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SECTION:

COMMON

IPCL -MGCC

SOP NO:
NC/CTS/CTS/

CHEMICAL CLEANING
1. PURPOSE
The purpose of this procedure is chemical cleaning and passivation of equipments
safely.
2. INTRODUCTION
Chemical cleaning is a method to remove unwanted contaminants from the
surfaces and walls of equipments, pipelines, vessels and heat exchangers.
Chemical cleaning also includes the conditioning or treatment of equipment. This
process is used for passivation to eliminate fouling, oxidation, process system
corrosion, and decontamination of process lines and vessels.
3. PREPARATION:
SR
ACTON
NO For Chemical Cleaning of cooler with CW in Shell Side
1
Ask the area operator to isolate the CWS & CWR & drain
the CW from shell side of the cooler from the LPD in inlet or
outlet line.
2
After ensuring that it is depressurized completely, provide
blinds as per blinding diagram & make respective entry in
the blind register.
3
Ensure availability of Low pressure Steam and Service
Water.
4
Do the blinding as per the blinding diagram and enter in
blind register.
5
Ensure that all the required chemicals (quantity as per the
calculation format) are available
6
Ensure that Lab sampling system is established and format
for data collection is available.
Exchanger.ppt

CONTROL
ROOM
Panel
Engineer

FIELD

Panel
Engineer

Operator

Panel
Engineer
Panel
Engineer

Operator

Operator

Operator
Operator
Operator

"Chemical Cleaning
"Quantity of chemical "analys is
Format.xls "
to be us ed.xls " procedure.pdf"

4. SAFETY
4.1 Use Rubber gloves, safety helmet, rubber boots, Chem. splash goggles, and rubber
apron.
4.2 Proper chemical handling procedures to be followed. See MSDS of Caustic,
Ammonia, Citric Acid, Ammonium bi Fluoride, Sodium Nitrite.
4.3 Use adequate rated & tested hoses.

REVIEWED BY
PAGE
CENTRAL TECHNICAL SERVICES
: AKP
REV.
NAGOTHANE
ISSUE
APPROVED BY
SOP
DATE
: RN
MANUAL
AUTHOR

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25/11/06
VK/MD

SECTION:
COMMON

IPCL -MGCC

SOP NO:
NC/CTS/CTS/

CHEMICAL CLEANING
4.4 In order to prevent damage to paving, manholes, sewers and underground
installation; all waste acid and alkali solution shall be properly neutralized to ph 7.0
prior to discharge
4.5 Adequate ventilation provision during cleaning operation.
4.6 The handling of acid preparation bath, heating and chemical cleaning operation
shall be supervised by a competent supervisor.
5. PROCEDURE:
Important points to ensure during chemical cleaning:
1. Visually inspect the pipes to be chemically cleaned, from the ends, prior to the
commencement of chemical cleaning operation and record the condition of the pipe.
2. Provide vents in all high points for effective removal of air and acid fumes during
cleaning operation.
3. Ensure full bore flow while circulating various chemicals throughout the circuit by
operating Vents intermittently.
4. Drain the solutions during chemical cleaning operation from the lowest point for
effective removal of slug and chemicals.
5. Maintain good velocity by use of adequate pump capacity for each circuit to
(preferably 0.5 to 1.0 m/sec) throughout the operation.
6. Ensure effective return of flow from the outlet and the vent.
7. Whenever acid is added corrosion inhibitor should be added first.
Control of cleaning process:
1. Take the solution samples every hour for analysis of pH.
2. Check acid concentration in inhibited ammoniated citric acid solution every hour
during the cleaning operation.
3. In case the acid strength falls below 2% by wt., part of the solution brought to
specified range of 3% by wt. by addition of fresh acid. Also add corresponding quantity
of inhibitor and ammonia.
4. Determine total iron content of the acid cleaning solution at intervals of every hour.
Total iron content should not exceed 5000 ppm with 3% citric acid solution.
5. In case the limit of total iron are attained the drain the cleaning solution in part and
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APPROVED BY
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DATE
: 25/11/06
: RN
MANUAL
AUTHOR
: VK/MD

SECTION:
COMMON

IPCL -MGCC

SOP NO:
NC/CTS/CTS/

CHEMICAL CLEANING
brought in specified range by addition of fresh inhibited ammoniated citric acid.
6. Monitor iron stabilization and acid concentration to determine the completion of
acid cleaning.
Degreasing:
5.1 Set up the loop connection.
5.2 Check completeness of circuit and ensure that all flanges joints are tight.
5.3 Fill the Tank with Service water.
5.4 Circulate water to check tightness of circuit.
5.5 Rectify leakages if any.
5.6 Circulate to flush circuit to remove all loose deposit, dirt, dust etc. and drain water
by opening all drain valves till the water becomes clear.
5.7 Once the clean water circulation is established, heat the water to 65 0C with
circulation and drain after half an hour.
5.8 Take the fresh water again and heat to 65 0C with circulation. Add 0.1 % detergent
and 2 % NaOH and circulate the solution for about two hours. Drain the solution
after this.
5.9 Wash the system with water till the water is clear and fresh water pH (7) is attained.
Acid Circulation & Passivation:
5.10 Fill the system with fresh water and add inhibitor Rhodine 92B (add one litre per
100 kg. Dry acid) in the same solution and circulate for about half an hour.
5.11 Add citric acid after obtaining 650C to 700C to minimum 5 % concentration. The
pH of the solution is to be made around 3 by the addition of ammonia solution.
Add 0.2 % ammonium bi fluoride after 3 hrs of circulation to solubalise silica.
5.12 Maintain the circulation and pH of the acid till iron pick up and acid concentration
attains equilibrium (650C to 700C ).
5.13 Then drain the acid solution taking care to neutralize the same before going to the
Effluent system.
5.14 Take fresh solution of 0.1 % citric acid with pH 3 at 800C and circulate for half
an hour. This step is to solubalise the free iron completely.
REVIEWED BY
PAGE
CENTRAL TECHNICAL SERVICES
: AKP
REV.
NAGOTHANE
ISSUE
APPROVED BY
SOP
DATE
: RN
MANUAL
AUTHOR

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00
01
25/11/06
VK/MD

SECTION:
COMMON

IPCL -MGCC

SOP NO:
NC/CTS/CTS/

CHEMICAL CLEANING
5.15 Then raise the pH of the same solution to 9 by adding ammonia solution
maintaining the temperature to 40 0C. To this solution add sodium nitrite to get 2 %
concentration and circulate for two hours to ensure passivation.
5.16 Drain out the solution under nitrogen taking precautions.
5.17 After completion of chemical cleaning and passivation visually inspect the pipes,
from ends at convenient locations and ensure that the surface are completely cleaned,
dry, free from rust and properly passivated. Record the visual observation.
5.18 Remove the blinds and update the blind register.
Note: If system contains Cu based alloys use NaOH instead of ammonia and
ammonium biflouride is not to be used.
The quantity of chemicals to be added to get a solution of 10 m3 is given in the
following table. By just entering the volume of the equipment to be cleaned, the quantity
of chemicals to be added can be obtained.

"Quantity of chemical
to be us ed.xls "

7. RESPONSIBILITY
6.1 Plant Process HOS.
6.2 Plant CTS .
6.3 Plant Mechanical HOS.
6.4 Plant Electrical HOS.
8. REFERENCES
7.1 Chemical cleaning procedure provided by C&I.
9. RECORDS
8.1 Plant log book.
8.2 The Chemical cleaning filled format.

REVIEWED BY
PAGE
CENTRAL TECHNICAL SERVICES
: AKP
REV.
NAGOTHANE
ISSUE
APPROVED BY
SOP
DATE
: RN
MANUAL
AUTHOR

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VK/MD

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