MALAYSIA LNG SDN BHD

(Co. No. 39964-H)

(A member of the PETRONAS Group of Companies)

P.O Box 89, 97007 BINTULU, SARAWAK

TEL: 086-856000
FAX: 086-252037

TECHNICAL SPECIFICATION FOR

CHEMICAL BOILER CLEANING

AND

WASTE TREATMENT

ISSUED DATE 2006

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Table of Contents

1 Introduction..................................................................................................................4
1.1 General.................................................................................................................4
1.2 Schedule...............................................................................................................4
1.3 Safety...................................................................................................................4
1.4 References............................................................................................................4
1.5 Definitions...........................................................................................................4

2 Scope of Work.............................................................................................................5
2.1 Engineering and Design.......................................................................................5
2.2 Chemical Boiler Cleaning....................................................................................5
2.3 Waste treatment...................................................................................................6
2.4 Warranties............................................................................................................6
2.4.1 Boiler integrity.................................................................................................6
2.4.2 Chemical cleaning...........................................................................................6
2.4.3 Waste treatment...............................................................................................6
2.5 Location and Layout............................................................................................7
2.6 Precedence of documents....................................................................................7
2.7 Alternative design................................................................................................7

3 Design requirements....................................................................................................7
3.1 Chemical boiler cleaning.....................................................................................7
3.1.1 Selection of the cleaning fluid.........................................................................7
3.1.2 Mechanical considerations...............................................................................7
3.2 Waste Treatment..................................................................................................7
3.2.1 Objectives........................................................................................................8
3.2.2 Collection of waste..........................................................................................8
3.2.3 Treatment of waste..........................................................................................8
3.2.4 Disposal of waste.............................................................................................8
3.3 Procedures............................................................................................................8
3.3.1 Pre-Cleaning....................................................................................................9
3.3.2 During cleaning...............................................................................................9
3.3.3 Post-Cleaning...................................................................................................9
3.3.4 Waste Treatment..............................................................................................9
3.4 Utilities................................................................................................................9

4 Monitoring and inspection...........................................................................................9

4.1 Pre-Cleaning inspection.....................................................................................10
4.2 Chemical analysis during Cleaning...................................................................10
4.3 Waste treatment monitoring..............................................................................10
4.4 Post-Cleaning inspection...................................................................................10

5 Documentation Requirements....................................................................................11

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6 Standards and Specifications.....................................................................................12
6.1 Pre-Cleaning Procedure.....................................................................................12
6.2 Cleaning Procedure............................................................................................14
6.3 Post-Cleaning Procedure...................................................................................16
6.4 Waste Treatment Procedure...............................................................................17
6.5 Waste water discharge limits.............................................................................18
6.6 Boiler Equipment Drawings..............................................................................19
6.7 Process Engineering Flow Schemes..................................................................20
6.8 Layout and Arrangement drawings...................................................................21

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1 Introduction

1.1 General
The Petronas MLNG Complex in Bintulu has nine natural circulation D-type boilers,
each generating 380 t/h of steam. Some tube failures have been experienced is the last
few year and investigation has revealed that the failures are caused by caustic gouging.
The root cause is found in a thick and irregular magnetite layer that enables build up of
porous metal deposits that serve as a precursor to the formation of a concentration cell.
Departure from nucleate boiling that would lead to over concentration of caustic,
subsequently lead to caustic corrosion and carbon steel stress corrosion cracking. Thick
magnetite layer could also lead to overheating of the tubes, subsequently leading to tube
rupture.
The solution to this problem is to remove the thick magnetite layer via chemical cleaning
followed by passivation in order to clean the boiler tubes. This, together with stringent
control of the water quality, will prevent the build up of new concentration cells.
During the investigation a number of tube samples have been analysed and the main
component removed from the tubes is iron, only very minor traces of deposits have been
found. Therefore the focus of cleaning is on magnetite removal rather than deposit
removal.
This technical specification covers the minimum requirements for engineering, design,
execution, inspection and testing requirements for chemical boiler cleaning and waste
treatment and disposal for a single utility boiler at the MLNG complex at Bintulu.

1.2 Schedule
The work is scheduled to be executed in the last quarter of 2006, provide that there are no
operational constraints. It is anticipated that at least one boiler is cleaned in this period.
The Contractor is to provide an initial realistic schedule indicating the various process
steps. This schedule will be used in the evaluation of the proposals. In principle there is
no limitation in process time although the shorter schedule will be preferred.

1.3 Safety
HSE is considered and important and integral part of the work. The Contractor shall
comply with MLNG safety standards and procedures and shall fully comply with the
HSE system. The contractor shall provide all relevant MSDS of chemicals being used and
brief relevant personnel on the matter.

1.4 References
With the quotation, the Contractor shall provide detailed references to prove experience.
It is required to demonstrate experience for operational cleaning of at least three boilers,
which are comparable to MLNG’s type and capacity. Specifically experience with
adequate circulation of fluid in the water walled section of the boiler is to be
demonstrated. In addition the experience of the Contractor with the removal of thick
magnetite layers rather than scale deposits shall be demonstrated.

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1.5 Definitions
The Contractor is the party, which carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a project or operation of a
facility. The Client may undertake all or part of the duties of the Contractor.
The Client is the party, which initiates the project and ultimately pays for its design and
construction. The Client will generally specify the technical requirements. The Client
may also include an agent or consultant, authorised to act for, and on behalf of, the
Client.
The words shall and must indicate a mandatory requirement.
The word should is used to state that which is considered good and is recommended but
is not absolutely mandatory.
The word may is used to state that which is considered optional.
2 Scope of Work
The Contractor is requested to safely carry out the chemical cleaning of the boilers and
the subsequent treatment and disposal of the waste generated.
In total there are nine boilers to be cleaned. The boilers are arranged in three modules,
every module is identical and contains three boilers. As the boiler volume is relative
large, it is anticipated that only one boiler is to be cleaned at a time. This specification is
based on cleaning of one boiler with the option to clean the other eight boilers in a similar
way in time.
This specification is based on the Clients current preference for cleaning and waste
treatment. The Contractor may quote and propose deviations from this scope but will
clearly indicate the reason for the change. Technical clarification of the deviations can be
required and this information may be used for the final specification.
It shall be ensured that all components required for a proper performance of the chemical
cleaning and waste treatment activities are included in the terminal points of supply.
Individual parts and components not specifically or explicitly mentioned but necessary
for operational completeness shall be in the scope of the Contractor. The Contractor is
responsible for overall planning and engineering and safe execution of the chemical
cleaning and waste treatment within his specified terminal points of supply.
If the Contractor has any doubts as to the meaning or interpretation of any provisions of
any of the enquiry documents, he must seek clarification from the Client as soon as
possible. The Client’s interpretation shall be final. Any clarifications required by the
Contractor are to be submitted in writing to the Client.

2.1 Engineering and Design

The Contractor is requested to perform all associated engineering and design work
required to perform the task.
All rotation equipment provided shall be spared to ensure that mechanical failures during
the chemical cleaning and waste treatment activities will not jeopardise the integrity of
the boiler and associated piping, instrumentation etc.

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2.2 Chemical Boiler Cleaning
The economiser and the evaporator of each boiler are to be cleaned. The boiler have two
superheater coils installed, these coils do not require cleaning and need to be protected
during the cleaning process. The total volume of the economiser and evaporator,
including the water walls enclosing the radiant cell have been calculated at 133 m 3, this
figure is based on a half full top drum and contains a 5% margin.
The objective of the cleaning is to remove the existing magnetite layer. Some traces of
copper deposits have been found. Tube samples can be made available on request of the
Contractor to verify the composition of the deposits and/or the effectiveness of the
proposed cleaning chemicals.
The Contractor is requested to define the connection points on the boiler, the temporary
connections and piping work
The Contractor shall provide all auxiliary equipment as pumps, storage tanks, dosing
pumps, chemicals etc. required for the cleaning

2.3 Waste treatment

The Contractor is requested to include the treatment and disposal of all the waste
produced during the cleaning process. There is no storage capacity available in the
MLNG Complex and therefore temporary storage is to be provided. The MLNG
treatment systems are very small compared to the expected waste stream and can
therefore not be used Hence all required treatment systems including consumables are to
be provided by the Contractor.

2.4 Warranties
The Contractor is fully responsible for the good and safe design an operation of the
supplied scope of the cleaning and waste treatment and handling. It is part of Contractors
responsibility to carry out any changes to the design and operation of the scope to meet
the required performance and authority requirements. It is also part of Contractors
responsibility to seek approval from DOSH before any changes is made to the boiler for
chemical cleaning.

2.4.1 Boiler integrity

The cleaning shall remove the existing magnetite layer and may not cause any damage or
deteriorate other boiler materials in the cleaning circuit. The superheater shall be properly
protected, damage to these coils will not be acceptable. The Contractor shall demonstrate
that risk minimisation has been carried out to minimise the deterioration and/or damage
of surrounding and/or connection systems.
2.4.2 Chemical cleaning
After the chemical cleaning of the boiler, visual inspection as defined in chapter 3.3 shall
be carried out to verify the effectiveness of the cleaning. The cleaning shall be deemed
successful when there are no visual signs of remaining scale and deposits. In case of
dispute an independent laboratory shall determine the remaining deposits. A guarantee

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value for DWD of less than 15 mg/m 2 shall be used as an acceptable limit, the method to
be used shall be NACE standard TM0199-99.

2.4.3 Waste treatment

The Contractor shall guarantee that the discharge of wastewater and solid waste shall not
exceed environmental discharge limits as indicated in the regulations provided in the
appendix.

2.5 Location and Layout

In the appendix the layout of the boilers is indicated. Also some possible locations for the
waste treatment are indicated on overall layout drawings.
The Contractor is requested to indicate tie-in connections, temporary piping and
equipment locations on these drawings with the proposal.

2.6 Precedence of documents

In case of conflicts or contradictions between this specification and applicable laws and
regulations, the Contractor shall seek clarification with the Client. In general the more
stringent requirement shall apply and all necessary modifications shall be part of the
Contractors scope.

2.7 Alternative design

The proposal offered shall be fully in accordance with the requirements of this technical
specification and any reference documents listed herein. Additional alternative proposals
may be considered where the Contractor can demonstrate clear advantage over the
requirements specified herein. In all such cases the Contactor shall clearly identify and
motivate all deviations from this technical specification.
3 Design requirements
This chapter contains design requirement for specific elements of the scope.

3.1 Chemical boiler cleaning

3.1.1 Selection of the cleaning fluid
It is not preferred to use a strong acid for cleaning of the boiler. This is based on the
finding of micro cracks in grain boundary on tube internal surface. Hydrogen ions can
deeply penetrate the tube metal through the micro cracks and corrode the metal where the
inhibitor cannot reach. In order to address this concern, chemical cleaning using either
EDTA or a weak organic acid is considered.
The Contractor shall clearly indicate in the proposal all chemicals to be used.
3.1.2 Mechanical considerations
Only the use of hard piped and pressure tested temporary lines is acceptable. When hoses
are used, it shall be proven that the fluid contained shall not pose any risk to people,
equipment or environment in case of leakage.

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A contingency plan shall be in place to handle tube leaks during the chemical cleaning
stage. Loss of containment either from boiler tubes, pumps, lines or process equipment
shall be catered for and the Contractor shall issue procedures to allow effective
neutralisation of the fluid.

3.2 Waste Treatment

Waste treatment is considered an integral part of the scope. As the treatment systems
from MLNG are small and limited, there is no spare capacity to allow treatment of the
generated waste. As a consequence the waste is to be treated on site, the water is to be
treated to the discharge specification and the solid waste is to be disposed off.
3.2.1 Objectives
The chemical cleaning procedures and strategy shall aim at minimisation and reduction of
waste at source by careful selection of the chemicals used and the minimisation of water
consumption.
The waste treatment system should be integrated in the overall cleaning strategy to
minimise handling and storage of waste and to minimise cost, labour and equipment.
The waste treatment and disposal shall be environmentally sound while minimising the
health risks to personnel.
3.2.2 Collection of waste
Considering the relative large volume of the boilers and the need for flushing, large
amounts of waste are generated. As there is no excess storage capacity on site, the
Contractor is requested to include temporary storage capacity for the generated waste
stream.
On the overall layout drawings it is indicated what areas may be used to locate the
temporary storage.
It should be noted that the site is located in an area with high rain intensity and
prevention of rainwater mixing with the generated waste may be considered beneficial to
reduce treatment capacity.
3.2.3 Treatment of waste
The Contractor shall treat any waste to comply with discharge regulations. It is expected
that treated water is either (partly) recycled or discharged to sea via the existing outfall
system.
The solid waste generated is to be dewatered, compacted and packaged by the Contractor
to allow easy transportation. The waste shall be classified and labelled in accordance with
MLNG practices and requirements.
3.2.4 Disposal of waste
MLNG shall dispose the generated solid waste.

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3.3 Procedures
The procedures are listed in the appendix 3.3.1, 3.3.2, 3.3.3, 3.3.4 and are under the
responsibility of the Contractor, however this chapter describes the procedures preferred
by the Client. The Contractor may quote modified or alternative procedures but shall state
detailed descriptions and the reasons for modification. The final procedures require
Client’s approval.
Specific attention to draining and flushing procedures is to be given in the context of
water demand. As the water inventory is limited in the complex, the Contractor shall
make every effort to minimise the total water demand for the complete cleaning cycle.
3.3.1 Pre-Cleaning
Temporary piping external to the boiler is to be installed before the boiler is stopped. All
equipment is to be put in place and is to be connected to the maximum extend as to
reduce the total downtime of the boiler.
Pressure testing and equipment commissioning shall be maximised as much as possible
before the boiler is taken down.
The Contractor is requested to indicated any scaffolding requirements, scaffolding is to
be installed by MLNG.
The Contractor is requested to indicate the type and demand of water to be used during
the cleaning as to allow MLNG to determine the source and tie-in location for these
streams.
The Contractor should evaluated the benefit of manual water jetting rather than to flush in
order to reduce the water consumption and to enhance the removal of scale and debris.
When the boiler is stopped, isolated, hooked up and insulation removed, the Contractor
will jointly inspect the boiler with the Client, after this the boiler will be handed over to
the Contractor.
3.3.2 During cleaning
The boiler shall be cleaned by circulating the cleaning fluid rather than soaking.
Contractor is to demonstrate that sufficient circulation is reached in the water walls
enclosing the radiant section to ensure sufficient protection of the tubes to prevent
excessive bare metal loss.
The Contractor is requested to indicate the parameters to be monitored and the criteria for
starting or ending a process step based on these parameters.
All wastewater produced shall be collected in suitable temporary storage facilities
provided by the Contractor.
3.3.3 Post-Cleaning
When the boiler is cleaned and opened, the Contractor will jointly inspect the boiler with
the Client. When satisfactory, the boiler will be handed over to the Client.
3.3.4 Waste Treatment
No current requirements.

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3.4 Utilities
The Contractor is requested to provide utility demand and requirements with the
proposal. In principle all normal utilities are present and can be requested. However it is
requested to minimise water consumption as there are constraints on the supply.
4 Monitoring and inspection

4.1 Pre-Cleaning inspection

A full video-scope review has been executed by MLNG for boilers 1F-5110, 1F5120 and
1F5130 to serve as a baseline reference. The boiler to be cleaned will be jointly inspected
and the condition documented by MLNG inspection engineer and the Contractor to
establish the pre-cleaned condition.
The location and scope of inspection is listed below, any additional points may be
proposed by Contractor on the mechanical drawings and requires approval from Client.
The inspection scope shall consist of, but not be limited to:
 Thickness readings taken from the accessible boiler bank tubes (as these are the
thinner tubes approximately 3.2 mm. In the intermediate chamber and the skyway
chamber.
 Video scoping of the roof tube and boiler bank tubes from the steam drum, 20%
across the total spread. The rear wall tubes have previously been inspected and
any remaining deposits that were not previously removed can be used as a
template for inspection

4.2 Chemical analysis during Cleaning

The Contractor shall assign a chemist on site to monitor the chemical parameters of the
cleaning fluid as to monitor and manage the progress of the cleaning. The Contractor
shall supply special analysis equipment where needed. In case any assistance of Client’s
facilities is needed, this needs to be indicated during the proposal. Client will review the
availability of requested resources and will inform the Contractor accordingly.
The bare metal loss will be determined by weighing of metallic test pieces before and
after the chemical cleaning. The Contractor is to provide these test pieces, where the
metallurgy is comparable to the relevant boiler pressure parts materials. These test pieces
will be grinded, degreased, marked and dried and securely installed in a place where it is
completely in contact with the cleaning solution. After use the weight and surface
appearance shall be recorded and reported in the close out report. The result will be
reported as bare metal loss in mg/cm2.

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4.3 Waste treatment monitoring
Analysis of the treated wastewater is required to ensure compliance with discharge
regulations. Client’s facilities and standard procedures will be used to analyse the water
quality discharge parameters.

4.4 Post-Cleaning inspection

In a similar manner as to determine the pre-cleaning inspection, Contractor and Client
shall inspect and document the condition of the boiler after the cleaning has been
executed.
The location and scope of inspection points is to be proposed by Contractor on the
mechanical drawings and requires approval from Client.
5 Documentation Requirements
The Contractor shall provide all documentation and procedures required to enable the
operational cleaning and waste treatment of the boilers. All procedures shall require
MLNG approval.
The learning of cleaning of the first boiler is to be included in the procedures and
documentation, such that complete documentation is provided by the Contractor to allow
effective cleaning of successive boilers.
The Contractor shall maintain and issue a process log and close out report. The process
log will contain all events, significant findings, remarks and actions taken during the
chemical cleaning and will serve as a record of the cleaning process. The close out report
will contain the process log, the procedures and all inspection findings as to serve as
future reference for cleaning of all other boilers.
The close out report will contain all findings including photographs of the pre- and post-
inspection of the boiler.
The close out report will contain the results of all analyses done during the cleaning
process.

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6 Standards and Specifications

6.1 Pre-Cleaning Procedure

ACTION
BEFORE CHEMICAL CLEANING
PARTY
To remove all drum internals and take them out of the drum, otherwise it is
MLNG
not possible to hand flush all evaporator tubes.
To take off the safety valves and blank off flanges. MLNG
To plug off the saturated steam lines in the drum with special plugs. MLNG/
Plugs to be provided by Contractor Contractor
To isolate all instrument lines. MLNG
To install effluent piping as per chemical cleaner recommendation MLNG
To provide scaffolding for spading fuel, steam lines MLNG
To stop boiler & cooling down boiler MLNG
To spade fuel source & steam line MLNG
To provide fire fighting hoses MLNG
To supply test pipe (new) with flanges to chemical cleaner and measure
MLNG
thickness of test pipe.
To install temporary cleaning equipment. Contractor
To install and inspect electrical connections for pumps of the chemical
MLNG
cleaners
To gag the relief valves and open manholes MLNG
To double block and bleed sight glass. MLNG
To disconnect instrumentation from drum. MLNG
To install (calibrated) pressure gauge on superheater steam outlet. MLNG
To install temporary vent as per recommendation by chemical cleaner MLNG
To supply and install necessary N2 nozzles as per chemical cleaner
MLNG
recommendation
To connect all necessary utilities (fire fighting water, N2/instrument air). MLNG
To check if all safety equipment is on site (1st aid box, eyewash bottles). MLNG
To restrict admittance to chemical cleaning area. MLNG
INSPECTION
MLNG/
To do full inspection of boiler before cleaning
Contractor

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To take thickness readings from the accessible boiler bank tubes (as these
are the thinner tubes approximately 3.2 mm). In the intermediate chamber
and the skyway chamber.
To provides scaffolding and lighting MLNG
To do video scoping of the roof tube and boiler bank tubes from the steam
drum, 20% across the total spread. The rear wall tubes have previously been
MLNG
inspected and any remaining deposits that were not previously removed can
be used as a template for inspection.

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6.2 Cleaning Procedure
DURING CHEMICAL CLEANING ACTION
(Action party will be the Contractor for all actions unless specifically stated PARTY
otherwise) 
1. Contractor shall remove the oxide and scale of the 1st and 2nd evaporator, Contractor
sidewall watertubes and furnace watertubes and the steam/water drum.
2. Contractor shall provide passivation of the cleaned surfaces.  
3. Contractor shall provide detail procedure based on standard procedure provided
indicating type of chemical used, chemical concentration, velocity, duration and
temperature during cleaning.
STANDARD PROCEDURE IF STANDARD PROCEDURE IF USING
USING ACID AS CLEANING EDTA BASED CHEMICAL AS
AGENT CLEANING AGENT
(MULTIPLE SOLUTION) (SINGLE SOLUTION)
Procedure 1: Iron oxide and scale removal.

1. Fill boiler with hot water (boiler feed water) of good quality up to a level of
about 30 cm from the top of the steam drum.
2. Adjust temperature to about desired temperature.  

3. Establish water circulation.  

4. Inject corrosion inhibitor and
circulate for proper distribution. This
is followed by injection of acid
solution to remove boiler scale.
5. Circulate acid solution. Test acid
solution and effectiveness of
inhibitor.
6.  Drain spent acid solution and take  
iron content reading and repeat step 1
if necessary.
7. Neutralize acid solution.
4. Inject the corrosion inhibitor and circulate
for proper distribution. This is followed by
injection of EDTA based chemical to
remove the boiler scale.
 5. Circulate and take reading every half and  
hour of cleaning solution until iron content
analysed reached plateau.
 
   

8. Drain effluent.    
Procedure 2: Passivation
10.  Fill boiler with water of good quality up to a level of about 30 cm from the
top of the steam drum.

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11.  Adjust temperature if necessary 5. Adjust the pH of the solution with the pH  
by adding fresh water, after partly adjusting chemical and then dose
draining. passivating agent.
12.  Establish water circulation.  
13.  Dose Inhibitor and chemical for    
passivation.
14.  Adjust pH by pH adjusting    
chemical
15.  Circulate for a minimum of 2 hours.   
Procedure 3: Draining and Rinsing   
Drain the rinse solution under 2 bar nitrogen into waste holding tank  

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6.3 Post-Cleaning Procedure
POST CLEANING PROCEDURE ACTION
PARTY
To drain the boiler under N2 pressure. MLNG
To disconnect N2 and open the drum after for ventilation. MLNG
To perform gas test before first entry MLNG
To do visual inspection MLNG/
Contractor
INSPECTION  
To do full inspection of boiler after cleaning MLNG/
Contractor
To box up the boiler MLNG
If inspection shows satisfactory cleanliness of the boiler, proceed with leak test. MLNG

To start up the boiler immediately after leak test. MLNG

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6.4 Waste Treatment Procedure
WASTE TREATMENT
(Action party will be the Contractor for all actions unless specifically stated ACTION
PARTY
otherwise)
Drain effluent into temporary tank (dimensions shall be provided by contractor to
determine suitable location) Contractor
Check for pH if out of 5.5-9.5 range neutralize the effluent  
Let the insoluble iron settle to the bottom of the tank  
Separate the liquid  
Take sample of effluent from the tank and analyse for COD, pH and dissolved iron
as per point wastewater limit specified by MLNG.  
1. Waste water  
To be defined by Contractor

2. Solid waste
To be defined by Contractor

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6.5 Waste water discharge limits
Waste discharge will be in line with the current Environmental Quality Act 1974 (ACT
127) & subsidiary legislation. A short summary of the limits applied is listed below,
however the (schedule B) tables listed in the legislation will be defining.
Limit
pH 5.5 – 9.0
BOD <50 mg/L
COD <100 mg/L
TSS <100 mg/L
Iron <5 mg/L
Sulphide <0.5 mg/L

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6.6 Boiler Equipment Drawings

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6.7 Process Engineering Flow Schemes

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6.8 Layout and Arrangement drawings

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