28895E00 - ENI TS - Pipe Cleaning Guideline
28895E00 - ENI TS - Pipe Cleaning Guideline
28895E00 - ENI TS - Pipe Cleaning Guideline
STD
Rev. 00 – October 2019
Pag. 2 of 50
REVISION TRACKING
INFORMATION REQUEST
For information about the content of this standard, please refer to persons mentioned on first
page or to Company Standard Team (mbxc&[email protected]).
INDEX
2.6.3.2 Degreasing 27
2.6.3.3 Rinsing 28
2.6.3.4 Acid stage 28
2.6.3.5 Neutralization/passivating stage 29
2.6.3.6 Final rinsing 30
2.6.3.7 Preservation 30
Chemical Cleaning for Stainless Steel Pipe 30
2.6.4.1 Pre-flushing 30
2.6.4.2 Degreasing 30
2.6.4.3 Rinsing 30
2.6.4.4 Acid stage 30
2.6.4.5 Neutralization/passivating stage 31
2.6.4.6 Final rinsing 31
2.6.4.7 Preservation 31
Chemical Cleaning Acceptance Criteria 31
Chemical Cleaning Safety Requirement 31
STEAM BLOWING 32
Steam Blowing Preliminary Activities and Preparation 33
Steam Blowing Execution 34
2.7.2.1 Boiler Blowing 38
2.7.2.2 Piping Blowing 38
Steam Blowing Acceptance Criteria 38
Steam Blowing Safety Requirement 42
HYDROJETTING-RETROJETTING-AQUAMILLING 43
Hydrojetting Preliminary Activities and Preparation 43
Hydrojetting Execution 46
2.8.2.1 Hydrojetting 46
2.8.2.2 Flushing 47
2.8.2.3 Preservation 48
Hydrojetting Acceptance Criteria 48
Hydrojetting Safety Requirement 48
ANNEXES 50
CLEANING MATRIX 50
Scope of this document is to provide the guidelines for performing different type of pipe cleaning
methods. It is very important to take care of the cleanliness of piping before it is put in service
and before the start up. Failure in doing that can cause several issues to start up and to process
operations.
The degree of cleanliness might differ according to the service and material of piping.
GENERAL REQUIREMENTS
During the Engineering phase, the cleaning method shall be established, together with the
detailed cleaning procedure and the acceptance criteria for each system/subsystem, based on
the Project specifications or Vendor recommendations.
For the cleaning of the pipes in the Annex 1 Cleaning Matrix, there is a summary of the cleaning
methods, the medium used and the criteria of acceptability.
Forms and certificates for pre-commissioning cleaning are included in the “Commissioning
Inspection Test Plan”
The distribution of this document is limited to Eni employees and contractors awarding for
Development Projects.
REFERENCE DOCUMENTS
The latest edition of each publication shall generally be used, together with any
amendments/supplements/revisions thereto, however new revisions/updates during an activity
or project will not be considered unless there are associated safety/environmental impacts.
To be noted that Company msg (management system guidelines), opi (operating instruction)
and pro (procedure) are for Eni Internal use only and not distributed to contractors.
General Definitions
The Company Standards shall comply with the use of the Company Terminology.
All acronyms and abbreviations used in the document are summarized in section 1.5.2
The cleaning execution and the correct implementation of the Procedure is in charge to the
corresponding function as per the following Responsibility Chart, with the support of the HSE
department.
ORDER OF PRECEDENCE
In conjunction with this specification, the codes, standards and regulations listed in section 1.3
shall be applicable. Reference to any Standard or Code shall mean the latest edition of that
Standard or Code including addenda, supplements or revisions, unless otherwise stated in this
document.
The order of precedence shall be as follows: (descending order)
International Standards are at the lower level of hierarchy, their contents, assumed as reference,
is developed and detailed within the Company Specifications considering the specific application
and the area of business in which Eni SpA is operating. On top of those there are the Local
Regulations, the Project Specifications than the Company Specifications. Any applicable local
mandatory rule prevails on this specification. Should there be a perceived conflict between this
standard and other referenced standards, or lack of clear definition as to the applicability of any
specification or standard, the Facilities Technical Units owner of the Standard, shall seek
guidance to the Standard Team.
PROCEDURE
ORGANIZATION TEAM
GENERAL PREREQUISITES
MANUAL CLEANING
This method is used by means of either scrapers or wire brushes when the length of the pipe is
not excessively large and the diameter is sufficient to allow the cleaning operation (usually for
diameters greater than 18 inches).
Large bore piping for flares or big feed gas lines are often manually cleaned during the fit up
before welding.
For large diameters, this method is carried out for each spool before installation, prior to fit- up
or tightening of the spool itself.
After a visual inspection of the internals of piping, no sand, stones or leftovers from construction
phase shall be visible inside, the cleanliness is to be compatible with the future service of the
piping. The commissioning Team with the approval of the commissioning manager will evaluate,
approve and certify the cleanliness.
Manual mechanical cleaning is an operation that may involve entering a confined space and must
be carried out by trained personnel with a suitable Work Permit.
All people involved shall wear proper PPE.
AIR BLOWING
Discontinuous Air Blowing is one of the most widely used methods for cleaning pipes.
Compressed air is used for blowing by means of portable oil-free compressors as per figure
below. The amount of air to be used is at least equal but most of the time much greater than
the volume of the blowing lines.
Generally, the air blowing should be limited to those systems that cannot be cleaned using water
or steam.
Fig. 1
1 Continuous Blowing
Air is blown continuously through the selected pipework from a source (air compressor or via
pressurized vessel) to bring away foreign matter (usually this method is applicable when the
flow rate capacity of the air compressor is sufficiently bigger compared to the size (diam and
length) of the pipework, such that the flow through the pipework is bigger than the one with the
process fluid at operating conditions.
2 Air Accumulation / Quick Depressurization
Air is accumulated in a column/drum/vessel or pipe then released into the downstream piping
to atmosphere, so removing trash and construction debris.
The quick depressurization is achieved by either a quick opening valve (d ≤ 6”) or a bursting
disc made of multiple either metal or plastic sheets e.g. HDPE (6” < d < 20”).
Quick depressurization causes high air velocity in the pipework, bringing away the foreign matter
and dirt from inside the pipe.
Rupture disks are fabricated at plant site from a variety of materials (paper, LDPE plastic sheets,
aluminum sheet, etc). Choice of material depends on disk diameter and pressure at which disk
is required to burst.
A series of rupture trials, starting with small thickness disks and gradually increasing their
thickness, is strongly recommended if not required before achieving correct disk thickness.
Once preliminary activities are completed and all safety measures taken, air blowing can start
possibly taking into account the following measures:
Continuous Blowing
Fig. 2
In general between 20 and 60 blows for each system will be necessary to ensure cleanliness. An
indication of the air flow necessary for the cleaning process can be determined by calculating
the Disturbance Factor (DF):
DF = Rb2 * d0
R02 * dc
If a rupture disk is used, continuously monitor pressure increases; when rupture disks blows
out, stop the flow of inlet air source to pipe system.
Experience has shown that with DF ≥ 1.5 the line is well cleaned and the polished metal target
to assess the cleanliness extent (see further) shows little or no evidence of pitting after the air
blow.
Fig. 1
Fig. 2
For the majority of process and utilities piping, air colour at outlet point is a sufficient indication
of whether or not a blowing may be considered completed.
A common method to assess the cleanliness can be a white paper sheet nailed on a wooden
plate, placed right in front of the blowing end of the pipework to be cleaned.
In special services (e.g. compressor intake line) a target plate (copper, aluminium, stainless
steel) shall be installed at the air outlet point. Cleanliness acceptability is based on the number
and size of marks left by entrained material on the plate. Target plate to be used shall be highly
polished and installed on the pipe when the exhaust air appears clean. Target plate shall be fixed
to a support which keeps it perpendicular to the pipe axis (see Fig. 3).
1. Pipe to be cleaned
2. Plate Support
3. Plate
Fig. 3
Plate dimensions shall be: a x b (0.2 x 0.8) diam. (see Fig. 3).
Plate shall be replaced after each air blowing, then marked with number of flow, stored and used
for comparison with other plates.
When the plate surface remains bright, it is possible to count the number of marks left by dirt
or rust particles.
When number and size of marks does not increase during two consecutive blowing operations
and are in conformity with equipment (supplied by piping under cleaning) manufacturer
recommendations it may be assumed that pipe circuit is clean.
Special consideration is to be done for coated piping which coating might be damaged by high
velocities used with air blowing, water flushing is usually preferable (lower velocities) to clean
coated pipes.
Air blowing is an intrinsically hazardous operation. Therefore, special safety precautions must be
taken to prevent injury to personnel and environmental pollution.
The hazards that may cause a personnel injury are both debris flying by exhaust opening and
high noise caused by both air blow off and by the rupture disk, if it’s present.
Ensure that proper communication for energization (even temporary) is sent to all involved
parties prior to start with the activities.
Make sure to avoid conflicts and overlapping with other activities, especially construction.
Place warning signs and fence around the entire blowing area with strips of a color (black/yellow)
distinguishable from those used for construction activities (red/white).
Restrict access into air blowing area to authorized personnel only.
Prevent any persons from entering the exhaust blow area, allowing adequate distance in the
direction of the blow and considering possible deflection of the blow.
Vessels used to hold air under pressure must be protected by the installation of dedicated
pressure safety valves. The air pressurization of the vessel will never be over its normal operating
pressure.
Flexible hoses used for vessel air pressurizing will be resistant to the air supply design pressure.
System under blowing shall be positively isolated (valve or blind) from connected systems on
which other activities may be going on.
Each isolation valve connecting lines or branches within the system under blowing will be verified
to be in the closed position by visually inspecting the valve stem and with the checking for the
presence of a blind flange.
Instruct involved personnel to monitor air blowing operation and to safely stop blowing activity
(stop of the involved system pressurization and successively controlled depressurization of the
same) when required.
Ensure that personnel involved in blowing operation wear appropriate personal protective
equipment such as gloves, boots, helmets, ears protection (where necessary) and goggles.
Because high noise is expected, proper warning signs must be displayed and ears protection are
mandatory in all noise affected areas. Moreover, presence of Acoustic Zoning Plans or inhabited
areas shall be carefully taken into account.
People working in the area affected by the noise, shall be previously informed to avoid panic
coming from unexpected high blast sound (e.g. blowing through a whistle or horn to warn before
an air blowing)
Before pressurizing with air, walk down through the system to check for its proper alignment
and integrity.
During system pressurization, check again for its integrity (no major leaks).
Prior to beginning air blowing operations a specific Job Hazard Analysis relating to the task shall
be carried out by the supervisor and provided to the operators. Preventive measures identified
in the JHA shall be followed by operators.
Temporary pipe installed to carry on air blowing must always be of a rating not lower than the
pipework to be cleaned.
WATER FLUSHING
Use of water as a cleaning agent is, along with air blowing, the most common method for cleaning
pipework.
Where possible, it is advisable to flush with water all lines and vessels of the installation as it is
more efficient than air blowing to eliminate dirt (sand, earth, iron dust, etc.).
Use of water will not be admitted in all parts of the installation because of the service of the pipe
that might be incompatible with the presence of water especially where there is no certainty that
water can be totally drained or removed.
1) Gravitational flushing: this method is carried out by naturally discharging water from a
previously filled vessel/tank towards the downstream pipes (e.g. cleaning of the suction
piping of a pump). If required, it is possible to increase the speed of the water flow by
slightly pressurizing the storage vessel using air or nitrogen (not applicable with
atmospheric tank/vessel).
2) Power flushing/Forced flushing: this method is carried out using a water source, usually
either a temporary or a permanent pump (e.g. firefighting system or a movable pump on
a trolley) with a sufficient flow capacity compared to the length and size of the pipework
to be cleaned.
- Identify pipework and prepare it for cleaning, (e.g. determine air inlets and outlets, install
temporary bypasses, jump-overs, blind disks, etc.)
- Prepare appropriate marked up P&IDs.
- Disconnect pumps, turbines, compressors intake and discharge lines and cover casing
nozzles to prevent entry of cleaning medium.
- Remove orifice plates.
- Remove any in-line service strainer/filter.
- Remove or blank or bypass control valves and safety valves.
- Blank and protect instrument connections/impulse lines.
- Do not flush into lines directly connected to exchangers, disconnect joints and cover
flanges instead. In case upstream piping is already cleaned, take care that water velocity
inside the exchanger does not exceed limits specified in the equipment data sheet. Never
flush water through a plate exchanger.
- When a pair of flanges has to be opened to allow water flow to flush out, take care that
the distance between the two flange faces is sufficient to let all the water out of the pipe
to be cleaned.
- Block out spring supports, spring hangers, etc. according to manufacturer’s instructions.
- Protect equipment near flushing outlets to prevent damage to fragile devices such as:
pressure gauge glass etc.
- If not removed, protect instruments and electrical equipment within the exhaust flushing
area with plastic sheets and tarpaulin. Similarly protect with plastic sheets or tarpaulin
rotating machinery sensible parts and static equipment openings from dirt and water jets
- When a vessel is used as a reservoir, remove vessel internals if possible. Ensure that its
relief valve is in normal operation before starting filling and/or pressurization. Similarly
assure that any piping system is adequately protected so that design pressure cannot be
exceeded.
- A meeting between Contractor Construction and Company Representatives of the Division
Responsible for the activity, to finalize all technical and safety aspects prior to starting
water flushing.
- The end of the pipe to be flushed might need to be anchored in case of high water
volume/flow discharged.
- Check valves should be either removed or the internals (flappers, etc.) be removed if this
is possible, if not remove the check valve and install a temporary spool.
- Fresh water with a known chloride content should be used. Raw water with high
conductivity can cause corrosion and pitting, no seawater shall be used (unless internal
coated piping suitable for seawater is to be flushed). Carbon steel pipe shall be water
flushed with a water having a chloride content which is less than 250 ppm. Attention
must be paid where special metallurgy is used, such as stainless steel pipes or austenitic
steel. They must be cleaned using water with a chloride content which is less than 50
ppm. In case the dissolved salts are poisonous for catalyst or process condition, final
washing should be done with demineralised water.
- Before starting any water flushing operation, it is to be verified that the installed supports
(either permanent or temporary) can withstand the additional weight of water inside the
pipe.
Water velocity during the flushing phase shall be 3 m/s as a minimum. Therefore, an adequate
calculation of the flow rate is to be provided in order to select and use the right pump.
During water flushing, hammering shall be avoided and piping supports have to be suitable for
the activity.
Low points have to be used to drain water using compressed air to facilitate and speed up the
process. Where there is no certainty that all the water can be totally drained water flushing is to
be avoided.
This flushing method (also called “Fill and dump”) uses the water stored in a vessel/tank (usually
suction piping of pumps connected to a vessel/tank are cleaned using this method).
A vessel (vented to atmosphere) is filled up to the desired level with water and then dumped to
a suitable place at grade level.
Fig. 4
If the fire-fighting system using water is already available this method for water flushing can be
an optimal way to clean piping suitable to be cleaned by water (quality of the water shall always
be checked to be compatible with the piping to be cleaned, see above). The firefighting system
shall be connected to the pipe to be flushed trough a temporary hose connection.
Fig. 5
The fire-fighting system network must be washed first for safety reasons then the fire-fighting
system can be used as a source of water for flushing the lines and process equipment.
Fig. 6
Fig. 7
Water flushing shall be carried on until no visible dirtiness and debris come out of the pipework
under cleaning.
The water coming out shall be clear and not murky.
Water flushing should not commence until all related piping and process equipment are fully
installed, the system has been checked for conformance with the P&ID’s drawings and the piping
systems have been hydro tested.
Dedicated HSE Plan for handling and disposal of the water shall be developed by either the
Service Provider or whoever will be in charge for the activities in accordance with the HSE Site
Plan. Arrangement shall be made for the safe and environmentally friendly disposal of the water.
CHEMICAL CLEANING
Chemical cleaning is the process of removing fouling deposits with chemical solutions. The
cleaning action may be entirely chemical, using acids or alkalis, but may also be assisted by
organic solvents or hot water.
Chemical cleaning is the cleaning procedure to be adopted if any special process, material or
contract specifications require a highly effective cleaning method for piping system.
Chemical cleaning methods are methods by which cleaning is obtained by immersion of
equipment/piping in a cleaning agent, or by circulation of cleaning agents in the liquid and/or
vapour phase through the equipment/piping. Cleaning agents may be acidic or alkaline solutions,
organic solvents, water, sometime combined with solid particles for abrasive action.
Usually this cleaning method is performed by a specialized contractor also called “Service
Provider” due to the necessity to provide specific skills, equipment and tools.
The main typical steps in the chemical cleaning activity are the following:
1. Pre flushing
2. Degreasing
3. Rinsing
4. Chemical cleaning (acid stage)
5. Neutralizing and passivating
6. Final Rinsing
7. Preservation
The above steps might all be required or not, depending on the pipe material.
Any item in a loop (i.e. assembly of permanent and temporary piping in which the cleaning agent
is circulating) that does not require chemical cleaning, shall be listed, dismantled and replaced
by spools if required.
A chemical cleaning loop shall be connected to temporary facilities in order to achieve conditions
required and thus perform in terms of velocity, heating, chemical cleaning, flushing and draining
at a satisfactory rate.
Samples must be taken at selected places from the same piece of equipment and, sometimes,
at various depths of the deposit layer, down to the metal surface. This will ensure the samples
are representative of the fouling in the equipment as a whole.
Storage in an air tight closed containers will prevent contact with air and evaporation of volatile
components, thus maintaining the samples as much as possible in their original condition.
Inorganic fouling deposits and rust are found in equipment, which has not been preserved from
internal corrosion. These deposits are essentially rust, caused by oxidizing action of oxygen on
the metal. Some other deposits such as carbonates, silicates, sulphates, sulphides of Cu, Mg can
be encountered in lines which have contained water; Ferrous sulphide can be encountered also.
Mixed deposits may be found in water circuits when algae, bacteria have growth in stagnant
water.
- Put a weighed quantity of the fouling deposit in a 20 or 100 mesh SS basket, depending
on the particle size of the sample,
- Immerse the basket in the selected cleaning agent at a temperature and concentration
to be determined for each separate case. For upper limits and for inhibitors see attached
tables,
- Keep the sample immersed for 1-2 hours, occasionally stirring and observe the cleaning
effect periodically,
- Rinse the remaining sample in water
- Dry the sample at about 80°C and determine its weight loss. A high weight loss indicates
a high cleaning efficiency.
NOTE: When acidic agents are used, the acid concentration must be checked regularly, adding
fresh acid when necessary. This holds for the laboratory test as well as for actual cleaning.
For the chemical cleaning the agents are generally selected from the following types:
A) Acid solutions
Hydrochloric Acid
Relatively cheap and usually readily available. Although it is very corrosive towards most metals,
effective inhibitors (see Table1) are available which greatly reduce corrosion without hampering
the cleaning action. HCl effectively removes many inorganic deposits, containing e.g. carbonate
and iron sulphide.
For calcium sulphate and silicate deposits, a pre-treatment with a hot sodium carbonate or
sodium hydroxide solution is sometimes required. The deposit becomes soaked with this solution
and during the subsequent treatment with HCl, CO2 is released, breaking up the sulphate/silicate
layer.
HCl is applied in concentration from 2 to 15% wt and temperatures from ambient up to 65°C.
Concentration and temperature to be utilized depend on the construction materials of the
equipment (see Table1). Also, when cleaning by circulation, the velocity of the HCl must be kept
within the limits given in Table 1.
Sulphuric Acid
H2SO4 is less versatile than HCl, but availability and price may make its use attractive. In
comparison with HCl, it is less suitable for cleaning cast iron, but it is preferred for stainless steel
where HCl causes pitting. The acid can be used for removal of many types of inorganic deposits.
The acid must be inhibited.
Sulphanic acid (amino-sulphonic acid) is a non-volatile crystalline acid. It can be easily handled,
transported and stored. It is suitable for the removal of rust, algae and scale from deposits. The
acid is applied in a concentration of around 5-6% wt at temperatures between ambient and
65°C. Appropiate inhibitors of any kind of construction material is given in Table 1.
Glycolic Acid
Glycolic acid (Hydroxyacetic acid) is an organic acid, used in addition to sulphuric acid for the
chemical cleaning of carbon steel. The commercial solution is at 57%. It is added in the
proportion of 0.5% wt in the cleaning bath.
Nitric Acid
HNO3 is an oxidizing mineral acid and it is used in addition to potassium dichromate within a
concentration of 0.5 % wt for the passivation of the stainless steel.
Citric Acid
Available in a crystalline form successfully applied for the removal of iron oxide in new boilers.
It is also effective for removing sulphide deposits in equipment and piping, but not for calcium
bearing deposits. Citric acid can be used either as a solution, or in the vapour phase. When
applied as a solution, a concentration of 5-6% wt is normal. Cleaning is carried out up to 95°C,
to reduce the cleaning time and thus to counterbalance the higher price against HCl. Appropriate
inhibitors for any kind of construction materials are given in Table 1.
B) Alkaline solutions
Sodium carbonate and sodium hydroxide are applied for pre-treatment before acid cleaning of
inorganic deposits, containing some organic material and/or containing a high percentage of
sulphates and silicates. The solution (5-10% wt concentration and maximum 70°C) has a
degreasing effect and converts sulphates and silicates into forms which are easily removed by
subsequent acid cleaning.
Sodium carbonate, trisodium phosphate and trisodium polyphosphate solutions are applied for
degreasing. The solution at 0.5% total concentration and temperature 50-70°C can be used to
avoid caustic embrittlement of steel. Some wetting agents can be added to this solution.
C) Water
Hot or cold circulation may, in many cases, be sufficient to remove loose fouling deposits or
water-soluble salts from equipment. Water is also used for flushing after cleaning with acidic or
alkaline solutions.
D) Chelating agents
Chelating agents as the tetrasodium salt of ethylene diamine tetra-acetic acid, [Na4(EDTA)], are
sometimes applied as additives to boiler feed water. By keeping hardness components in
solution, the boiler is kept clean while on stream. Any existing deposits are also dissolved.
E) Neutralising/Passivating Solutions
Neutralization after chemical cleaning can be realised by a 2-5% wt solution of sodium carbonate
or sodium hydroxide which is circulated at ambient temperature. Neutralising/passivating
solutions can be alkaline solutions containing borax and trisodium phosphate. They are applied
after acid cleaning when the equipment is not immediately put back into operation and a
passivated metal surface is required.
F) Inhibitors
When chemical cleaning with citric acid is used, it is possible to neutralise with Ammonium
Citrate, by pH increasing of the bath (addition of ammonia in the bath). For passivating of
stainless steel, nitric acid/potassium bichromate solutions are used. Potassium bichromate
contributes (action of chromate) by improving the efficiency of passivation. Sodium Nitrite is
sometimes used in addition with a passivating bath (citric acid-ammonia) within a concentration
of 0.3-0.4% weight.
When acids are applied for chemical cleaning, the acidic cleaning solutions must be properly
inhibited. Table 1 gives a list of inhibitors which have been found to be satisfactory in practice,
with their dosage, temperature limits and manufacturers.
Most inhibitors consist of non-volatile compounds. These will not be effective in protecting the
construction material in the vapour phase above the acid.
Above the maximum temperatures, as given in Table1, the inhibitors will no longer give an
acceptable reduction to the corrosion rate. This may partly be due to decomposition of the
inhibitor.
NOTE: The effectiveness of the inhibitor in pre-inhibited acid will gradually decrease and it is
therefore recommended that only uninhibited acid be ordered for cleaning.
Type Dosage %
HCl 65 °C Carbon Steel, Rodine 213 0.4
15% wt 12 Cr Steel, Rodine214 0.4
0.5 m/s Cu & Cu Alloys Chemetar 0.5
IAX
Hydrox30
Norust CM 0.3
150
Mogul DX 0.5
1028
Norust CM 0.3
150
Clensohib 0.5
Norust 0.5
AS35
Mogul DX
1025
Table 1
- Identify the Service Provider (SP) if the activity will be performed by a third party.
- Identification of the piping systems for which the chemical cleaning is required.
- Selection of the method to be used for the chemical cleaning for the different piping
systems (according to the material and service). Verification and approval of the chemical
cleaning method proposed by the SP.
- Mechanical preparation of the piping circuits including the installation of systems
isolations, temporary spool installation and temporary terminal point adapters.
- Removal of all sensitive fittings and installation (control valves, instrumentations, etc);
- Installation of the temporary piping required for cleaning agents circulation and wastes
collection.
- Provision of safe and clear working area including scaffolding when necessary, no
hazardous overhead activities by others during chemical cleaning, etc.
- Provision of the required utilities (water, air, diesel oil, electrical power) as required by
SP or whoever will perform the cleaning activity.
- Lighting arrangement during night, if required.
- Development of the detailed procedure and the activities schedule. The detailed
procedure will contain the description of the chemical cleaning process and chemicals
used for the different steps. Following information are required:
o Chemicals to be used and method of introduction and disposal.
o Concentration, temperatures, circulation rates and contact time of chemical
solutions to be used.
o P&IDs identifying the position of isolations, temporary spool installation etc.
o Wastes disposal management.
o Details of the inhibitor to be used.
o Agreement on the criteria to verify the cleanliness.
o Sampling and testing schedule to assess the progress of the cleaning activity.
o Schematic drawings of the circuit to be cleaned and to be used to introduce and
circulate chemicals. Drawings shall indicate size and type of all cleaning
connections and location of sampling points (when required).
o Development of a dedicated HSE plan for chemical cleaning activities.
o Details about mobilization and demobilization if a Service Provider is appointed for
the cleaning activity and supervision and provision of skilled manpower that will
be involved.
o List of all temporary equipment for chemical solution circulation and list and
quantity of the chemicals to be used such as but not limited to:
Centrifugal pumps, water tank, waste tanks
Suction and discharge hoses
Necessary fitting/valves, connections
Reverse flow manifolds
Analytical kit to perform the analysis necessary during the cleaning
Supply of chemicals required for the chemical cleaning
- The use of PTFE gaskets is highly recommended
- During the chemical cleaning the solution, extremely corrosive, shall be carefully removed
by the piping system, in particular to the dead parts where it is easy the stagnation of
the fluid
- Chemical cleaning for the designated piping loop shall be performed after mechanical
completion; pressure testing and construction flushing have been completed.
- Remove the critical equipment that may sustain damage during Chemical Cleaning
process. Isolate or replace them by spool pieces.
- Hook up the whole system in a closed loop including flow reversal fittings, heat
exchangers, temperature and pressure gauges. Install vents at high points and drain at
low points.
2.6.3.1 Pre-flushing
Perform tightness test for the temporary Chemical Cleaning system to the maximum of pump
discharge pressure. In case of leakage, first remedy leaks then refill the system with water until
no leaks are found. Start circulation for fresh water flushing for two hours, drain and refill with
fresh water, circulate and start heating for alkaline cleaning [degreasing] stage.
2.6.3.2 Degreasing
Chemical cleaning is less effective if there is grease in the pipe and as consequences presence
of grease causes wasting of chemical cleaning solution, that’s why it is recommended to perform
degreasing before the introduction of chemical cleaning solution.
Cold or hot degreasing is carried out only if pipes have been delivered prefabricated by the
vendor or prefabricated on site and then greased or are thought to contain an oil based
preservation.
1. Solution:
- chemical composition:
o Sodium Carbonate Na2CO3 (3 g/l) or Sodium Tripolyphosphate Na5P3O15 (2 g/l)
and Trisodium Phosphate Na3PO4 (1 g/l) (in either cases a suitable proprietary
wetting/surfactant agent may be used),
- control parameters
o Temperature: ambient
2. Solution:
- chemical composition
o Caustic soda 1.0% w/w
o Surfactant 0.1% w/w
o Antifoam 0.02% w/w (if required)
- control parameters
o Temperature limit: 70-80 ºC
o Residence time: 8-12 hours
o pH: 8-14
Circulate the solution heating the fluid till to ambient or 70-80 °C according to the solution
selected. Circulate for 6 to 8 hours reversing the flow hourly, maintaining the temperature at
ambient or between 70-80 °C according to the selected solution . Check the pH every 30 minutes
ensuring that it is in the range 8-14, bleed vents and drain low points.
In case the pH drops below 8 then add more caustic soda to the system to maintain the pH in
the correct range.
Once completed, drain the system to dedicated effluent tank for neutralization and disposal. Fill
the system with clean water and rinse the system.
2.6.3.3 Rinsing
Rinsing to be performed with clean potable or preferably demineralized water (in any case, even
if no degreasing has taken place). Water pH minimum 7.0.
1. Solution
- Chemical composition
o Hydrochloric Acid (HCl): 200 g/l (from a solution 33% wt concentration specific
gravity = 1,165)
o Ammonium Bifluoride NH4HF2 (10 g/l)
o Inhibitor Rodine 213 or Armohib 28,2 (g/l) = (1% of HCl content) or Norust
PR or equivalent.
- Preparation
o Mix the chemicals as follows (per batch):
2. Solution
- Chemical composition
o Citric Acid 3.0 to 3.5% w/w
o Corrosion inhibitor, Rodine 31A 0.05% w/w (the selected one with the
concentration advised by the manufacturer)
- Control Parameters:
o Temperature limit 70-80 °C
o Residence time 8 to 12 hours
o Total dissolved iron 10,000 ppm Maximum
Fill the system with water, circulate and heat it to achieve the temperature in the range of 70 to
80 °C. Blend fill the following to the circulating solution:
Circulate for a minimum of 8 hours, reversing the flow hourly. Maintain the temperature above
70 °C. Bleed vents and blow down drains occasionally if any. Test each sample for free citric acid
and total Iron. If the free citric acid strength falls below 1.0%, or if the total iron exceeds 1.0%
w/w, drain completely and refill with new fresh solution. Do not add fresh acid to partially spent
solution.
Note: The effectiveness of the inhibitor contained in the acid can be verified by submerging an
untarnished carbon steel specimen in a sample of the acid, which has been adjusted, to proper
concentration. If one or more streams of bubble appear, rather than an occasional isolated
bubble, the acid shall not be used until adequate additional inhibitor is provided and the acid is
proven safe by adding more inhibitor.
During this phase the following analytical tests shall be carried out:
Note: Samples for analysis of oil and iron content and pH during cleaning process shall be
provided by whoever is in charge for the Chemical Cleaning activity.
- Chemical composition
o Citric Acid >1% w/w
Confirm the free citric acid strength is above 1.0%. If the strength is less than 1% w/w inject
0.5% w/w fresh citric acid. Add inhibitor with the concentration advised by the manufacturer.
After circulating for 2 hours inject alkaline solution (ammonia) to reach a pH value in the range
between 9.5 - 12.
Add Sodium nitrite to the strength 0.5% w/w or 10 g/l. Circulate for further 3 to 6 hours. Drain,
possibly under Air pressure (10psi), to the effluent tank for disposal.
Optional: After rinsing, drain and fill up the system with demi-water having a pH adjusted with
Ammonia to 8-8.5 and Eliminox 5 ppm for preservation if the service of the piping is compatible
with the above solution (e.g. piping for boilers, steam etc.).
2.6.3.7 Preservation
The conditions in which the system can be left after Chemical Cleaning is to be followed by the
project specifications. Leaving the system full of air after water rinsing is often not acceptable.
Preservation is usually obtained by filling the system up with inhibited water or under slight
nitrogen overpressure.
2.6.4.1 Pre-flushing
Apply as per chemical cleaning of carbon steel pipe.
2.6.4.2 Degreasing
Apply as per chemical cleaning of carbon steel pipe.
2.6.4.3 Rinsing
Apply as per chemical cleaning of carbon steel pipe.
In a suitable tank charge 100 l of demineralized water (if bigger quantities than 100 l of chemical
solution are needed then use the same components with same proportions).
2.6.4.7 Preservation
Apply as per chemical cleaning of carbon steel pipe.
- 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, welding slag, rust, corrosion, oxides, paint or other foreign material.
- Dew point after drying and inerting shall be as per Drying and Inerting Procedure issued
for the project/plant in which the chemical cleaning activity is carried out.
- Visual or borescope inspections will be carried out to determine the effectiveness of
cleaning if needed.
Once the chemical cleaning has been completed the whole pipework which has undergone
the cleaning is to be reinstated as per as built design drawings.
The operators and all the people involved shall be informed and be aware of the risks connected
with the use of acidic and alkaline solutions. Before the beginning of the activities, a dedicated
meeting with the site HSE manager will be held in order to plan and coordinate the activities.
Dedicated HSE Plan for handling and disposal of chemicals shall be developed by either the
Service Provider or whoever will be in charge for the Chemical Cleaning activities in accordance
with the HSE Site Plan. Arrangement shall be made for the safe and environmentally friendly
disposal of used agents via a neutralization unit or disposal tank. Direct disposal to a sewer may
be performed only after neutralization and or confirmation of environmental acceptability.
Materials Safety Data Sheets (MSDS) should be consulted to determine the hazards of handling
specific chemicals.
Personnel involved in the cleaning activities shall use the personal protective equipment (PPE)
required by the Site HSE Plan (safety hat, safety shoes, safety goggles and safety belt as
required).
Precautions must be taken to protect personnel, equipment and facilities. This includes provision
of venting to prevent the accumulation of any toxic or explosive gas mixture, safe disposal of
used solutions, provisions for safe transfer of dangerous chemicals (always to be kept in closed
and suitable containers/tanks) and constant vigilance for hazards and leaks during the cleaning
operation.
An emergency shower with eye wash shall be available to wash away splashed hazardous
chemicals.
The cleaning area shall be closed off to unauthorized personnel and warning signs shall be posted
to forbid smoking, welding and unauthorized entering of the cleaning area.
When necessary, adequate drip pans shall be placed underneath the equipment to avoid soil
contamination.
Wastes collection must be handled and disposed-off carefully and following a dedicated HSE
plan.
STEAM BLOWING
This guideline applies for the piping circuit outside of the Boiler Package battery limits for which
the dedicated guideline doc. No. 28897.COS.AVV.STD is available.
Steam blowing is performed to remove debris, loose scale and rust from steam lines suitable for
process steam or steam turbine operation.
Steam blowing is normally applied to steam service pipes and especially to the last portion of
pipe before entering into the steam turbine where a high degree of cleanliness of the inner part
of the pipe is of vital importance.
Blowing of steam piping and boiler super-heaters before starting up a new plant, after the
erection has been completed, is aimed to remove all foreign matters (mainly welding slags and
objects left) that may still be present in the steam generator or in the live steam piping.
Considerable damage to equipment may result from missing or incorrect blowing, in the event
that these particles circulate in the steam system or turbines during the initial run.
After each maintenance operation involving major welding works on the boiler or live steam
piping, foreign matters may remain in the system and must be removed by further blowing.
- Steam blowing should not commence until all related piping and process equipment are
fully installed. The system has been checked for conformance with the P&ID diagrams,
punch list completed, the piping systems have been hydro-tested and QA/QC
documentation produced.
- Marked up P&IDs showing the pipework to be cleaned, all the temporary installation, the
outlet point to atmosphere and any other useful information shall be prepared and
attached to the procedure to prepare the circuit for steam blowing.
- Temporary piping and silencers for depressurising to atmosphere should be installed and
properly anchored.
- The installed temporary piping and supports shall satisfy quality assurance requirements,
according to maximum pressures, temperatures and mass flow occurring during the
steam blowing operations. Temporary piping should never create steam flow restriction.
- Verify that the pipe supports, anchors, guides, clamps and similar items are correctly
installed as per construction drawings and they are assuring the required expansion of
pipe due to thermal cycle.
- All steam traps shall be removed and the space left open. Steam trap to be wired into
place at the location for reinstatement at a later date.
- Soil protection shall be prepared, use a 6 mm steel plate, to protect the soil in the area
from erosion during the steam blow operations if possible unless blow point is over paved
area or it is not directed to ground.
- All restrictions in the piping such as orifice plates, flow measurement tubes and
thermowells shall be removed prior to steam blowing. Remove the following and upon
completion reinstall:
o Safety valves
o Check valves
o Rupture disks
o Orifice plates belonging to flow meter elements
o In Line mixers/strainers
o Spargers
o Spray nozzles
o Control valves except ball/gate type
o Self-actuated valves except ball/gate type
o Emergency shut off valves except ball/gate type
o All other items which could be damaged by the ingress of dirt or restrict the blow
path.
Note: The above equipment/instrument/other accessories, where steam blowing has been
finished, can be reinstalled and used for steam blowing of their downstream pipes as required.
- Control valves shall be replaced with spool pieces or removed and pipe blown on both
side via the by-pass valve.
- Steam should be always blown from a clean system to unclean systems and steam
header(s) shall be cleaned first.
- In order to remove mill scale, the steam valve controlling the steam blow should be of
the quick opening type (if available) and it should be located well up stream of the piping
to be cleaned.
- A temporary valve for blowing should be provided on the temporary blowing piping. If
this valve is not available, the boiler stop valve can be used after checking with the
manufacturer that this valve allows this kind of operation.
- It is advisable that the blowing circuit(s) are defined already at the engineering stage in
order to arrange for the necessary materials (pipes, silencer if required) and to avoid
welding during erection of parts that have to be subsequently removed for blowing.
- To avoid water hammer, temporary piping shall not be laid with siphons. In case of
siphons installation, they shall be provided with adequately sized drains.
- Check that where spring hangers are installed the pre-set pin remains in place until
blowing is complete.
Steam is vented directly to atmosphere through the use of temporary vent piping and
acoustically engineered noise suppressor or silencer, which attenuate noise levels down to an
acceptable range.
The thermal cycle achieved when alternating blowing and cool down of the piping system to be
cleaned induces exfoliation of the adhesive deposit of iron oxides layers and others kind of
deposit. Also rust, welding slags or spatters become liable to peel off the pipe internal surface
due to the repetition of expansion and contraction of the pipe. This produces a more effective
blow-out which would be impossible by usage of kinetic energy alone. The effectiveness depends
on the steam velocity, the change of temperature in time and the number of blows.
Between blows there should be a cool down period of 180 minutes (never less than 30 minutes)
for not-insulated pipes and 480 minutes (never less than 180 min) for insulated pipes.
The steam flow required for blowing can be estimated using the following formula:
Where:
In case the above formula cannot be applied due to operational constraints then steam blowing
is considered effective if the steam blowing velocity is equal or higher than the steam velocity
during operation.
In case of operation temperature of the steam cannot be reached then a reduction of 30% is
acceptable as long as the steam is superheated.
Criteria used to determine optimal steam blow mass flow rate are a DISTURBANCE FACTOR
greater than 1.0 (suggested value is between 1.25 - 1.4) and a minimum fluid velocity of 50
m/s.
Where:
The disturbance factor is a ratio of the mass velocity head during the steam blow to the mass
velocity head at conditions representative of the most turbulent and severe operating condition
in the line. DF greater than one is an indication that the conditions created during the steam
blow will never be reached during normal operation.
To obtain optimum cleaning, the volumetric flow conditions during blowing should be equal to
the normal operating conditions at maximum load.
Since it is impossible to reproduce these conditions when blowing into the atmosphere,
equivalent conditions must be produced using lower pressure steam and an appropriate flow
rate, so that the result of volumetric flow by velocity is equal to that at the maximum operating
load.
The blowing procedure requires extremely severe operating conditions for the boiler and steam
piping, involving great and rapid temperature changes that are much greater than those
occurring during normal operation. The resultant stresses are very important in those parts
where steel thickness is considerably big, such as steam drums, headers and high rating piping.
For this reason, it is important that the blowing cycles are the minimum required to reach the
necessary cleaning.
The steam temperature during blowing should be as near as possible to the operating one.
Do not admit steam to the system until water (condensate) is still coming out from any drain.
Steam blowing shall not involve equipment unless a special procedure is prepared.
During the blowing operation it is necessary to check that steam is never vented in closed
environments but always in the atmosphere instead; if necessary, temporary piping must be
provided to convey the steam vents outside the buildings.
Make sure that the portion of piping upstream the isolation valve for steam blowing is at
operating pressure and temperature and free of condensate.
Crack open the battery limit isolation valve by pass or the steam valve itself (if no bypass is
provided) and start warming up the system to be blown.
Make sure that a small amount of steam is flowing (indicative value: 1-2 tons/hr).
Open all vent valves on the system to facilitate the heating phase and open all drain valves on
the system to drain all trapped water.
Make sure that from the first drain valve (close to battery limit or to the operating valve)
condensate start to come out. Do not increase steam flow if condensate is not coming out.
In case water (condensate) doesn’t come out from the drains distributed all along the pipework
to be cleaned, in order to be sure that the connected piping is not plugged, stop the steam
blowing and once the system is sufficiently cool, connect a flexible hose with clean water to back
fill the pipe where the condensate doesn’t come out and right after drain it to check if it has been
unplugged.
According to the magnitude of the system slowly increase the steam flow. Make sure that starting
from the first drain near to the admission point, first condensate and then steam comes out.
Check all the drain valves up to the last one in the system.
Throttle down drain valves starting from the closest one to the admission system to increase
header steam pressure.
Warm out the system at a rate of 50 °C per hour, measured along the system and at discharge
point.
Check the piping all along the pipe system to be cleaned, especially the expansion joint pipe
supports for it is not uncommon to find steam pipe supports mistakenly welded to the steel
structure. If this happens close steam admission valve to the system and rectify.
Check pipe support position against pipe rack (beam). Pipe support should always be in the
middle of the beam. In case a support has moved far from the centre but still on the beam, stop
steam admission and rectify or verify with piping Dpt.
For each heating step (i.e. every 50 °C) the whole piping should be inspected and ensured that
it is free to move, supports are in right position and no leaks are present.
In case pipe support falls down from the beam do not stop the steam flow but do not increase
it, make proper arrangement to lift the pipe instead. There is a danger of pipe rupture if steam
is cut and pipe is cooled down. Support can move back touching the beam.
Initial steam blowing should first be made at low pressure to remove large objects in the piping
and gradually raising the pressure during later blows to the designed or calculated required flow.
Repeat the above steps until the system is cleaned as per selected cleaning criteria.
While steam blowing is ongoing also perform hot bolting of flanged connections.
In order to reduce the noise impact, a Silencer with atomized water injection is often required,
as per figure below.
Fig. 8
Fig. 9
Usually the boiler is blown first and then the rest of the piping system while keeping the boiler
at constant pressure and controlling the blowing rate by using the valve located on the line
upstream the piping system to be blown.
1. Start the boiler and bring it to the nominal pressure by venting through the startup vent,
2. Open the blowing valve gradually, keep under control the increase in load by keeping
constant the boiler pressure (using burners), and closing the startup vent as soon as
possible,
3. Blow for about 15 minutes (blowing for a longer period would be inefficient), then close
again the blowing valve gradually; at the same time reduce the boiler load and re-open
the startup vent to keep the boiler at minimum operation conditions,
4. Allow the piping to cool down and repeat blowing until reaching an acceptable degree of
cleaning or meeting the acceptability criteria agreed for the piping system under steam
blowing.
NOTE:
Prior to restart steam blowing operation from cold condition make sure the entire piping system
is completely drained.
Keep record of all the process conditions and operations during the steam blowing activities for
future reference and certification.
The acceptability criteria may differ according to the purpose and service of the piping system
to be cleaned.
Piping feeding a steam turbine will have much severe acceptability criteria than the piping used
for steam tracing.
Here follow some acceptability criteria that can be considered as a reference in case no others
are available or agreed upon; whenever steam feeds an equipment, always check with the
manufacturer what are the acceptability criteria for the specific equipment.
1. The target plate shall be exposed for twenty (20) minutes to a steady flow of steam at the
design process conditions (MCR),
2. The number of flaws observed on the target plate shall not exceed five (No. 5) per square
centimeter,
3. The size of each raised face impact (e.g. a dent on the surface) shall not exceed 0.5 mm,
4. The size of each non-raised face impact (e.g. a scratch on the surface) shall not exceed 1.6
mm,
5. Steam blowing is considered acceptable when two consecutive target plates show acceptable
results as per above criteria.
- Heat Exchangers
- Steam Ejectors
- Atomizers
- Pressure let down stations/control valves
- Desuperheaters
- Control Valves
- Columns/Drum/Tanks
- Steam spargers
- Heater for tempered water
- Jacket/Coil
- Exhaust Steam Lines of MP steam turbines.
Steam blowing is deemed as completed and successful when no dirt or debris is witnessed at
the blow-off point after two consecutive steam blowing.
Steam blowing is deemed as completed when a single steam blowing cycle has been carried out.
The figures below show typical pipe connections with Target plate and its dimensions.
- Reconnect with final gaskets all flanges disconnected during mechanical preparation for
blowing.
- Reinstall all caps, plugs or blind flanges to the vent and drain nozzles.
- Reinstall all control valves and check for correct flow direction.
- Reinstall in-line instruments.
- Check that the pipe supports, anchors, guides, clamps and similar items are correctly
installed as per construction drawings.
- Check that all strainers and traps have been re-installed.
- Reinstall check valves or their internals and flow direction.
- Verify bolt tensioning
The need of specific measures for piping and equipment preservation after cleaning and up to
Ready for Start-up will be evaluated on a case-by-case basis, as a reference:
- Carbon Steel piping should be preserved by keeping the internal side of piping free from
Oxygen (e.g. filling them with Nitrogen) or using a liquid, vapor or powder corrosion
inhibitor (e.g. CORTEC VpCI® 629, CORTEC VpCI® 639, CORTEC VpCI® 705, CORTEC
VpCI® S-10).
Steam blowing is a hazardous operation and safety precautions must be taken to prevent injury
to personnel and to prevent environmental pollution. The hazards that may cause a personnel
injury are steam flow and debris flying by exhaust opening, high temperature of the parts
undergoing steam-blow, noise level caused by steam blow off.
- Observe and enforce all local codes and regulations to safeguard plant, personnel and
the environment.
- Place warning signs and fence the entire blowing area with colored strips/warning tape
- Restrict access into air blowing area to authorized personnel only.
- Prevent any person from entering the exhaust blow area, allowing ample distance in the
direction of the blow and considering possible deflection of the blow;
- Roads leading to working area of the piping system to be blown shall be closed to vehicles
traffic.
- Piping system under blowing shall be positively isolated (double block and bleed or valve
plus blind) from connected systems on which other activities may be going on.
- Each isolation valve connecting lines or branches within the system under blowing shall
be verified to be in closed position by visual inspecting the valve stem and checking the
presence of the blind.
- Instruct personnel on how to monitor steam blowing operation and to stop blowing
activity when required.
- Ensure that all the personnel involved in blowing operation wear appropriate personal
protective equipment such as gloves, boots, helmets, ears protection and goggles.
- Steam blowing produces high noise level and thereby is liable to interfere with other
ongoing construction work in addition to the potential for causing ear damage to
personnel in the vicinity. It is necessary to take appropriate measures such as installation
of temporary silencers whenever required.
- The high noise warning sign shall always be displayed.
- Ears protection is mandatory in all noise affected areas and shall be made of two
protection levels (e.g. ear plugs plus ear muffs).
- Before conducting any steam blowing activity, the Utilities panel operating personnel shall
be notified on the following matters, to prevent boiler operational upsets during blowing
caused by Boiler Feed Water consumption and steam demand variations
Steam blowing schedule
Approximate steam consumption and duration
- Exposed piping will be checked for non-contact with combustible materials such as
scaffold wooden boards, etc. to prevent any outbreak of fire.
HYDROJETTING-RETROJETTING-AQUAMILLING
Hydro-jetting is a timely effective and environmentally friendly methodology to clean pipe and
equipment internal surface. Hydro-jetting can remove, sand, weld slugs, and different deposits
from the lines and equipment using only high-pressure water without any additives.
The cleaning is performed using high pressure water via a mechanical device which controls,
feeds and rotates the hose that carries a jetting nozzle.
The nozzle rotates in order to give uniform coverage for cleaning and removal of loose materials,
contamination of pipe and tube internal surfaces.
The purpose of this type of cleaning method is to remove rust, mill scale and loose construction
debris as part of the pre commissioning of the piping system to be cleaned. Please note that
any surface coatings, lacquer protection or non-standard mill scale that has become part of the
metal surface during the manufacturing or any heat treatment process will not be removed by
this equipment.
Hydrojetting (up to 8” size piping and 5-6,000 psig), Hydromilling (above 8” size piping and up
to 10,000 psig), Aquamilling, Retrojetting are words indicating similar methods of cleaning using
high pressure water jetting, some of them are covered by proprietary licenses and patented
systems.
- Prior to start any activity any sensitive instrument or valve should be removed
- Check valves or control valves shall be removed, if this is not possible then cleaning up
to the valve from either side will be required
- Full bore isolation valves can remain in-situ
- Reducers with a gradual diameter change can be left in-situ. Where a step change in
diameter occurs this will have to be removed or cleaned from either sides.
- Preparation of marked up P&ID and dedicated procedure/Method of statement showing
all details (entry points, piping to be hydrojetted, etc.) in order to carry out a proper job
on the piping system to be cleaned
- In case of big piping system to be cleaned, in terms of length of pipe and complexity of
distribution along the plant, it is highly advisable to select and design the piping system
to be cleaned already during the engineering phase to avoid unwanted modifications after
fabrication and pressure test. There are some strict requirements with regard to access
points of the hydrojetting equipment and limitations on how many bends the cleaning
nozzle can go through. Without a proper early plan in some cases it might be necessary
to cut and re-weld, already built and hydro-tested piping, in order to perform hydro
jetting.
- Here follows a reference guide to the main requirements and limitations mentioned
above:
Average maximum length for head nozzle (along with the hose connected)
penetration inside a pipework is around 150 mt, depending on the number
of bends located on it (the higher the number of bends the lower the
distance that can be covered by the head nozzle)
As an absolute minimum, a 4” opening preferably 6” is required for the
entry of the jetting nozzle. Any limitation in the size of the entry point will
also limit the size of the debris which can be removed. The cleaning process
is designed to draw all debris back to the point of entry, where it is then
removed. It is not uncommon in new constructions to find large items such
as hard hats, gloves, drinks cans, hand tools and even scaffolding
materials. As such it is always preferable to have as large an entry as
possible
The number of entry points required will be dictated by the configuration
of the system to be cleaned. The required entry points will be marked on
the drawings provided. Required entry points will be defined together with
SP (service Provider or Specialized Contractor) during dedicated method of
statement preparation. As a reference, about 140m can be cleaned from a
single entry point depending on the number of bends in the line.
Note: for any system, a proper drainage is required for the cleaning water and debris. This
should be taken in consideration when swinging of flanges is used to provide entry. If it is not
possible to provide an entry point on the bottom of the pipe or a suitable drainage, this should
be highlighted in advance as an alternate means of removing the water and debris will have to
be considered.
- Provide sufficient available area (20 mt radius) around the entry point to allow for the
equipment to be placed.
- High pressure hoses must be tested before usage with a pressure 1.5 times the working
pressure, and marked with manufacturer’s maximum operating and testing pressure.
- Selection of the cleaning degree to be achieved on each part to be cleaned according to
the service of the piping involved, usually NACE 5/SSPC-SP-12, standard W-J2 is
used for this kind of method, but may differ according to the service of the pipe to be
cleaned.
Hydrojetting Execution
Most of the time this kind of cleaning method is performed by specialized contractors, also called
Service Provider (SP), for the specific knowledge and equipment necessary to carry it out safely
and properly.
2.8.2.1 Hydrojetting
The cleaning is achieved introducing a flexible hose able to stand very high pressures with a
special jetting head at its end that is able to scratch out dirt and deposits from the pipe wall and
to remove any material or debris present inside the pipe, see below.
Fig. 9
2. Pneumatic/Hydraulic
Feed Unit, to feed high pressure water hose in/out of pipe at continuously adjustable feed.
3. Safety Protection Hose, to lead high pressure water hose from Feed Unit to pipe entry.
4. Protection Hose Connector, to connect Safety Protection Hose to pipe entry to convey
forces from the hydraulic Feed Unit to the point of entry.
5. Smash Plate, to close pipe entry, to avoid debris being shot out of pipe uncontrolled and
to keep the nozzle from exiting the pipe uncontrolled.
2.8.2.2 Flushing
This stage is usually performed using a specific jetting head that floods the pipe allowing to
evacuate all the materials and debris, from the previous stage, through the entry point which
should be big enough to let the debris to exit from the pipe.
2.8.2.3 Preservation
During this stage one or more products (e.g VPcI Cortec 377) are sprayed inside the pipe system
cleaned in the previous stages and it is usually applied using the hydro jetting equipment itself
and offers a long lasting passivation - usually 1 month or more. For effective passivation the use
of demineralized water or similar is recommended. Depending on the level of system fouling and
the pipework configuration it may be possible to combine the flushing and passivation stages,
thus offering both water and time savings.
As a precaution it is also recommended, after the passivation, to preserve the system under
positive pressure using nitrogen until the system is put in service.
Final acceptance of the cleanliness of pipe or equipment is based on internal inspection. At the
end of the flushing stage no more debris shall be seen coming out of the entry point. Lines will
be accepted as cleaned if the inner surface will be free of rust, mill scale, weld slugs, sand, etc.
Commissioning Manager is responsible for all commissioning activities including overall safety,
health and environment performance. All commissioning personnel assist the Commissioning
Manager to ensure the compliance with the established schedule, project and safety
requirements.
The following general instructions shall be followed and adhered to:
• Dedicated work permit must be obtained following specific procedure.
• An emergency procedure has to be issued considering unwanted events coming from
dry-out activity.
• All personnel working at site must be informed in advance when dry-out is going to
be carried out.
Before starting the activity COMMISSIONING personnel has to prepare dedicated “Circuit Flow
Diagram” (marked up P&ID) in which equipment and pipes to be involved have to be highlighted.
The diagram also has to show all circuit modifications to be applied to carry out the activity. In
particular, the following information has to be shown:
• Temporary blinds to be installed.
• Valves to be maintained close during the activity.
• Temporary spools to be put in place.
• All additional supports and anchors to be installed.
COMMISSIONING Supervisor shall verify, before starting the activity, that the piping system has
being prepared in compliance with all prescriptions written in the Circuit Flow Diagram.
During hydro-jetting, proper measures shall be taken to safeguard personnel and prevent
environmental pollution. The following represent minimum precautions:
Wear the correct personnel protective equipment for this kind of activities such as:
ANNEXES
CLEANING MATRIX