Doc.
No : MEP-P-ES-009
PRECOMMISSION CLEANING OF
PIPING SYSTEM Rev 0 page 1 of 10
Rev Date : 25 July 2005
PT. MEDCO E&P INDONESIA
STANDARD SPECIFICATION
FOR
PRECOMMISSION CLEANING OF PIPING SYSTEM
MEP-P-ES-009, Precommission Cleaning Of Piping System, rev 0, 25 July 2005
Custodian: Surface Engineering
Doc. No : MEP-P-ES-009
PRECOMMISSION CLEANING OF
PIPING SYSTEM Rev 0 page 2 of 10
Rev Date : 25 July 2005
TABLE OF CONTENTS
PAGE
1 SCOPE 3
2 CLEANING REQUIREMENTS AND METHODS 3
2.1 General Requirements 4
2.2 Water Flushing 4
2.3 Air Flushing Instrument Piping and Tubing 6
2.4 Chemical Cleaning 6
2.5 Post Cleaning Requirements 9
2.6 Pigging 9
3 INSPECTION & TESTING 10
3.1 During Chemical Cleaning 10
3.2 After Cleaning 10
4 OPERATING RECORDS 10
MEP-P-ES-009, Precommission Cleaning Of Piping System, rev 0, 25 July 2005
Custodian: Surface Engineering
Doc. No : MEP-P-ES-009
PRECOMMISSION CLEANING OF
PIPING SYSTEM Rev 0 page 3 of 10
Rev Date : 25 July 2005
1 SCOPE
This specification defines the minimum requirements for the mechanical
precommissioning and chemical cleaning of piping systems including in-plant piping and
flowlines. Minimum requirements for equipment, chemicals, cleaning procedures, testing
and post cleaning passivation of metal surfaces to prevent pre-startup contamination are
defined.
2 CLEANING REQUIREMENTS
2.1 General Requirements
2.1.1 CONTRACTOR shall internally clean all piping on completion of the
pressure testing. The minimum cleaning requirements are defined in the
following table:
WATER CHEMICAL COMPRESSED WARM FILLED
SERVICE FLUSHING CLEANING AIR PURGE AIR WITH COMMENTS
Note 4 Note 4 DRIED WATER
Flowlines Yes No No No Yes Sealed, if not in
service
In-Plant Yes Note 1 No Yes No Sealed, if not in
Piping service
Lube and Yes Note 5 No Yes No Sealed, Nitrogen or
Seal Oil air purge
Piping
Instrument No No Yes No No Sealed, nitrogen
Lines purge
Suction Yes Note 2 No Yes No Sealed, if not in
lines for Note 3 service
compressor
s and
pumps
Flare Lines Yes No No Yes No Sealed, if not in
service
Chilled Yes Optional No No Yes Add Inhibitor
Water Lines
MEP-P-ES-009, Precommission Cleaning Of Piping System, rev 0, 25 July 2005
Custodian: Surface Engineering
Doc. No : MEP-P-ES-009
PRECOMMISSION CLEANING OF
PIPING SYSTEM Rev 0 page 4 of 10
Rev Date : 25 July 2005
Notes: 1. Generally in-plant piping will normally not be chemically
cleaned. Any special cases for chemical cleaning will be
identified by COMPANY.
2. Compressor suction and discharge piping (including antisurge
and operational recycle lines, and associated headers) must be
cleaned to gray metal. Sandblasting and inert gas blanket lay up
may be substituted for chemical cleaning with prior COMPANY
approval.
3. Pump suction lines may be cleaned by water flushing or hydro-
blasting (600 PSIG minimum) with COMPANY approval.
4. All piping must be accepted as clean by COMPANY's
representative before being signed off as mechanically complete
and ready for operation.
5. Lube oil piping must be cleaned to the equipment manufacturer's
specifications. The minimum acceptable flow rates of hot oil
(130 - 160oF) must be 1.5 times normal. The piping system must
be vibrated (mechanically or manually) during oil circulation
through a 200 mesh screen for a minimum of four (4) hours. The
system will be judged clean when two (2) successive screens
contain less than 3 particles per square inch.
2.1.2 Each system shall be prepared for cleaning by first removing all
equipment subject to corrosion or damage. Where pieces of equipment
are removed, suitably sized spool-pieces shall be provided and installed
by CONTRACTOR to ensure continuity of system. Temporary strainers
shall also be provided and installed by CONTRACTOR in suitable areas
to protect items of equipment.
2.2 Water Flushing
2.2.1 Water flushing shall be performed with clean, fresh water from a source
approved by COMPANY. CONTRACTOR shall supply all equipment
required to provide and pump an adequate volume of water through the
piping to achieve minimum flushing rates.
2.2.2 To achieve satisfactory flushing, the following table summarizes the
minimum velocities and times required ensuring satisfactory flushing of in-
plant piping. Alternative flushing methods, such as Slug Flow Flushing
(using a combination of air and water) may be submitted for COMPANY's
review and approval. A complete description of equipment, extra pipe
supports required, safety procedures, and flushing procedures, etc., must
be submitted for COMPANY's approval when requesting permission to
substitute an alternative flushing procedure.
MEP-P-ES-009, Precommission Cleaning Of Piping System, rev 0, 25 July 2005
Custodian: Surface Engineering
Doc. No : MEP-P-ES-009
PRECOMMISSION CLEANING OF
PIPING SYSTEM Rev 0 page 5 of 10
Rev Date : 25 July 2005
NOMINAL MINIMUM MINIMUM MINIMUM
PIPE SIZE FLUSHING RATE VELOCITY TIME
(INCHES) (US GPM) (FPS) (HOURS)
2 45 5 1.0
4 250 6 1.0
6 700 7 1.0
8 1,500 8 1.0
10 2,500 9 1.5
12 3,000 10 1.5
14 5,000 11 1.5
16 9,500 12 1.5
18 10,000 13 2.0
20 15,000 14 2.0
22 20,000 15 2.0
24 25,000 16 2.0
2.2.3 Minimum water flushing time for in-plant piping systems (Table in 2.2.2) is
measured from the time when flush water begins to flow out of the section
of piping located farthest away from the injection location.
2.2.4 Minimum flushing time for flowlines is different from in-plant piping and
shall be calculated on the following basis:
X = Length of flowline (from flush water injection point to discharge
point) in feet.
V = Minimum flushing velocity from table in Feet Per Second.
T = Minimum flushing time in hours.
(X) (10)
T=
(3600) (V)
2.2.5 CONTRACTOR shall provide a means of disposal for the water used for
flushing which will not overload COMPANY's drain systems or adversely
MEP-P-ES-009, Precommission Cleaning Of Piping System, rev 0, 25 July 2005
Custodian: Surface Engineering
Doc. No : MEP-P-ES-009
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affect the environment. This method must be defined in writing by
CONTRACTOR and approved by COMPANY prior to commencement of
flushing operations.
2.3 Air Flushing Instrument Piping & Tubing
2.3.1 All instrumentation lines shall be cleaned by subjecting the pipework (or
tubing) to a blast of low pressure 80-150 psig compressed air throughout
the entire system. The following table defines the minimum requirements
for this cleaning:
NOMINAL MINIMUM MINIMUM MINIMUM
PIPE SIZE AIR FLOW RATE VELOCITY TIME
(INCHES) (SCFM) (FPS) (MINUTES)
_ 50 10 30
_ 145 10 30
½ 100 12 30
1 200 12 30
1 250 12 30
2.3.2 To ensure adequate cleaning, the system must be sub-divided into easily
purged sections. The system shall be blown down from the compressor
end; major distribution piping first; bulkheads and instrument supply
tubing last.
2.3.3 Filter regulators, positioners, and all instrument users shall be removed
from the distribution system during system flushing.
2.4 Chemical Cleaning
2.4.1 All piping must be water flushed in accordance with section 2.2 prior to
commencement of any required chemical cleaning.
2.4.2 Chemical solutions shall not be introduced into the system unless high
point vents and low point drains are available to ensure proper filling and
complete removal of the solutions.
2.4.3 Where piping is removed for chemical cleaning, CONTRACTOR must tag
MEP-P-ES-009, Precommission Cleaning Of Piping System, rev 0, 25 July 2005
Custodian: Surface Engineering
Doc. No : MEP-P-ES-009
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PIPING SYSTEM Rev 0 page 7 of 10
Rev Date : 25 July 2005
each item to ensure that it is returned to the same location.
2.4.4 Piping spools may be connected together when the chemical solutions
are circulated by pumping. In such a case, only CAF or similar gaskets
shall be used. Spiral wound gaskets are expressly prohibited.
2.4.5 When a chemical bath or batched circulation is used, spool lengths shall
not exceed 8 feet.
2.4.6 After completion of the cleaning process, the systems shall be suitably
sealed to avoid possible ingress of contamination. No further work shall
be performed on the system without prior written approval of the
COMPANY. It is strictly forbidden to do so.
2.4.7 The following procedures shall be used in the sequential order shown
below whenever chemical cleaning is required (Section 3.0 of this
specification):
a) Alkaline Detergent Wash for Oil and Grease Removal
b) Solvent Cleaning for Rust and Mill Scale Removal
c) Post Cleaning Passivation
2.4.8 Alkaline Detergent Wash for Oil and Grease Removal
a) For carbon and low alloy steel piping, fill equipment with alkaline
solution containing 3% Sodium hydroxide, 1% sodium metasilicate, 1%
trisodium phosphate and 0.1% non-ionic detergent.
b) For type 304, 316 and other high alloy steel piping, it is mandatory that
chloride free caustic (Rayon grade) be used.
c) Heat solution to a temperature between 170oF (77oC) and 200oF
(94oC) and circulate intermittently for at least 6 hours. The circulation
rate shall be the same as specified for water flushing in the table
shown in 2.2 of this Specification, unless otherwise approved by
COMPANY.
d) Drain system and flush with fresh potable water until the effluent pH is
less than 8.
2.4.9 Solvent Cleaning for Rust and Mill Scale Removal
a) For type 304, 316 and other high alloy piping systems, this entire
section 2.4.9 shall be omitted. Under no circumstances should a
hydrochloric acid solution be introduced into a stainless steel piping
MEP-P-ES-009, Precommission Cleaning Of Piping System, rev 0, 25 July 2005
Custodian: Surface Engineering
Doc. No : MEP-P-ES-009
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PIPING SYSTEM Rev 0 page 8 of 10
Rev Date : 25 July 2005
system.
b) For all other piping, fill system with 6% hydrochloric acid containing
0.25% ammonium bi-fluoride inhibited with 2 gallons per 1000 gallons
Amohib 28, Thodine 213 or COMPANY approved equivalent.
c) Heat solution to 160oF (72oC) and circulate for at least 15 minutes
each hour for a minimum of six hours or until reaction is complete.
When circulating, the rate shall be the same as specified previously for
water flushing, except that velocities should be limited to 12 ft/sec for
the large diameter piping.
d) Take samples at least once per hour following circulation and test for
acid strength and total iron concentration. If acid concentration drops
below 3%, add acid to bring concentration to 5%. Continue cleaning
until iron and acid concentrations reach equilibrium.
e) Drain system and flush with potable water (to which 0.1% citric acid
should be added to reduce after-rusting).
f) Neutralize system with 1% soda ash solution.
g) Drain system, open, and inspect.
Note: 1) Use of inhibited hydrochloric acid is acceptable for carbon and
low alloy steels only. It is not acceptable for system containing
stainless or high alloy steels.
2) Other commercially proven acid cleaning/passivating methods
(such as inhibited citric acid) may be submitted for approval by
COMPANY.
2.4.10 Post Cleaning Passivation
a) For all piping systems, both carbon and stainless steel, circulate a
solution of either:
i) 2 to 5 percent phosphoric acid at 180oF (82oC) for 1 hour or,
ii) 1% sodium hydroxide and 0.5% sodium nitrite at 180oF for 2 hrs.
b) Drain and air dry.
c) When the time between cleaning and startup exceeds 10 days, steps i)
and ii) shall be used followed by plugging all openings and pressurizing
at 5 to 10 psig with nitrogen.
MEP-P-ES-009, Precommission Cleaning Of Piping System, rev 0, 25 July 2005
Custodian: Surface Engineering
Doc. No : MEP-P-ES-009
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PIPING SYSTEM Rev 0 page 9 of 10
Rev Date : 25 July 2005
2.5 Post Cleaning Requirements
2.5.1 Upon completion of all required flushing and cleaning operations, the
clean in-plant piping sections that will not be immediately placed in
service shall be dried using heated air. CONTRACTOR shall furnish all
necessary air handling and heating equipment to achieve the following
minimum drying rates:
NOMINAL MINIMUM MINIMUM MINIMUM
PIPE SIZE AIR FLOW RATE TEMPERATURE TIME
(INCHES) (SCFM) (HOURS)
4 750 180oF (82oC) 8
o o
6 1150 180 F (82 C) 8
8 1500 180oF (82oC) 10
10 1900 180oF (82oC) 12
12 2300 180oF (82oC) 12
2.5.2 Flowlines that will not be immediately placed in service shall be filled with
clean, fresh, inhibited water and sealed.
2.5.3 Alternatives to hot air drying, such as pressuring/depressuring with
nitrogen until no free liquid is observed at low point drains during
depressuring and nitrogen blanketing until placed in service, may be
submitted for COMPANY approval.
2.6 Pigging
2.6.1 Long lines with diameter six inches or greater and limited clean water may
make water flushing impractical. An alternative that may be considered in
these cases is line pigging.
2.6.2 A plan detailing lines proposed for pigging, type of pig, method of
propelling the pig, and line lay-up after pigging must be submitted to
MEP-P-ES-009, Precommission Cleaning Of Piping System, rev 0, 25 July 2005
Custodian: Surface Engineering
Doc. No : MEP-P-ES-009
PRECOMMISSION CLEANING OF
PIPING SYSTEM Rev 0 page 10 of 10
Rev Date : 25 July 2005
COMPANY for approval.
3 INSPECTION AND TESTING
3.1 During Chemical Cleaning
3.1.1 A test shall be conducted during the filling of the equipment to make
certain that acid is properly inhibited. A sample of circulating fluid shall be
retained for test purposes. One acceptable test involves heating the
inhibited solution to 170oF (77oC) into which a coupon, approximate size 1
x 1 x 1/8 inch (25 x 25 x 3 mm) is placed. Inhibitor concentration is
satisfactory if no continuous stream of hydrogen bubbles is observed after
30 seconds.
3.1.2 During cleaning with hydrochloric acid, the solution shall be analyzed at
least once per hour for ferric iron and total iron. Ferric iron content greater
than 1.5%, with an increasing slope on the curve when iron is plotted
versus time, indicates excessive corrosion and solutions should be
dumped as fast as possible.
3.1.3 If an alternative chemical cleaning method is proposed, corresponding
tests and controls must be submitted for COMPANY approval.
3.2 After Cleaning
3.2.1 To assess that the necessary degree of cleaning has been achieved,
internal inspection by COMPANY's representative is required at flanges
and joints.
3.2.2 Once approved by COMPANY as "clean," the clean system must be
"protected" by nitrogen blanketing and/or sealing as specified in section
2.5 of this procedure.
4 OPERATING RECORDS
4.1 The cleaning CONTRACTOR shall prepare and maintain a continuous log of the
cleaning operation for each system, recording all aspects including:
a) Chemicals used.
b) Temperatures, concentrations and circulation rate of cleaning solutions.
c) Test results.
4.2 A copy of the log shall be submitted to COMPANY on completion of each cleaning
operation.
MEP-P-ES-009, Precommission Cleaning Of Piping System, rev 0, 25 July 2005
Custodian: Surface Engineering
