Rev.

Page

Document Number

Project Package Originator Discipline Doc. Type Unit n° Serial n°

0 /8
RAPID P03 VOR CON MST 0002 1002

PETRONAS RAPID PROJECT

(P3-DIESEL HYDROTREATING UNIT)

METHOD STATEMENT (MST) FOR

AIR BLOWING AND WATER FLUSHING

OWNER Approval:
Name: 
Date
(DD-MMMYY):

Signature:

Document Class:

1
 Rev. Page

Document Number

Project Package Originator Discipline Doc. Type Unit n° Serial n°

0 /8
RAPID P03 VOR CON MST 0002 1002

PETRONAS RAPID PROJECT

(P3-DIESEL HYDROTREATING UNIT)

DATE WRITTEN BY CHECKED BY APPROVED BY

REV. STATUS – REVISION MEMO
DD-MMM-YY (name & signature) (name & signature) (name & signature)

2
 HOLD’s

HOLD No. REF. § DESCRIPTION ACTIONS

3
 TABLE OF CONTENTS

1. PURPOSE……………………………………………………………………………………………4
2. SCOPE………………………………………………………………………………………………..4
3. RESPONSIBILITIES…………………………………………………………………………….....4-5
4. WORK METHOD………………………………………………………………………………..…5-13
5. SAFETY INSTRUCTION……………………………………………………………………..……13

4
1. PURPOSE
This procedure is to provide a standardized frame of work for preparation and development of detail
procedure (Method Statement) for piping cleaning by air blowing and water flushing.
The potential risks associated with piping cleaning activities and mitigations as well as acceptance criteria
to determine the activity completion with satisfaction are defined in this procedure.

2. SCOPE
This procedure describes the general requirements for piping cleaning activities which are applicable. Detail
procedures (Method Statements) for the execution of air blowing, water flushing, steam blowing,
mechanical cleaning and lube oil flushing for various pipelines will be developed as required on a system
basis using the philosophies described here.

3. RESPONSIBILITIES
The responsibilities of CONTRACTOR PC&C personnel regarding the performance of piping cleaning
activities are described as below.
A) Area Lead Engineer
 Responsible for planning and organizing all PC&C activities, including the rectification and
closing of punch items in a timely manner, for the design area.
 Determine the correct category and responsible party / discipline for punch item, disagreement
for punch category must be discussed with OWNER.
B) Pre-commissioning and Commissioning Engineer
 Responsible for preparation Method Statement, including JHA, for piping cleaning
(system / sub-system wise)
 Responsible for monitoring work completion and progress as per schedule
 Ensuring that all punch items in his area of responsibility are closed properly and in timely
manner.
 Perform Site walk-down / audit for initial punching before OWNER inspection.
C) Pre-commissioning and Commissioning HSE Supervisor
 Responsible to ensure the implementation of safety precautions per Method Statement
D) Pre-commissioning and Commissioning Manager
 Organize all PC&C activities system-wise, systematic testing of the FACILITY, and handover
to the OWNER.
E) Pre-commissioning and Commissioning Supervisor
 Responsible for monitoring and inspection piping cleaning activities
 To work in close liaison with Construction team for any necessary rectification during piping
cleaning

5
  Responsible for safety and quality of the work
 Monitor the punch killing activity by Construction, Sub-contractor or Vendor

4. WORK METHOD

4.1 AIR BLOWING

4.1.1 SCOPE OF APPLICATION
Air blowing should be applied to the following pipes.

 Chemical Line

 Instrument / Plant Air Line

 Nitrogen Line

 Fuel Gas Line

 Hydrocarbon Line

 Combustion Air Line

Air blowing may not be limited to above services only and may be applied to other service
for which other cleaning methods are originally scheduled so as to suit site requirements.
Air blowing utilizes kinetic energy of air flow, which removes trash and construction debris
inside of the pipes. High velocity must be attained so as to obtain large kinetic energy since
the specific gravity of air is lower than water.

4.1.2 BLOWING METHOD

Compressed air (Instrument Air quality) will be used to blow instrument air and nitrogen to
ensure free moisture removal.Dry compressed air with dew point of (-) 20 oC will be used
for other services. Air blowing will be conducted by any one of the following methods.

METHOD 1: ACCUMULATION METHOD

Air is accumulated in a column / drum / vessel or pipe then released into the downstream piping
to atmosphere in order to remove the trash and construction debris.
When columns are used as air reservoir, tray installation shall be performed after air blowing
activities. Alternatively, trays man ways could be left opened to prevent damages on internals
subject to the approval of OWNER.
When this method is applied, quick opening valve such as knife gate valve or butterfly valve is
recommended to be used to avoid loss of pressure in reservoir before enough opening
(enough air velocity) is reached.
The quick opening valve size shall be equal to the size of the line to be blown to ensure adequate
air velocity in the line.
Air blowing using Accumulation Method is the preferred Air Blowing method and it shall be
maximized by using temporary lines as necessary to connect air accumulator to the blowing
circuits.

6
 Final Box Up of vessels used for air blowing shall take place only after the cleaning activity of
all pipe connected around the vessel is completed.

METHOD 2: DIRECT BLOWING METHOD

The pipe to be air-blown is connected to the air supply source using a temporary pipe or hose
and blown directly from source to atmosphere. This method is limited to small bore piping
(normally below 4”).

METHOD 3: CLEANING RUN OF COMPRESSOR / BLOWER

Piping connected to a compressor or blower can be air blown by operating the compressor /
blower discharging to the atmosphere or re-circulating through filters. Air flow is to be kept as
much as possible within operable range and power consumption shall be checked to prevent
overload of the driver.
It is necessary to investigate with VENDOR in advance whether or not the compressor or
blower can be operated with this method. Detailed procedure shall be prepared and submitted
to OWNER for review and approval (including operating conditions / limitations calculated by
VENDOR for this mode of operation).

METHOD 4: PISTON BLOWING

The pipe being air blown is pressurized and depressurized through a quick opening valve or
bursting element fitted at the end of the pipe. This method is used in cases where an air
reservoir is not available

4.1.3 PRECAUTIONS
The following precautionary measures will be observed when blowing activities are
conducted.
 The blowing points are secured against recoil and whipping.
 Line shall be properly drained and thoroughly dried before to start air blowing to avoid
uncontrolled water spillage at the exhaust point.
 The blowing discharge area shall be cordoned off with tape, warning notices posted and
patrolled by safety officer and Pre-commissioning team member to ensure personnel
safety. Advance notification shall be made and announcements via temporary field
communication system such as megaphone or Horn prior to initiation of blowing
activities.
 As foreign materials and dirt may fly out during air blowing, equipment which could be
affected shall be protected.
 Surrounding area, piping and equipment shall be protected from dirty wet air.
 3 to 4 bar is recommended for air reservoir pressure whilst blowing using the
accumulation and piston method. However, each system design pressure will be
checked and never exceeded. For the case where design pressure of the equipment and
piping is lower than the potential maximum air pressure supplied from the temporary
compressor or the permanent air facility such as Instrument Air or Service Air, safety
valves shall be installed on the equipment or piping to prevent overpressure.
 Due to high velocity of air for effective cleaning, large noise along with debris may be
anticipated. Therefore, the suitable head / eye and ear protection shall be provided for
the persons on site.
7
  Safety precautions must be in force to prevent unauthorized work on the piping systems
that are being used to perform the air blowing.
 Proper piping supports to be ensured and piping to be secured using chain blocks and /
or slings wherever necessary.

4.1.4 PLANNING
The piping to be air blown is classified as per section 4.1.2 above mentioned. The classification
may be changed so as to meet site requirements. Guidelines for method selection based on
process services are given in the following table:
Method 1 Method 2 Method 3 Method 4
Chemical Line X X

Instrument / Plant Air X X X

Nitrogen Line X X X

Fuel Gas Line X X X

Hydrocarbon Line X X X

Combustion Air Line X

Utility lines have priority for flushing operation so that they are available for air blowing
process equipment and piping.
The main process, offsite or utility lines shall be blown from the upstream end after removing
the flanges and fittings at the end of the line. Branches shall be blown sequentially in the
same.
When air blowing loop includes equipment such as tube side of heat exchangers / heater
tubers /tubes of air fin coolers, blow-out points shall be assigned at the inlet flanges of such
equipment. To prevent debris entering the equipment from its inlet flanges, the equipment
shall be blinded. After the above air blowing is completed, the downstream air blowing can
be started throughout the equipment.
Detailed air blowing method statement will be developed for each individual system and
submitted to OWNER for review and approval. Air blowing route will be determined and
shown on marked-up P&IDs. The following items will be indicated:
 Lines being blown

 Major valves position and sequencing

 All temporary valves, piping, spools, spades, etc.

 Checklist on the valve / instrumentation position (open / close)

4.1.5 PREPARATION AND EXECUTION

The following items should be prepared before execution.

 Remove the following and, upon completion, reinstate:

8
  Safety Valves

 Check Valves, as required

 Rupture Disks

 Restriction Orifice, Orifice Plate or Flow Meter Element

 Thermowells

 In-line Mixers / Strainers

 Spargers, Distributors

 Spray Nozzles

 Control Valves

 Self-activated Valves

 On / Off Valves, Emergency Shut Off Valves

 All other items which could be damaged by the ingress of dirt or restrict the blow
path
 Check all the line supports are installed in line with isometrics
 Install temporary piping spools and fittings required for air blowing (including
temporary PSV if required, refer to section 6.4). For the temporary piping which will
be pressurized, pressure test is required prior to air blow.
 Prior to the commencement of air blowing, the route shall be checked at site by
CONTRACTOR and OWNER to confirm that all the site preparation has been done
according to the approved method statement.
After all preparation works have been checked and confirmed at site, the air blowing activity
can be executed as plan.

4.1.6 ACCEPTANCE CRITERIA

When any foreign materials which could interfere with plant operation is no longer present in
the discharge air, no visible dust or debris and no free water are present in the discharge air and
a minimum of two (2) blows have been performed, the cleanliness shall be checked by
CONTRACTOR and OWNER. If the check result is satisfactorily for CONTRACTOR and
OWNER, air blowing shall be deemed completed.

4.1.7 POST WORK

After piping air blowing, the following work should be carried out:

 Piping shall be reinstated as per P&IDs.

 Suitable measures shall be taken to maintain the internal cleanliness of piping systems
once blowing is completed until being placed into service. Open ends shall be covered
by plastic until reinstatement is completed.
9
 All blows shall be documented and recorded on P&IDs by CONTRACTOR and OWNER
immediately upon completion of the blow. Once a subsystem is completed, related air blowing
check sheet shall be signed by all parties and uploaded in the Completion Database

4.2 WATER FLUSHING

4.2.1 FLUSHING METHOD

METHOD 1: POWER FLUSHING

This type of flushing normally involves taking a section of piping and flushing it from a “start-
point” to open end. Pumps, either permanent or temporary, can be utilized to attain the high water
velocity (2-3 m/s) necessary to dislodge and carry debris and loose materials inside the pipe; these
materials are then collected in filters / strainers or discharged at an open end. Alternatively, the
flushing water can also be circulated in a closed loop. Temporary strainers are to be provided at
suitable location to collect debris.
In case permanent pump is to be used for power flushing, the pump shall not be energized prior to
the completion of all necessary tests and checks. For temporary pumps, permanent system
protection against overpressure shall be ensured.
NOTE:
In order to minimize the water consumption and the amount of waste water to be disposed, tight
spool-by-spool cleaning and inspection should be applied for all spool and piping; air blowing should
also be carried out prior to water flushing.

METHOD 2: GRAVITY FLOW FLUSHING

In addition to cleaning the pipe inside, this method is also used for cleaning vessels. The vessel is
filled to the desired level with flush water and the water is then discharged out to downstream lines
by gravity flow; the valve opening time should be minimized to keep high water velocity. The flush
water removes the loose debris and carries it out of the equipment and the pipes. Typical example is
the flushing of pump suction line.
The major problem with this method is the disposal of large quantities of water involved which
may overload the drain systems.

4.2.2 PRECAUTION
The following precaution items should be attended before activity.
 Attention has to be given for potential corrosiveness of water.
 Chloride content of water contacting with stainless steel pipes or vessels is limited to 50
ppm maximum. Treated water shall be used for the final rinsing and the water shall be
immediately drained and the piping dried using dry air or nitrogen upon completion of
flushing to avoid chloride corrosion.
 Prior to filling vessels, tanks, or overhead piping systems with water, check that the
equipment and their foundations / supports are designed to withstand full water weight.
 When vessels or tanks are used as water reservoirs, appropriate vent (opening) shall be
available to replace the displaced water volume and prevent vacuum generation.
 The discharge area shall have a suitable grade for drainage. It should be protected from
erosion. It must be free of unsealed electrical or other equipment which could be
damaged by water. Ensure that sufficient drainage area is available to prevent flooding;
temporary piping and connection will be provided if required. A general procedure for
10
 disposal of drained water will be submitted to OWNER as a separate deliverable.
 Ensure construction debris is not flushed into equipment.
 Avoid damaging of the pump due to wrong selection of mesh size for temporary
strainer.
 Monitoring and control of pump parameters during water flushing to avoid overload on
pump motor

4.2.3 PLANNING
The Method Statement along with marked-up P&IDs for each water flushing circuit (shall be
identified on system basis) shall be prepared including the drainage route (draining to open
ditch, underground drain system, etc.).
It shall be confirmed that the required quality and quantity of water is available at Site. Also,
it shall be checked that the pumps is available at Site and they can accommodate the head
loss while maintaining flushing water velocity.
In order to reduce the flushing frequency of each loop, the following methods can be applied:
 Preliminary cleaning by air blowing on pipes prior to water flushing

11
 Preserve pipe cleanliness before installation

The following devices in each water flushing block shall be removed and replaced with
temporary spool as required:
 Safety Valve / Rupture Disk

 Orifice Plate or Flow Meter Element

 Inline Mixer / Inline Strainer

 Sparger / Spray Nozzle

 Control Valve

 Self-activated Valve

 Emergency Shut-off Valve

 Thermowell

 Pressure sensing devices (isolate all pressure taps to prevent plugging)

 Supports, Hangers, Pads

 Other items which could be damaged by the ingress of water, pressure pulse or dirt,
may restrict the flushing flow path, or may collect the debris
All removed components shall be stored and covered for protection from contamination or
damage. Small instruments shall be tagged and boxed away from the work site. Large valves
may be stored nearby provided they do not cause obstruction and are covered by plastic with
plywood flange covers secured to both faces.
Equipment shall be bypassed in flushing route. If bypass is neither possible nor practical, a
temporary strainer shall be provided at the inlet flange to prevent debris from entering the
equipment.
The main process, offsite, or utility lines shall be flushed in the normal flow direction by
removing the fittings at the end of the line. Main headers shall be cleaned before the
branches, large diameter pipes shall be cleaned before small diameter ones. Dead ends shall
be avoided or, if not possible, cleaned separately by an appropriate method.
For equipment to be used for water flushing, e.g. vessel for water reservoir and pump for
water circulation, check that the relief valves or other safety
instrumentations are in normal operation; confirm that the quantity of inlet water to the
vessel does not exceed the maximum quantity of water that can be vented through the relief
valve. A special care shall be taken for vessels designed only for an atmospheric pressure
service to avoid a high pressure due to water head during flushing.
Temporary strainer of 40-mesh (to be confirmed on Site per Vendor recommendation) shall
be provided at pump suction.
The JHA (listing of risks and mitigative actions) is mandatory for PTW application and shall
be attached in Method Statement.

12
 Temporary materials such as spool and piping, tools and equipment, shall be listed and
prepared in advance prior to actual Site preparation.

4.2.4 EXECUTION
The following is typical execution steps for water flushing:

 Apply the required PTW for water flushing execution

 Prepare the flushing circuit by replacing the sensitive parts with temporary spools as
per Method Statement. Install yellow blinds at the limit of the flushing loop, if
required.
 Put safety requirements in place and notify all the concerned parties.

 Check the route for water flushing as per Method Statement.

 Take sample of source water for reference.

 Perform water flushing as planned (consider to flush all drains and pressure taps).
 Take sample at flushing point when clear water is received. Confirm water flushing
completion with OWNER.
 Rinse the flushing circuit with inhibited water (as necessary).

 Record water flushing results on the relevant check sheet and signed-off by OWNER.

NOTE:
 After flushing of pump suction line by gravity flow, install temporary strainer at
suction and carry out flange alignment. Pump mechanical run shall be performed
afterward.

 Stop pump or water supply immediately if abnormal situation is seen during flushing.

4.2.5 ACCEPTANCE CRITERIA

After no visible debris or foreign material is no longer detected in the flushed water, a final
visual sample shall be taken in a clear sample bottle and witnessed by OWNER. Compare the
sample of flushed water with the sample of source water and if OWNER witness is satisfied
with the sample, water flushing shall be deemed completed. If required, water sampling can be
carried out for all vent and drain points.

4.2.6 POST WORK

The following activities are carried out after water flushing is accepted by OWNER:

 Drain and dry the pipes. If the piping is to remain filled with water, in-service tightness
test shall be performed and preservative chemicals shall be injected as required.
 Complete reinstatement as per P&IDs. All temporary piping and tools shall be

13
 removed. Temporary gasket to be replaced as per recommendation.
 Preserve (with dry air or nitrogen) and maintain internal cleanliness of the pipe until it
is placed into service.
 Close the PTW.
 Once a subsystem is completed, related water flushing check sheet shall be signed by
all parties and uploaded in the Completion Database. Sample of check sheet is enclosed
as Appendix A

5. SAFETY INSTRUCTION
5.1.1 All required work permits and documents will be obtained and kept available at site in
permit boxes.
5.1.2 All personnel involved will wear necessary PPEs at all time.
5.1.3 The workers will be made aware of safety requirements related to this activity through Tool
Box meeting.
5.1.4 Good housekeeping should be maintained at all time.
5.1.5 Fire extinguisher and fire hose shall be available at working area.
5.1.6 When working at height, fall protection measures shall be taken.
5.1.7 Remove all materials and tools from site after completion of job

14