Doc No : 7T04-CM-00-PC-012

-ew PROJECT SPECIFICATION

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Chemical Cleaning Procedure
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PROJECT SPECIFICATION

Chemical Cleaning Procedure

PROJECT NO. 7T04

PROJECT NAME ERC Refinery Project

COMPANY Egyptian Refining COMP ANY (TAKRIR) S.A.E.

SITE Mostorod, Egypt

\ / A

l. [«'
« Ii4 ,
41
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0 3 Sep 2 0 1 6 For Approval K-H CHOI J.S.Park S.Prinsloo S.I.Lee

PREPD CHKD CHKD APPR REVD DATE

REV. DATE DESCRIPTION

CONTRACTOR COMPANY

G s Engineering 8Construction
S E O U L , KOREA

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TABLE OF CONTENTS

1. Purpose 3

2. Scope 3

3. Reference 3

4. Responsibilities 3

4.1 CONTRACTOR Responsibility 3

4.2 COMPANY Responsibility 3

5. Definition 4

6. Planning 4

6.1 Line cleaning guide and specification 4

6.2 Chemical Cleaning Treatment Selection 5

7. Procedure 6

7.1 Outlines of Procedures 6

7.2 Preparation a n d execution 6

7.3 Cleaning Record 8

7.4 Safety Precautions 8

8. Cleanliness Acceptance Criteria , 8

9. Reinstatement 9

10. E q u i p m e n t Lay-Up , 9

11. Documents 9

12. Recordkeeping 9

13. Attachments 10

13.1 P re- c omm i ss i o ni n g Check Sheet for C h e m i c a l Cleaning 10

13.2 Blind List. 1 1

13.3 Protection G u i d e l i n e for Specific I n s t r u m e n t Type 12

13.4 Piping list Planned To Be Chemically Cleaned 13

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1. Purpose.

The purpose of this procedure is the establishing of the basis of the detailed procedures which w i l l be

used to carry out the chemical cleaning activities to clean the newly constructed p i p e l i n e s or the new

equipments. This procedure will be used as a general procedure for the chemical cleaning to remove the

foreign material, dirt, dust, rust .. . etc. which are easy to be removed from the pipelines by chemical

cleaning in order to avoid its harmful effect especially on the rotating equipment such as the compressors.

2. Scope.

T h i s document covers the application of the chemical cleaning at site for the utility and process pipelines

or the equipments such as compressors suction lines, lube oil interconnect lines . . . etc. for ERC refinery in

Egypt. Detailed chemical cleaning method statements w i ll be prepared for the chemical cleaning of each

specific chemical cleaning package.

3. Reference.

(1) 7T04-CM-00-PC-023 Guide and Specification on Li n e Cleaning Method and Criteria.

(2) 7T04- PM-00-PC-0 1 6 Project specification for field pressure testing of piping.

(3) 7T04-CM-00-PC-001 Pre-commissioning and C o m m i s s i o n i n g Execution P l a n .

(4) 7T04-CM-00-MA-003 Pre-commissioning and C o m m i s s i o n i n g Manual.

(5) 7T04-CM-00-PC-008 Turnover Control Procedure.

(6) 7T04-CM-00-PC-006 UNICCS Control Procedure.

(7) 7T04-CM-00-PC-009 Blind Control Procedure.

4. Responsibilities.

4.1 CONTRACTOR Responsibility.

(1 ) The CONTRACTOR is responsible for the chemical cleaning of all lines and equipment in

accordance with this procedure.

(2) The CONTRACTOR shall submit to the COMPANY a detailed method statement for chemical

cleaning for each specific chemical cleaning package with its attached marked up P&ID.

(3) The CONTRACTOR shall provide all materials and services to carry out the chemical cleaning

activities.

(4) The CONTRACTOR shall scan and record all approved Pre-commissioning check sheets related to

the completed chemical cleaning activities until turnover be completed and transferred to the

COMPANY.

4.2 COMPANY Responsibility.

(1) The COMPANY shall review and approve the general chemical cleaning procedure.

(2) The COMPANY shall review a l l chemical c l e a n i n g detailed method statements and the marked up

P&!Ds related to the chemical cleaning activities and the C O M P A N Y has the right to comm ent on

it.

(3) The COMPANY shall witness the chemical cleaning activities and confirm the cleanliness after j o b

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completion by signing the record sheets.

5. Definition.

(I ) COMPANY; Egyptian Refining Company (Takrir) S . A . E

(2) CONTRACTOR; GS E & C (GS Engineering & Construction Co.)

(3) System; subdivision of a plant Unit, either processing or utility or offsite, which performs a

specific operational role or function in the Plant.

(4) Sub-system; further s u b d i v i s i o n of a system which performs a given operational function that may

have little or no interference with the other subsystem.

(5) Chemical Cleaning Package; Part of system or sub-system or more than one sub-system w i ll be

chemical cleaned as one loop using one method statement.

(6) Plant; means the hydro-cracker plant complex which is to be designed, engineered, procured,

constructed, erected, interconnected; pre-commissioned, commissioned, started-up, tested,

completed and delivered by the CONTRACTOR at the Site .

6. Planning.

6.1 Line cleaning guide and specification.

According to the notes in P & I D ' S and the guide and specification on line cleaning method and criteria,

piping for the compressor suctions are planned to be cleaned basically by chemical cleaning. In

addition, lube oil interconnecting piping constructed at the field w i l l be chemical cleaned.

Process/ Service
Description Cleanliness Drying Remarks
Utility fluid

Compressor
p p Process hydrocarbon F D/E Suctions (as per

attachment # 1 3 .4 )

CCR( K - 1 3 0 1 A/ 8 )
p N Nitrogen F F
& HPU (K-1602)

Interconnecting pipe
p LO Lube Oil F E
sections

CCR Unit (Air

p PA Dry air F E Compressor-Air

Drver)

C l e a n l i n e s s Specs Description

Fine (F) A l l foreign material removed to a target specification, chemical analysis, or particle count.

Drying Method Description Dryness level

D Drain and dry. Dry with o i l free air Dew point of lower than O deg. C

E Drain and dry. Dry with o i l free air Dew point of lower than -20 deg. C

F Drain and dry. Dry with nitrogen Dew point of lower than -30 deg. C

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6.2 Chemical Cleaning Treatment Selection

6.2.1 Hot Alkaline Treatment Selection

(1) Where o i l , grease, carbon, or other organic compounds are present, these must be removed

during cleaning.

(2) Soda ash (Na2C03) degreasing is a m i l d treatment used where contamination is primarily

light oil and grease.

(3) Caustic degreasing (NaOH) is the treatment used for all new equipment, and where mill scale

is present.

(4) Permanganate (KMn04) degreasing is used where organic contamination is heavy (> 25%)

and carbonized.

6.2.2 Acid Cleaning Selection

(a) Hydrochloric Acid

Inhibited hydrochloric acid is a most widely used acid since it produces good solubility with a

wide variety of scales, is economic, and is easy to handle. It exhibits good corrosion

characteristics when correctly inhibited and the process is controlled within the accepted

li m it s .

(b) Citric Acid

Citric acid is compatible with alloy steels, requiring low chloride contents and presents good

handling, safety, and corrosion characteristics, in comparison to hydrochloric acid. It is less

aggressive in its attack of some iron oxide scales and therefore usually requires higher

temperatures or longer contacts time.

The normal reasons for its selection are:

(I) Presence of austenitic materials of construction.

(II) Rust removal, neutralization and passivation can be carried out using a single solution,

thereby considerably reducing cleaning time by eliminating the need to drain, flush,

and refill the equipment between the stages.

6.2.3 Neutralization and Passivation

(1) Following acid cleaning, it is essential that the equipment be thoroughly neutralized. This is either

achieved by neutralization alone, usually with 0 . 5 % sodium carbonate, or during the passivation

treatment, where the process requires pH values of 7 or greater.

(2) The select i o n of passivation treatment is so m eti m es governed by the selection of the acid. W here

c i t r ic acid process has been used, t hese are extended to effect neutralization and passivation by a

s u itable pH adjustment and the addition of an o x idi z i ng agent. t

I can also be achieved by the

nitrite/phosphate treatment.

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7. Procedure

7.1 Outlines of Procedures

It is necessary to c l e an some new equipment initially before they are put into service. Cleaning is

accomplished by a combination of (not necessarily in the sequence listed herein).

- Mechanical Cleaning.

- High Pressure Water Jetting (HPWJ) or Water F l u s h i n g .

- H o t Alkaline Treatment.

- A c i d C l e a n i n g and Neutralization.

- Passivation.

- Flushing.

- Drying and/or l n e rt i n g .

For some equipment it may not be necessary to use all of the above steps since the degree of

contamination and the equipment configuration will vary from unit to unit.

The stages of chemical cleaning w i ll be decided before the cleaning is started.

7.1.1 Mechanical Cleaning.

This is to mechanically remove, using power brushes or reamers as much of the rust, scale, and

deposits as p o s s i b l e from the equipment.

7.1.2 High Pressure Water Jetting (HPWJ) or Water Flushing.

HPWJ can be used alone or to supplement the chemical cleaning to remove the rust or deposits if

access is a v a i l a b l e .

7.1.3 Hot Alkaline Treatment.

T h i s is used to remove grease and o il , and for effective a c i d cleaning stage.

7.1.4 Acid Chemical Cleaning.

This i s used to chemically remove mill scale, mineral deposits and corrosion products.

7.1.5 Neutralization and Passivation.

Neutralization is used to neutralize acids and passivation to form a strongly adherent protective oxide

layer on the wetted surfaces.

7.2 Preparation and execution.

(1 ) Chemical c l e a n i n g route shall be determined and shown on a marked up P&ID.

(2) Install all necessary temporary piping, sacrificial valves, pressure, temperature and level

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instruments. Do not use instruments and valves with copper or copper alloys, or austenitic stainless

steels.

(3) Install b l i n d s , and adequately sized temporary drain valves, and vents to permit rapid dumping of

acids. Use temporary plugs or s l i p blinds to isolate sections that do not require cleaning.

( 4) Instruments such as control valves, orifice plates . . . etc. shall be removed to protect them as per the

attachment #3 (Protection G u i d e l i n e for Specific Instrument Type).

(5) Store all chemicals needed for the procedure on-site prior to commencing cleaning, including

emergency neutralizing agents, nitrogen and wet lay-up chemicals.

(6) Install fittings for liquid sampling, flow elements, temperature probes, pipe-spools with on-line

access fittings for corrosion monitoring probes.

(7) P ro v i d e adequate lighting at all operating points.

(8) Plan for the disposal of waste water and chemical solutions.

(9) Ensure that an adequate supply of utility water is available for fl u s h i n g and c l e a n i n g .

( I 0) Perform checks on valve l i n e u p s as required for each major flush and circulation path.

(1 1 ) Perform checks on valve lineups as required for flushing and reversing circulation.

( 12) Check and ensure that the flow design includes: flow reversal manifold and valves, control valves and

bypass to control circulation within specified limits, blend filling of corrosive chemicals without exposure to

the atmosphere.

(1 3 ) Test the cleaning circuit hydrostatically at 1.25 times the dead head discharge pressure of the circulating

pump, after installation of all temporary piping and connections, prior to chemical cleaning.

( 14) Ensure that an external heat source is available to maintain the cleaning fluid temperature, within the limits

specified.

( 1 5) Ensure spare pumps are available in case of a pump failure to maintain circulation.

( 16) Ensure sufficient holding tank capacity is available for draining and neutralizing cleaning solutions if

necessary.

( 17) Ensure, using standard samples, that on-site chemical analytical procedures and laboratory analytical

procedures yield results w i t h i n + / - 20 %.

( 18) Determine the v o l u m e of the equipment by fil l i n g water and d ra i n i n g it through a flow meter installed in the

drain.

(19) Ensure that the chemical cleaning contractor is on-site with m i x i n g tanks, chemicals, flow meter, corrosion

monitoring equipment, pH and temperature probes, and pumping equipment to blend fill and circulate

chemicals.

(20) Flush the equipment with water until it runs clear to remove all loose and soluble materials.

(21) Use commercial grade quality for all chemicals except where austenitic materials are present in the

e q u i p m e n t to be cleaned. In this case, the total chlorides of a l l the chemicals in the mixture must not y i e l d a

final solution containing greater than 50 m g / L a s c h l o r i d e .

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(22) Install at least one corrosion probe in the circulating loop for on-line monitoring and control of the corrosion

rates.

(23) Flow restriction such as orifices and probes must be removed to obtain optimum velocities during cleaning.

All equipment removed shall be tagged and inventoried for later reinstallation into his proper location.

(24) Warning tags should be installed on components which are isolated from the piping during chemical

cleaning.

7.3 Cleaning Record

Log Sheets of cleaning operations are maintained by Subcontractor to record temperatures, pressures,

time and date of cleaning process, chemical additions, and results of chemical cleaning analysis.

7.4 Safety Precautions

(1) Keep operational and tested, permanent or temporary eye wash fountains and safety showers

within 1 5 meters and accessible in 1 0 to 1 5 seconds of the work site, prior to commencement of

chemical cleaning.

(2) Keep connected to an operable water supply, hoses adjacent to the equipment and systems b e i n g

cleaned to handle any chemical s p i ll s .

(3) Rope off the area where the blending and heating of chemical solutions is performed and post

"DANGER" signs.

(4) Ensure all nitrogen cylinders if in use, have individual regulators and are adequately secured.

Also, ensure the nitrogen manifold has a safety relief valve attached.

(5) All personnel handling chemicals shall wear protection equipment required by the Chemical

Hazard B u ll e t i n s or M S D S of the materials involved.

(6) The Subcontractor shall supply adequate portable fire extinguisher for its equipment.

(7) When nitrogen is being used or has been used for draining chemical solutions or for any other

purpose during cleaning, nitrogen shall be vented to a safe place or sufficient ventilation shall be

provided.

8. Cleanliness Acceptance Criteria

(I) V i s u a l and/or video borescope inspections are carried out to determine the effectiveness of c l e a n i n g .

(2) No v i s i b l e traces of water, loose or adherent scales/deposits inside the equipment are acceptable.

Water, after flushing, shall be thoroughly drained from the lines. All low point drains and the

required vents to drain water from any p i p i n g or equipment which may retain water must be opened.

Other necessary steps for complete water removal such as air blowing shall be carried out where

required.

(3) Lines shall be dried to reach the dew point level as per the required dryness level.

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(4) COMPANY, CONTRACTOR, and Subcontractor w i ll attend the inspection after cleaning.

9. Reinstatement

Basically reinstatement of the l i n e s for w h i c h p r e - c o m m i s s i o n i n g cleaning is fi n i s h e d w i ll be performed

by Construction P i p i n g t e a m .

(1 ) On the completion of the cleaning, remove the temporary spools and spades.

(2) Install all the dropped items such as orifice plates, control valves, strainers, relief valves . . . etc.

(3) Reconnect the l i n e s or instrument which were disconnected for the operation.

( 4) Use permanent gaskets for reinstatement.

(5) Proper bolt tightening machine shall be prepared and used.

10. Equipment Lay-Up

If the startup of the equipment after cleaning is likely to be delayed by more than 60 days, dry it with

nitrogen to a dew point of -30 deg C and store it under a positive pressure of nitrogen for corrosion

protection.

1 1. Documents.

The following documents shall be prepared for the chemical cleaning packages for each System or Sub­

Systems.

(I) Method statement for the designated chemical cleaning package based on the general chemical

cleaning procedure.

(2) Marked up P&IDs define the chemical cleaning packages and the pipelines and the chemical solution

inlet and outlet points and define the boundary isolation and the temporary installed items (spading,

and spools . . . etc.).

(3) Chemical cleaning check sheet.

(4) B l i n d l i s t in of chemical cleaning package.

12. Recordkeeping.

(1) Signatures shall be obtained on the check sheets from the CONTRACTOR representative and the

COMPANY representative who have witnessed the chemical cleaning.

(2) Signed check sheets w i ll act as the approval records for the acceptance of the chemical cleaning

completion.

(3) Approved chemical cleaning completed check sheet for each package should be recorded to go

forward to the next stages of the P r e - c o m m i s s i o n i n g activities such as reinstatement.

( 4) A l l approved check sheets for the task c o m p l e t i o n should be scanned and registered at U N I C C S .

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13. Attachments.

13.1 Pre-commissioning Check Sheet for Chemical Cleaning.

Egyptian Refining Company

(TAKRIR) 8.A.E. Pre-commissioning Checksheet

GSEsC
Egyptan ehnwng Company '
ERG 1ll Au=e4 dlull

Chemical C l e a n i n g
@ mrsus 0., urn.

ERC Refinery Project

Sub-System No. Unit.No. MC Package Date. (DD-MM-Yer) FormNo. 0PP.017 rev.0

L.oention / Item.No. or Tag No. Flushing Package No.

No. Check Items Pass Fall NIA Remark

1.7.1 Method statement

Hems lo be protected were removed anu storeu al a sale place

1.7.2

I emporary spouts were instuieu properly

1.7.3

1.7.4 Chemical circulation loops were installed firmly and leak tested

temporary euupment anu aevice was 1pstau/eu m a sie manner

1.7.5

1.7.6 Chemical solution was charged successfully

Cleaning circulation has been stopped after sampling result of circulation

1.7.7
solution reached values specified in procedure

1.7.8 Cleaning circulation has been disposed as per environment regulation

1.7.9 Cleaned surface was flushed with water and water has been completely drained

1.7.10 System has been dried

Comments :

SIGNATURE
SUBCONTRACTOR CONTRACTOR COMPANY
REGISTER

Name

Signature

Date

Q P P - O 1 7 Rev. O
dGs Engineering 8Construction

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13 . 2 Blind List .

P&IDNormal
MC
Unit Subsystem Equipment Package
Package Line No P&ID No Class Size Paddle
No No No No F-8(0pen
No (Spacer/
/Close)
Plank)

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1 3..3 P roteetion G ut l I Ii. n e for Sp e e

i de a e In s:tr u m e n t T y p e
:f

To Be

Removed For
No ITEMS Notes
Blowing And

Flushing

I Control Valves (Throttling)- all Styles YES

Control Valves (On/Off Automated Block Valve, lined (all)or Butterfly

2 YES
VIV)

3 Regulators YES

4 Analyzer Elements YES

5 S a m p l e Valves YES

6 Analyzer Sample Probe with Sample Line YES

7 Magmeters - Flange Class 300# or higher NO

8 Pitot Tubes (Annubar) excluding transmitter YES

9 Turbine Flow Meters YES

10 Vortex Flow Meter YES

1 1 Insertion Flowmeter- Flanged or Threaded (Not Turbine Meter) YES

12 Armored Purge Flow Meters YES

13 Variable area or Rotameters YES

14 Oval Flow Meter YES

15 Coriolis Flow Meter YES

16 Orifice Flowmeter (Plate) YES

17 Integrated Flow Orifice Assembly (Excluding Transmitter) YES

1 8 Wedge Meters E x c l u d i n g Transmitter and Seal YES

19 Float Type L evel D evice YES

20 D iaphragm P ressure Sensor YES

21 P ressure G auges YES

22 Thermocouples YES

23 Thermowells - Flanged NO

24 Ventur i Type tl o wm eter YES

25 G au g e g lasses NO

26 Pressure switc h es Y ES

27 PSV ' s and TSV ' s Y ES

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13.4 Piping list Planned To Be Chemically Cleaned

(A) Compressor Suctions Lines.

Unit Related Equipment No.

NHT(l 1 ) K - 1 1 0 1 A/B Suction

Reformer(12) K - 1 2 0 1 Suction

K-1202A/B Suction

K-1302A/B Suction

CCR(13) K - 13 0 1 A / B Suction

K - 1 3 0 3 A / B Suction

K-1401A/B
DHT(l4)
K-1402A/B

K - 1 5 0 1 A / B / C Suction
H C U ( l 5)
K - 1 5 0 2 Suction

DCU(22) K-2201

K-1601A/B
HPU(16)
K-1602

(B) Lube Oil Interconnecting Lines.

Unit Related Equipment No.

Reformer (1 2 ) K-1201

HCU(IS) K-1502

K-2201
DCU(22)
Jet Pump

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