VES - 5803

PRECOMMISSION CLEANING OF PIPELINE SYSTEMS

TABLE OF CONTENTS
PAGE
1.0

SCOPE

2.0

CLEANING REQUIREMENTS AND METHODS

2.1
2.2
2.3
2.4
2.5
2.6

3
4
5
5
7
8

3.0

4.0

General Requirements
Water Flushing
Air Flushing Instrument Piping and Tubing
Chemical Cleaning
Post Cleaning Requirements
Pigging

INSPECTION & TESTING

3.1
3.2

8
8

During Chemical Cleaning

After Cleaning

OPERATING RECORDS

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1 .0

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.

2.0

CLEANING REQUIREMENTS AND METHODS

2.1

General Requirements
2.1.1

All piping shall be internally cleaned by Contractor on completion of the pressure

testing. The minimum cleaning requirements are defined in the following table:
WATER
FLUSHIN
G
Note 4

CHEMICAL
CLEANING
Note 4

COMPRESSED
AIR PURGE

WARM
AIR
DRIED

FILLED
WITH
WATER

Flowlines

Yes

No

No

No

Yes

Sealed, if not in
service

In-Plant Piping

Yes

Note 1

No

Yes

No

Sealed, if not in
service

Lube and Seal

Oil Piping

Yes

Note 5

No

Yes

No

Sealed, Nitrogen
or air purge

Instrument
Lines

No

No

Yes

No

No

Sealed, nitrogen
purge

Suction lines
for
compressors
and pumps

Yes

Note 2
Note 3

No

Yes

No

Sealed, if not in
service

Flare Lines

Yes

No

No

Yes

No

Sealed, if not in
service

Chilled Water
Lines

Yes

Optional

No

No

Yes

Add Inhibitor

SERVICE

Notes:

COMMENTS

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 - 160o F) 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.

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2.1.2

2.2

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.

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 to ensure 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.

2.2.3

NOMINAL
PIPE SIZE
(INCHES)

MINIMUM
FLUSH ING RATE
(US GPM)

MINIMUM
VELOCITY
(FPS)

MINIMUM
TIME
(HOURS)

45

1.0

250

1.0

700

1.0

1,500

1.0

10

2,500

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

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.

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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 FPS.

T=

(X) (10)
(3600) (V)

T = Minimum flushing time in hours.

2.2.5

2.3

Air Flushing Instrument Piping & Tubing

2.3.1

2.4

Contractor shall provide a means of disposal for the water used for flushing
which will not overload Company's drain systems or adversely affect the
environment. This method must be defined in writing by Contractor and
approved by Company prior to commencement of flushing operations.

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
PIPE SIZE
(INCHES)

MINIMUM
AIR FLOW RATE
(SCFM)

MINIMUM
VELOCITY
(FPS)

MINIMUM
TIME
(MINUTES)

3/8

50

10

30

3/8

145

10

30

1/2

100

12

30

200

12

30

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.

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 each item to
ensure that it is returned to the same location.

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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 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 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.

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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.

2.5

Post Cleaning Requirements

2.5.1

Upon completion of all required flushing and cleaning operations, the clean inplant piping sections which 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
PIPE SIZE
(INCHES)

MINIMUM
AIR FLOW RATE
(SCFM)

MINIMUM
TEMPERATUR
E

MINIMUM
TIME
(HOURS)

750

180o F (82o C)

1150

180o F (82o C)

1500

180o F (82o C)

10

10

1900

180 F (82 C)

12

12

2300

180o F (82o C)

12

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2.6

3.0

2.5.2

Flowlines which 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.

Pigging
2.6.1

Long lines with diameters six inches or greater and limited clean water may make
water flushing impractical. An alternative which 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 layup after pigging must be submitted to Company for approval.

INSPECTION AND TESTING

3.1

3.2

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 are 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.

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.

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4.0

OPERATING RECORDS
4.1

4.2

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.

A copy of the log shall be submitted to Company on completion of each cleaning

operation.

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