column of Line Designation Tables List by the
symbols: CC (Chemical Cleaning) and DF (Detergent Flush). The extent of piping is shown on
piping drawings and isometrics.

3 CLEANING

3.1 REQUIREMENTS
Carbon steel piping shall have its internal surfaces cleaned to base metal. All dirt, grease, paint,
rust and mill scale shall be removed. Stainless steel piping shall have all dirt and grease removed.
No particulate matter larger than 130 microns shall remain in the piping after cleaning.

3.2 PROCEDURE
The cleaning contractor shall submit detailed cleaning procedures with his proposal for review by
the owner. The procedures shall include the quality control and inspection requirements, which
will be used to accomplish the requirements of this specification. The procedures shall include
data and information on chemicals, minimum flushing velocity, filter sizes, and the methods to be
used for determining completion of degreasing, pickling and passivation

3.3 MATERIALS
Cleaning solutions used shall be compatible with piping materials, valve trim, gaskets, and all other
components in the piping. Chemical cleaning shall not exceed 0.2 mils metal penetration.

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Disouq Field Development Project

Specification for chemical cleaning of piping

Solutions and water used for detergent flushing of stainless steel piping shall not exceed 50-PPM
chloride content.
See Piping Material specification for the full description of piping materials.

Equipment outlines and specifications give materials of construction for packaged equipment
piping which requires recleaning.

3.4 IN-PLACE CLEANING


The cleaning contractor shall submit drawings which show the following for all piping cleaned in
place:
Cleaning contractor's equipment( including documentation; manuals, certificates)
Circulating loops.
Valve operation sequences.
Location of blinds and hose connections,
Size and type of hose connections,
Temporary piping requirements, and
Any necessary piping modifications required to complete cleaning.

A mark-up of the piping drawings is acceptable. A mark-up of equipment outlines is acceptable


for piping supplied with equipment.

3.5 EQUIPMENT ISOLATION


When only the field fabricated piping is to be cleaned, all piping connections shall be inspected to
ensure that the piping is completely disconnected from the console assembly and machinery. No
cleaning solutions shall contact the equipment. Where equipment-supplied piping is to be
recleaned, all connections shall be inspected in accordance with the mark-up of the equipment
outline drawings. No cleaning fluids shall come in contact with machinery bearings and seals.

3.6 GENERAL CONDITIONS FOR CHEMICAL CLEANING

3.6.1 A spool assembly shall replace control valves during chemical cleaning.

3.6.2 All instruments shall be protected from the chemical cleaning solution:
Orifice plates shall be removed.
Spool assemblies shall be substituted for all meters.
Valves in the pressure taps shall be closed and the drain valves on the instruments opened
Thermo wells are to be removed and sockets to be plugged out.
Permanent strainers and filters are to be removed.

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Disouq Field Development Project

Specification for chemical cleaning of piping

3.6.3 All relief valves shall be removed and nozzles blanked off

3.6.4 Temporary valve, 3/4 minimum size shall be installed at the high points of the systems to be
circulated for venting purposes.

3.6.5 All process reciprocating and rotating equipment and their ancillary systems shall be disconnected
and blind off.

3.6.6 The chemical cleaning solution must not be allowed to stand undisturbed in any part of piping at
any time. The filling, circulating, draining, flushing and neutralizing operations are to be
continuous for each of the systems to be treated.

3.7 INSPECTION
In order to establish that the piping has been properly cleaned an examination shall be performed
on completion of the following steps:

Degreasing.
Pickling.
End of cleaning.

The cleaning contractor shall allow the owner or owner representative to review the tests used to
determine completion of the degreasing and pickling steps. On completion of cleaning, the piping
shall be visually examined. There shall be no foreign material visible to the naked eye and no
grittiness to the touch. A removable greasy and rust test specimen of steel shall be provided at
convenient point in the system so it may be removed to observe the progress of the cleaning
operation
A pre-weighted, stressed, carbon steel corrosion coupon shall be placed in the circulation system
by which corrosion during the process may be monitored and end result corrosion may be
calculated.

3.8 ACCEPTANCE
The cleaning contractor shall make a record of all lines cleaned. For carbon steel piping the record
shall include the degreasing, pickling, and end of cleaning examinations and type of passivator
used. For stainless steel piping the record shall include the degreasing and end of cleaning
examinations. The owner or the owner's representative shall date and sign the record to confirm
acceptance when each examination is completed. The record shall be available for owner review at
all times. The record shall be submitted to the owner on completion of cleaning.

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Disouq Field Development Project

Specification for chemical cleaning of piping

4 CHEMICAL CLEANING SOLUTIONS

The following materials have been successfully used for mill scale removal and general cleaning:

Inhibited Hydrochloric Acid.


Inhibited Phosphoric Acid.
Citric Acid (Ammoniated).
Vertans (Dow Industrial Service).

Other solutions may be used provided they have been proven by experience by a reputable cleaning
contractor.

Experience has shown that the Citric Acid and Vertans methods generally require no removal of
normally encountered metal components in the circuit. However, in specific cases, the chemical
cleaning contractor must determine whether any components need to be removed.

5 PROTECTION

5.1 GENERAL
This section covers drying, rust prevention, and sealing of cleaned piping. When disassembling or
reassembling cleaned piping, extreme care shall be taken not to introduce foreign material into the
piping or equipment. Use lint-free and ravel-free rags for wiping and cleaning. Before breaking
any joint on cleaned piping, wash the outside with solvent.

5.2 DRYING
The cleaning contractor shall drain and dry the cleaned piping. Carbon steel shall be dried to -40
degree F dew point Stainless steel shall be blown out with dry air.

5.3 RUST PREVENTION


The cleaning contractor shall apply a rust preventative on the internal surface of cleaned carbon
steel piping immediately after drying. Lube oil and seal oil piping shall be coated with a rust
preventative approved by the equipment manufacturer.

Compressor suction piping shall be coated with Shell Ensis Fluid S, or with a mixture of 35 pounds
of Chevron Rust Preventative and 3/4 gallons of Chevron Thinner Number 350. Or it may be
coated with any other acceptable corrosion-preventative oil meeting the requirements of the latest
edition of MIL-C-22235. Any excess coating material that collects in the bottom or dead ends of
the pipe should be drained before sealing the pipe openings.

5.4 SEALING
The contractor shall permanently connect the cleaned piping after drying and rust prevention.
Where piping and equipment cannot be immediately connected, it shall be sealed with temporary
or permanent protection as defined below.

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Disouq Field Development Project

Specification for chemical cleaning of piping

5.5 TEMPORARY PROTECTION


Piping that will be erected within 7 days can have temporary protection. Flanged pipe ends shall
be sealed with polyethylene film, 5 mils minimum thickness, taped in place with Number 472
Scotch brand vinyl tape 1-1/2 inches wide. Taped surfaces must be dry before tape is applied.
Threaded connections shall be fitted with line-class pipe plug. All equipment and temporary
protective covers must remain in place until permanent connections are made.

5.6 PERMANENT PROTECTION


Permanent protection shall be applied to all piping and piping connections which will not be
permanently erected within 7 days. This procedure should not be used except where absolutely
necessary.

Flanges shall be blanked with 1/8-inch thick (minimum) metal flange protectors and sealed with a
1/8-inch thick soft rubber gasket to keep out moisture. Covers shall be held in place by a minimum
of 4 bolts through 6-inch nominal pipe size and by one-half of the flange bolts for pipe sizes 8-inch
and larger. Threaded connections shall be fitted with line-class plugs.

The contractor shall identify all permanently protected pipe spools. Stencil or paint
CHEMICALLY CLEANED on each carbon steel spool with waterproof paint in figures not less
than 3/4-inch high. Mark stainless steel piping DETERGENT FLUSHED.

Cleaned piping shall be stored out of contact with the ground in a manner to minimize the
possibility of penetration of moisture debris.

5.7 LUBE AND SEAL OIL SYSTEM


Final oil flushing of lube and seal oil systems should be started as soon as possible after completion
of chemical cleaning and detergent flushing. Where lube oil and seal oil piping will not be oil
flushed within 7 days after completion of erection, ferritic steel piping including the console piping,
and machinery piping shall be purged with nitrogen and sealed under a 5 psig nitrogen pressure.

6 DISPOSAL OF CHEMICALS
All chemical streams, rinses and drains shall be contained or shall be collected in suitable vats or
tanks. No streams shall be allowed to drain upon the ground. Approval must be obtained prior to
start draining any material to an existing sewer system.
(According to EGYPTIAN laws and regulations)

7 GUARANTEE

The contractor shall give written guarantee of the effectiveness of removal of mill scale and other
oxides, and stating the maximum amount of base metal which will be removed during the cleaning
operations.
(Contractor to sign that the disposal was done in accordance to the EGYPTIAN laws and
regulations).

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