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1.0.SCOPE OF WORK: The scope of work Pickling and Flushing of both CS and SS Pipeline internal surface at KCC Line II Project. The final result of cleaning of CS pipeline shall be internal surface free from weld particles and rust whereas the SS lines will be free from micro metallic particles. 2.0. PROCEDURE: To performance chemical cleaning job Written approval and permission prior. This proposed chemical cleaning procedure is for the DE-GREASING, ACID PICKLING, HIGH SPEED OIL FLUSHING is based on system isometrics and estimated average volume of 1,000 US Gallons for all the three CS & SS lines as per the given drawings. had appoined 3B to follow the vendors spec for the chemical cleaning job. The following procedure is written in accordance to the vendors recommended procedure. 2.1: RIG-UP:
2.1.1 Connect 1 or 2 flexible rubber hose to the inlet and out of the KCC plant lines to be cleaned. 2.1.2 Follow the diagram to rig-up including the mixing tank, boiler, centrifugal pump and frac tanks. 2.1.3 Make sure to connect a hose from top vent point to mixing tank. This will ensure the positive flow of liquid in the line and no air patches in the line. 2.1.4 Make sure to connect lower drain point. 2.1.5 Connect reducer of 1 or 2 at the ends of the return line for circulate. 2.1.6 Install strainer inside the mixing tank at suction hole while performing pickling. Install 20 micron filter and 5 micron filters in the discharge line during the high speed flushing using oil as media of flushing. 2.1.7 Fill the system using fresh cold water in the CS line, circulate and check for the leaks.
PASSIVATION
9. Fill the system and heat to 150 F (70C). 10. Add Soda Ash, Liquid Caustic and Sodium Nitrite. (Refer Safety Note) 11. Circulate for three hours. 12. Drain the system. 13. System is neutralized, passivated and coated with protective thin coating of nitrite. 14. CS pipeline Pickling and Chemical cleaning job completed. 15. Purge with Nitrogen or dry air to dry the internal surface of pipeline. (* By the Weight of System) (** By the Volume of System)
OIL FLUSHING
16. Rig-up the system by connecting CS & SS lines. 17. Install 20 micron filter or SS mesh at the suction of centrifugal pump or inside the mixing tank. 18. Install 5 micron filter at the discharge line 19. Fill the system with Oil provided by Descon / Client 20. Circulate & check for the leaks, fix the leaks, if any 21. Start circulation using Medium speed ( 2 foot/ sec ) & gradually increase to 4 to 6 foot/ sec 22. Continue circulation for 2 hours and dump the oil 23. Fill the system using the oil provided by Descon / Client and circulate for 6 hours 24. During circulation observe & clean the filters ( if required ) at every 2 hours 25. Drain the system 26. Fill the system using the oil provided by Descon / Client and circulate for 6 hours 27. During circulation observe & clean the filters ( if required ) at every 2 hours 28. Check with Client before dumping / draining the system 29. Job completed
NOTE: 1. It is important that DESCON shall maintain 0.5 psi positive nitrogen pressure after completion of 3B job till the boxing the lines or immediately continue oil flushing. 2. End result of chemical cleaning will be a silver shiny colored piping surface internal coating or a black colored magnetite coating. Both are acceptable results. If DESCON disagrees with these criteria then it must be notify to 3B prior to the job.
Safety Note:
1) Acid mask, PPE is required. Acid safety training will be given to the 3B operator and site persons. 2) 3B Automatic suction line system will be used to mix HCl. 3) Special care should be taken while dealing with HOT solution of the system. Rubber gloves, rain coat, boots and safety face shield must be used. 4) Daily tool box meeting will be conducted prior to the job. 5) Change shift note and job brief will be provided by out going crew to the in coming crew. 6) Besides installed temperature gauges on the equipment, laser temperature gun will be used to check the temperature of the lines. 7)All area of chemical cleaning should be barricaded with sign board Chemical Cleaning job in Progress. 8) Make sure the availability of potable eye wash station (DESCON to provide) at the job site. 9) Chemical resistance coverall, gas mask, face shield and PPE is required for the persons mixing the chemicals whereas all other need general PPE.
3.1: CHEMICALS TO BE USED ON JOB (3B WILL SUPPLY): MSDS will be submitted for all the material: a) b) c) d) e) f) g) h) i) Beyond 2001 HCl Rodine-50 PEN- 5 Antifoam Soda Ash Liquid Caustic Sodium Nitrite Nitrogen cylinders -10 numbers.
NOTE: All the above manpower will be on 24 hours basis, half numbers each shift. EQUIPMENT 1 2 3 4 5 7 8 Centrifugal Pump 800 GPM -Size 5x5 Mixing tank, 2000 Gal - Size 10 x4x5 Fittings Pickup Frac tank /Waste holding tank - Size 40x7x81 Trailer Steam generator Qty 1 1 Lot 2 1 1 1 -
40 feet 6 x 12
4.6. Supply of dry flushing oil as required. 3B estimate about four volume of the system. 4.7. Chemical waste will be collect in waste holding tank (Frac Tank). Waste disposal cost is not considered. Incase if Descon wants 3B to handle, transport and dispose the waste then separate quotes will be provided. See the waste disposal section -5 below for further details. 4.8. Continuity of work for the duration of project. 4.9. Maintenance support around the clock operation as required at 3Bs site. 4.10. Provide forklift/crane to load, unload, spotting the equipment and rig-up/de-rig. 4.11. Lighting at the site around the clock operation. 4.12. Scaffolding if required at the site to access all the tie-in points. 4.13. All security passes and permits as per the requirement for 3B /ISCO equipment and personnel. 4.14. Representative or inspector of DESCON to witness the results. The degree of cleaning could be judged by visual inspection or black light inspection. Presence of gray shining or black magnetite coating should be end result of cleaning and acceptable. 4.15. One technical person and PRO from DESCON to assist 3B around the clock. 4.16. All special or extra (other than regular) safety gears as required by DESCON safety regulations to all working crew of 3B like H2S masks or any other special safety gears as required by DESCON. 4.17. Written notice to proceed the job and approval of the procedure, terms and condition. 4.18. All safety signs (additional to normal) as required by the DESCON around the contractors equipment. 4.19. All fabrication work to provide 2 and 4 150# flanges connecting points for 3B equipment. 4.20. Suitable shaded 8 x 20 space to store chemicals at job site. 4.21. Potable eye wash station close to working site.
7.0. MOBILISATION
CLIENT (DESCON) Documents Required for CONTRACTOR (3B) Mobilization of Cleaning Equipment Package: 7.1.1 Contract for the Work
7.1.2 Eight days written notification to proceed. 7.1.3 Final Scope Definition
Rev#1
DESCON (KCC, SHUAIBA AREA) PIPELINES CHEMICAL CLEANING & OIL FLUSHING
Comp. Line
KCC lines.
Centrifugal Pump
ATTACHEMENTS IRON TESTING PROCEDURE: 1. Turn on the DR - 700 and set the reading 50.03.1 by using up / down arrows or side arrows. 2. Take 0.1 ml or (100 micro liters) sample; add 100 - ml DI water. 3. Take 25 ml from the above dilution and place the sample, press Zero set. 4. Add 1 reagent pillow for 25 ml in the above step 3 sample, wait for 3 minutes. (If 10 ml reagent pillow, than take 10 ml sample). 5. Place step 4 sample with reagent and press READ. ppm Iron = The Calorimeter value 1000 % Iron = The Calorimeter value 1000 = ppm divided by 10,000 For HCl testing: 1) Take 2 ml sample of the system acid solution. 2) Add few drops of mixed indicator. 3) Titrate 0.5 NaOH solutions from red to green end point. 4) % HCl = ml of Caustic used x 0.89. 5) Record the conclusion and report the result.
7. Wash the glass electrode and always keep it immersed in water so as to maintain its sensitivity.
MAK/12/805 2012
Rev#1
12
July
DESCON (KCC, SHUAIBA AREA) PIPELINES CHEMICAL CLEANING & OIL FLUSHING
pH
Iron % Temp F
Acid %