Ins d - Copy

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1.5.3. Observance of Rules

Construction Contractor shall obey the safety and sanitation rules

prescribed by Consultant.

1.5.4. Measures for Safety

Construction Contractor shall take utmost care not to give any damage to the

plant personnel and equipment including third person during the works.Necessary additional measures for safety shall be taken, when Consultant

requires to do so.

1.5.5. Governmental Procedures

Governmental procedure concerning the safety and sanitation should be taken

by Construction Contractor when it is his duty. In this case, these procedures

shall be taken after getting Consultant's personnel approval.

1.5.6. Participation in Council for Safety and Sanitation

Construction Contractor shall participate in the council for safety and sanitation

which will be established at the site and cooperate in prevention of accident.

2. CODES AND STANDARDS - Piping and Equipment Cleaning Specification

2.1.

The applicable codes and standards shall be as per ASME B31.3 (LatestEdition) Process Piping.

2.2.

It shall be the responsibility of Construction Contractor that the works

conform to the specified codes and standards or legal requirements.

2.3.

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Where there are conflicts between drawings and specifications and the

specified codes and standards or legal requirements, such conflicts shall be

immediately referred to Consultant.

3. GENERAL REQUIREMENTS - Piping and Equipment Cleaning Specification

3.1. TREATMENT FOR PIPING COMPONENTS

Vinyl caps which cover end of piping component such as pipe and valves shall not be

removed till the fabrication.

3.2. CLEANING OF FABRICATED PIPING - Piping and Equipment CleaningSpecification

Inside surface and welding surface of fabricated piping shall be free from slag,

chambers, scales and other foreign matter with grinder, chisel, wire brush, etc., and

be air blower. After completion of air blowing and checking, ends of the piping shall

be covered with vinyl or veneer cap, etc. till the installation in the field.

4. PROCEDURE OF CLEANING - Piping and Equipment Cleaning Specification

4.1.

GENERAL

4.1.1.

Cleaning method shall be selected in the following method considering

kind of fluid, pipe material and condition of internal surface of piping to be

cleaned. Cleaning method and extent to be applied shall be as specified in

Specific Job Requirements. (See Table 1)

A. Water cleaning shall be applied in case that the fluid of piping is liquid. But,

in case that water cleaning is not adequate, other suitable flushing method shall

be applied.

B. Air cleaning shall be applied in case that fluid of piping is gas. But in case

that air cleaning is not adequate, other suitable cleaning method shall be

applied.

C. Chemical cleaning shall be applied to field installed Lube Oil

line, compressors suction lines, plate type heat exchanger inlet line, steam

generation loops, piping around adsorber tower and all other parts that specify

in operation or vendor’s manual unless otherwise specified by the Owner.

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D. Oil cleaning shall be applied to field installed Lube Oil line

after chemical cleaning, unless otherwise specified by the Owner.

E. Mechanical cleaning -

F. Steam cleaning shall be applied in case that the fluid of piping is steam and

for other equipment that specify in operation manual. But, in case that steam

flushing is not adequate, other suitable flushing method shall be applied.

G. Others

4.1.2.

Temporary strainers shall be used as follows:

A. After installation of piping, the temporary strainers with 80 mesh x #38screen shall be installed and cleaning performed until no foreign material comes

to the strainer.

B. The temporary strainers shall be installed at pump suction piping, piping

upstream of control valve and other location specified in Specific Job

Requirements.

C. Mark plate shall be attached to the temporary strainers to distinguish from

other strainers.

D. After a constant period of initial operation, all temporary strainers shall be

removed.

4.2. WATER CLEANING - Piping and Equipment Cleaning Specification

4.2.1.

As a rule, pure water, service water, steam condensate industrial water,

etc. shall be applied with maximum chloride ion content 50ppm and sea water

shall not be applied. If using of sea water is unavoidable, washing by fresh water

shall be carried out at least on time to prevent corrosion after using of sea

water. In any case, sea water shall not be used for cleaning of austenitic,

stainless steel.

4.2.2.

Water cleaning shall be performed by the method of running be

pressurized water and hammering, or rapid draining with water filled.

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Hammering shall, however, not be performed for austenic stainless steel pipe,

copper pipe, aluminum pipe.

4.2.3.

After cleaning, drying by compressed air or natural drying shall be

carried out. Drying by superheated steam shall be carried out with agreement

between Owner and Consultant.

4.2.4.

Number of times of cleaning shall be as follows:

A. Primary cleaning - two times or more

B. Secondary cleaning - one time or more

4.2.5.

The primary cleaning shall be performed for each assemble piping. And

secondary cleaning, as a rule, shall be performed for whole of the piping system

including the equipment.

4.2.6.

Where instruments are included in piping system to be cleaned the

instruments shall, as a rule, be disconnected and spool pipe (distance piece)

shall be inserted instead.

4.2.7.

When cleaning is carried out in condition where control valve is

connected, the procedure shall be as follows:

A. Disconnect companion flanges in upstream side of the control valve and

cover openings of the control valve.

B. Clean the piping of upstream side.

C. Connect the control valve and piping of upstream side after completion of

cleaning.

E. Close the control valve, open by-pass valve, and then clean the piping of

downstream side. Where the by-pass valve is not installed, the temporary strainer

having austenitic stainless steel screen of No. 50 specified in ASTM E11 shall be

inserted.

4.2.8.

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All accessories such as circulation pump, temporary pipes, spools, hoses,

strainer, tank, etc. shall be supplied by Construction Contractor.

4.3. AIR CLEANING - Piping and Equipment Cleaning Specification

4.3.1.

Air cleaning shall be performed by the method of blowing be pressurized

air and hammering. Hammering shall, however, not be performed for austenitic

stainless steel pipe, copper pipe and aluminum pipe.

4.3.2.

Number of times of the cleaning shall be as follows:

A. Primary cleaning - two times or more

B. Secondary cleaning - one time or more

4.3.3.

The primary cleaning shall be performed for each assembly piping. The

secondary cleaning shall, as a rule, be performed for piping from equipment to

adjacent equipment. Whether of not the equipment is included, the cleaning

method shall be determined considering shape, internal construction and

packing of the equipment and according to overall cleaning plan.

4.3.4.

Treatment of instruments and handling of temporary strainer shall

conform to the requirements specified in Para. 4.1.2.

4.4. CHEMICAL CLEANING - Piping and Equipment Cleaning Specification

4.4.1.

Chemical cleaning shall be applied to field installed lube oil line and compressor

suction lines, plate type heat exchanger inlet line, steam generation loops,

piping around adsorber towers and all other parts that specify in operation or

vendor’s manual.

4.4.2.

Construction Contractor is responsible to provide specific procedures for each

chemical cleaning. These procedures shall include marked up drawings, volume

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of system, required chemical materials, neutralization procedure and all other

requirements.

T he application of chemical materials shall be in accordance with supplier’s

instruction.

As a rule, chemical cleaning by circulation or pickling shall be applied and

the general procedure shall be as follows:

1) System isolation and flushing with water.

2) Degreasing before chemical application.

3) Sufficient rinsing.

4) Acid cleaning

5) Sufficient rinsing

6) Passivation

7) Preservation up to start up

8) Any procedure or method for chemical cleaning shall be subject to the

Owner’s approval and the performance of such chemical cleaning shall be to the

Owner’s satisfaction.

4.4.3.

Where oil cleaning specified in Para. 4.5 is applied, the inside of piping shall be given

a coat of anti-corrosive oil except when oil cleaning is to be carried out successively

after completion of the chemical cleaning.

4.4.4.

Detail procedure and check list for chemical cleaning is shown in attachment #1

and #2. Licensor or vendor’s instructions shall be considered by ConstructionContractor.

4.5. OIL CLEANING

4.5.1.

Oil cleaning shall be applied to the field installed lube oil piping system after

the chemical cleaning specified in Para. 4.4 has been performed. Vendor’sinstruction shall be considered by Construction Contractor.

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4.5.2.

The procedure shall be as follows:

A. The cleaning shall be performed by the method of circulation of the oil and

hammering. Hammering shall, however, not be performed for copper pipe.

B. Oil to be used shall have the good quality, and be suitable for the

machinery, and shall be completely replaced with the specified oil after cleaning.

C. After completion of cleaning, piping system shall be checked that no foreign

matters are present in temporary strainer having two screens of No. 200

specified in ASTM E-11 for oil piping of centrifugal compressor, and in temporary

strainer having a screen of No.100 specified in ASTM E-11 for other oil piping.

4.6. STEAM CLEANING - Piping and Equipment Cleaning Specification

4.6.1.

Steam cleaning shall be performed after completion of pressure test. Pipe

support shall be attached to exhaust piping to prevent accident caused by the

reaction force. In general, following items are required during the cleaning.

A. Removal or opening of steam trap, vent and drain

B. Warming up for piping (To be blown gradually with cooperation by operator)

C. Checking for expansion joints, spring hangers, etc. caused by thermal

expansion.

D. Steam cleaning temperature (Cleaning shall be performed at the

temperature near to the operating temperature considering operating condition

of boiler.)

E. Cooling down (To remove the scale effectively by temperature change, it is

required to perform cleaning and cooling cyclically, having temperature

difference as large as possible between cleaning and cooling period.)

4.6.2.

Judgment on result of steam cleaning shall be generally be done by checking of

the target inserted in line opening or foreign material present in the drain

sampled if applicable. Strict requirements of steam driven machinery suppliers

shall be considered.

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4.7. MECHANICAL CLEANING - Piping and Equipment Cleaning Specification

4.7.1.

Mechanical driven rotary cleaning tool or wire brush shall be applied and

pushed through the inside of the pipe.

4.7.2.

Shot or sand blasting, if required, shall be performed.

4.8. OTHER CLEANING METHODS - Piping and Equipment Cleaning Specification

4.8.1.

Cleaning by the use of pig shall conform to specific job requirements.

4.8.2.

Cleaning by sodium hydroxide solution shall conform to specific job

requirements.

4.8.3.

Special cleaning, if specified for special piping components of systems,shall conform to specific job requirements.

4.8.4.

Some piping cannot be cleaned by any method due to the special

configuration such as too big bore piping (non flushing line).

Non flushing lines shall be identified at the initial stage of piping works, and will

be manually cleaned before installation with witness of Owner.

DETAIL PROCEDURE FOR CHEMICAL CLEANING

1 General Requirements for Chemical Cleaning - Piping and Equipment Cleaning

Specification

1.1 The layout of the circulation system shall assure complete circulation and

that there are no dead ends or branches that will create traps.

1.2 Each circulation system must have adequate high point vents and low points

drains.

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1.3 The piping to be chemically cleaned must be sufficiently flushed and

degreased prior to chemically cleaning operation.

1.4 The piping shall be pre-inspected to assure that no foreign material is

present which cannot be removed by chemical cleaning.

2 Chemical Cleaning - Piping and Equipment Cleaning Specification

2.1 The circulation loop shall be established and the system shall be filled with

water or the rinsing water used at degreasing operation.

2.2 The water shall be circulated and water temperature shall be raised

to required temperature.

2.3 When the temperature is achieved, chemicals shall be injected:

2.4 The solution shall be circulated until the iron content in the solution levels

out constant , but in any event a circulation period of 8 hours is recommended.

2.5 During the circulation period, the complete filling of the piping with solution

shall be checked. Any gas volumes accumulated at high points shall be safely

vented.

2.6 After the circulation period, the system shall be drained and flushed to

tankers by displacing the inhibited acid with rinse water until the pH value of the

outflow is equal to that of the inflow and no appreciable amounts of debris

appear at the drain points.

3 Passivation - Piping and Equipment Cleaning Specification

3.1 After pH value is adjusted, circulation shall be re-established and water

temperature shall be raised to required temperature.

3.2 When the temperature is achieved, the water in the system shall be treated

as follows:

1) Inject 0.5% w/w citric acid and circulate for 30 minutes.

2) After this time, Inject ammonia to a pH of 9.5.

3) When solution is homogeneous, Inject 1% sodium nitrite.

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4) Circulate the solution for a minimum 4 hours, then drain the system and rinse

briefly with ammoniated water.

3.3 After this treatment, the system shall be throughly drained and blown

through with nitrogen.

3.4 No water shall remain in the cleaned piping.

4 Preservation - Piping and Equipment Cleaning Specification

4.1 The chemically cleaned piping surface shall be properly protected until

commissioning of piping.

4.2 Pipe spools cleaned in a batch operation shall be sprayed with a lightpreservation oil and all openings shall be sealed to avoid ingressing of foreign

material.

4.3 Compressor suction piping and process piping shall be blanketed with

nitrogen.

5 Inspection and Testing of Chemical Cleaning

5.1 All parts shall be visually examined prior to commencing chemical cleaning

operations to determine the adequacy of pre-cleaning and to determine the

presence of mill varnish.

5.2 The log for each cleaning operation shall be kept to identify the

piping included in the individual circulation loop.

5.3 The log shall state the chemicals and concentrations used, duration of each

individual cleaning step, temperatures, name of inspectors, time, etc.

5.4 Temperature must be closely monitored, especially the temperature of the

degreasing solution cannot exceed 80°C.

5.5 The concentrations and the efficiencies of the solutions shall be controlled by

chemical analysis. As a minimum following test shall be performed.

1) sulphuric acid strength

2) iron level in solution

3) inhibitor efficiency

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4) citric acid strength (until ammonia is added)

5) pH value of solution

6) Conductivity

7) Alkalinity

8) Clearness

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Ins d - Copy