DOCUMENT NO. REV.

PT Caltex Pacific Indonesia PP-PI-PP-001 1

DATE : AUG 31, 2001 SHEET : 1 OF 12

PROCEDURE PREPARED BY Nurhasan NHS

CHECKED BY Nurhasan NHS
APPROVED BY Shawn SPD

PIPING CLEANING PROCEDURE

PT. CALTEX PACIFIC INDONESIA

REV DATE PAGES DESCRIPTION PREPD CHKD APPD

0 8/31/01 ALL ISSUED FOR IMPLEMENTATION NHS NHS SPD

1 15/5/02 ALL CPI SPEC REVIEW TEAM (TOTO, TRB, FIB, ANDR) Team Team Team
 TABLE OF CONTENT

1. GENERAL .......................................................................................................................... 2

1.1. Scope of Works.......................................................................................................... 2

1.2. References................................................................................................................. 2
1.3. Terminology.............................................................................................................. 2
1.4. Definition.................................................................................................................. 3

2. QUALITY ASSURANCE.................................................................................................... 4

2.1. General..................................................................................................................... 4
2.2. Qualifications............................................................................................................ 5
2.3. Other Cleaning Procedures........................................................................................ 5

3. SAFETY AND SANITATION............................................................................................. 5

3.1. Observance of Laws and Regulations and Prevention of Accident................................. 5

3.2. Personnel in Charge for Safety and Sanitation............................................................. 5
3.3. Observance of Rules .................................................................................................. 5
3.4. Measures for Safety ................................................................................................... 6
3.5. Governmental Procedures.......................................................................................... 6
3.6. Participation in Council for Safety and Sanitation. ...................................................... 6

4. EXECUTION ...................................................................................................................... 6

4.1. General..................................................................................................................... 6
4.2. Cleaning Procedures ................................................................................................. 7
4.3. Identification of Cleaned Item................................................................................... 11

5. ATTACHMENTS.............................................................................................................. 11

OPTIONAL ATTACHEMENTS FOR THIS SPECIFICATION:

ADDENDUM 1: Project Specific Clarifications & Requirements
PT. CALTEX PACIFIC INDONESIA Piping Cleaning Procedure
PP-PI-PP-001 Rev. 1

1. GENERAL

1.1. Scope of Works

This procedure prescribes the requirements for internal cleaning procedures of piping
system, including the following :
?? Cleaning CONTRACTOR requirements
?? Precleaned material requirements
?? Field flushing and cleaning requirements
Not included in this procedure are the flushing, cleaning, passivation and sterilization
sanitary piping systems.

1.2. References
The publications listed below form part of this procedure. Each publication shall be the
latest revision and addendum in effect on the date this specification is issued for
construction unless noted otherwise. Except as modified by the requirements specified
herein or the details of the drawings, Work included in this procedure shall conform to the
applicable provisions of these publications.
1.2.1. ASME (American Society of Mechanical Engineers)
1.2.1.1 B31.1 Power Piping System
1.2.1.2 B31.3 Chemical Plant and Petroleum Refinery Piping
1.2.1.3 B31.4 Liquid Transportation System for Hydrocarbon, LPC,
Anhydrous Ammonia and Alcohols
1.2.2. AWWA (American Water Works Association)
1.2.2.1 C651 Disinfecting Water Mains
1.2.3. CGA (Compressed Gas Association, Inc.)
1.2.3.1 G4.1 Cleaning Equipment For Oxygen Service
1.2.4. Chlorine Institute
1.2.4.1 Pamphlet 6. Piping System For Dry Chloride
1.2.5. NACE (National Association of Corrosion Engineers)
1.2.5.1 NACE No. 2 Blast Cleaning Near White
1.2.6. SSPC (Steel Structures Painting Council)
1.2.6.1 SSPC-SP-10 Near White Metal Blast Cleaning
1.2.6.2 SSPC-VIS-1 Pictorial Surface Preparation Standards For Painting
Steel Surfaces

1.3. Terminology
In this specification, the following words and terms shall have the meanings hereby
assigned to them, unless noted otherwise.

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1.3.1. COMPANY
Refers to PT. CALTEX PACIFIC INDONESIA, as the ultimate user and owner,
the authorized representative of COMPANY or COMPANY third party
inspection.
1.3.2. CONTRACTOR
Refers to company selected by COMPANY, which may be responsible for the
detailed engineering design, material and equipment procurement, and
construction as specified by Contract, Scope of Work, or Work order.
1.3.3. Vendor
Refers to the company selected by COMPANY or CONTRACTOR, which is
responsible for the purchase agreement or purchase order of the goods/services
specified in this specification
Note:
?? For EPC (Engineering, Procurement and Construction) project purposes:
The terminology shall have the meanings as above.
?? For Direct Procurement by COMPANY purposes:
Vendor shall also be responsible as CONTRACTOR.

1.4. Conflicting Requirement

1.4.1. In case of conflict between this Specification and its associated Specifications
and the above Codes and Standards, the Vendor shall bring the matter to the
COMPANYs attention for resolution and approval in writing. However, the
most stringent requirement shall be applied.
1.4.2. Should conflicts exist between this specification and other documents, the
following order of precedence shall govern:
?? Scope of Work
?? Data Sheets.
?? This Specification
?? Other COMPANY Specifications
?? Other Referenced Publications
?? Approved for Construction Drawings
?? Vendors Code

1.5. Definition
1.5.1. Blowout
Blowing of a vapor such as air, nitrogen, or steam at sufficient velocity to remove
all foreign matter from piping system.
1.5.2. Chemical Cleaning
Cleaning which involves the use of chemical agents to dissolve and remove the
contaminants.
1.5.3. Cleaning

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The process of removing deposits, scales, corrosion products, or other foulants

which restrict flow, impair heat transfer, or contaminate product being conveyed
in the piping system.
1.5.4. Degree of Cleaning
A detailed description of exactly to what extent contaminants shall be removed
from the piping system.
1.5.5. Disinfecting
Removal of contaminants harmful to human health if contained in potable water.
1.5.6. Field Cleaning
Any cleaning procedure performed on piping system after field installation.
1.5.7. Flushing
Circulating flushing fluid at sufficient velocity to remove all foreign matter.

1.5.8. Mechanical Cleaning

Cleaning accomplished by hand, power tool, or abrasive cleaning.
1.5.9. Neutralization
Reaction between hydrogen ion from an acid and hydroxyl ion from a base to
produce pH neutral water.
1.5.10. Paint Stripping
Removal of mill applied varnishes or other paint.
1.5.11. Passivation
Formation of a protective oxide film by pickling or other processes for resistance
to corrosive attacks on the material.
1.5.12. Pickling
Soaking or flushing with an acid solution to remove rust, mill scale, or to form an
oxide film on the internal or external surfaces.
1.5.13. Precleaned Products
Material that have been chemically cleaned, mechanically cleaned, paint stripped,
disinfected, passivated, rinsed, pickled, or protected from corrosion by shop
fabricator or manufacturer before installation.
1.5.14. Rinsing
Removal of residual cleaning agents by washing out with fresh or de-ionized
water.

2. QUALITY ASSURANCE

2.1. General

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2.1.1. Cleaning Procedures

2.1.1.1 All cleaning procedures will be specified with a degree of cleaning
required and an inspection procedure to ensure the degree of cleanliness
has been achieved.
2.1.1.2 For chemically and mechanically cleaned surfaces, an inspection record
will be filled out by the cleaning CONTRACTOR. Refer to
Attachment L.
2.1.2. Precleaned Material
Upon delivery of precleaned material to the jobsite, packaging procedures will be
done in accordance with Attachments B of this procedure, Cleaning Procedures
Before Installation .

2.2. Qualifications
2.2.1. Cleaning procedures will be performed by a reputable cleaning CONTRACTOR
approved by COMPANY.
2.2.2. Utilize personnel who are trained in the cleaning, protection techniques and
safety rules.

2.3. Other Cleaning Procedures

Alternative cleaning procedures not specified in this document may be prepared and
submitted to COMPANY for approval.
?? Steps of the cleaning or passivating procedure.
?? Chemicals and equipment to be used.
?? Required time for each step.
?? Process temperatures

3. SAFETY AND SANITATION

3.1. Observance of Laws and Regulations and Prevention of Accident

CONTRACTOR shall observe the applicable laws and regulations for safety and sanitation
concerning the following items, during the works and be fully responsible as the enterprise.
?? Laborers safety and sanitation.
?? Prevention of environmental pollution
?? Handling of dangerous substances
CONTRACTOR shall be taken utmost care for safety and sanitation at site to prevent any
possible accident, providing necessary protective facilities and preventive devices.

3.2. Personnel in Charge for Safety and Sanitation

CONTRACTOR shall assign the personal in charge of safety and sanitation at site and let
him manage the safety and sanitation affairs.

3.3. Observance of Rules

CONTRACTOR shall obey the safety and sanitation rules prescribed by COMPANY.

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3.4. Measures for Safety

CONTRACTOR shall take utmost care not to give any damage to the plant personals and
equipment including third person during the works. Necessary additional measures for
safety shall be taken, when COMPANY requires to do so.

3.5. Governmental Procedures

CONTRACTOR should take governmental procedures concerning the safety and sanitation
when on his duty. In this case, these procedures shall be taken after getting COMPANY
personnels approval.

3.6. Participation in Council for Safety and Sanitation.

CONTRACTOR shall participate in the council for safety and sanitation which will be
established at the site and cooperate in prevention of accident.

4. EXECUTION

4.1. General
This section includes the requirements and procedures for field cleaning and protection of
all process and utility piping after installatio n and before commissioning.
4.1.1. Field Cleaning Requirements
4.1.1.1 Completely remove weld slag, flux, debris, grease, oil and any foreign
matter on the surfaces of field fabricated items.
4.1.1.2 Re-clean all pre-cleaned surfaces as specified in accordance with this
procedure.
4.1.1.3 Protect cleaned surfaces in accordance with this procedure.
4.1.2. General Preparation for Cleaning
4.1.2.1 All cleaning will be done after pressure testing.
4.1.2.2 Schedule field cleaning as close to the commissioning of the equipment
as possible.
4.1.2.3 Protect threaded connections, flange faces and valves to prevent damage
by abrasive.
4.1.2.4 Block off, disconnect, or remove the following items from the piping
system to be cleaned :
?? Filters and screens
?? Exposed instruments, gages and cylinders
?? Orifice plates
?? Oil reservoirs
?? Relief valves, control valves and plug cooks
?? Expansion joints
?? Reciprocating compressor pulsation bottles
?? Exchangers

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?? Material that may become damaged by cleaning solutions or

procedures such as items with organic seals.
4.1.2.5 Temporary strainers shall be installed at the time of installation of piping.
After completion of cleaning of the pipe by the method selected
according to Attachment A of this procedure for each part of the piping
line.
Position of installing temporary strainer shall be as follows :
?? Pump suction side in the piping.
?? Upstream of control valve in the piping, if necessary.
?? Other position, as required.
4.1.2.6 Do not allow aluminum, copper, galvanized steel, magnesium or zinc
surfaces to come in contact with solutions having a pH of less than 4.0
or a pH of more than 10.
4.1.2.7 Do not contact piping containing austenitic material with the following
materials :
?? Acid solutions containing halides or chemicals such as hydrochloric
acid. Alternative solvents are acceptable provided the diluted
chloride content does not exceed 25 ppm (25 cm/m).
?? Caustic soda (NaOH) solutions.
?? If degreasing is required, sodium carbonate and trisodium phosphate
solutions may be used, provided the chloride content does not exceed
100 ppm 100 cm/m.
?? Rinse water that is not clean or exceeds 100 ppm (100 cm/m)
chloride.
4.1.2.8 Do not introduce chemical solution into piping unless high point vents
and low points drains (supplied by piping CONTRACTOR) are
available to ensure proper filling and complete removal of solutions.
4.1.2.9 Do not apply heat directly to piping containing acid solutions.

4.2. Cleaning Procedures

4.2.1. General
?? Each service utilized in the process and utility piping is listed in the service
index found in Attachment A
?? A particular cleaning procedure is assigned for all piping systems whic h
utilize this service.
?? General cleaning procedure for piping system will be described as follow.
Specific requirement for each type of cleaning procedures as per list on
Section 5 will be described on Attachment B to Attachment K of this
procedure.
?? All disposal methods of cleaning fluids shall be approved by COMPANY
prior to cleaning.

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4.2.2. Water Flushing

4.2.2.1 Water for Flushing
As a rule, pure water, drinking water, steam condensate or industrial
water shall be used. Seawater shall not be used. If using of seawater is
unavoidable, washing with fresh water shall be carried out at least once
or more to prevent corrosion after using of sea water. In any least once or
more to prevent corrosion after using of sea water. In any case, seawater
shall not be used for cleaning of austenitic stainless steel.
4.2.2.2 Degree of Water Flushing
Flushing shall be performed till the water becomes free from foreign
matter, scale, etc. This shall be decided by observing turbidity of water
taken out (into beaker or cup).
4.2.2.3 Procedure for Water Flushing
4.2.2.3.a. Water flushing shall be performed in the method of running by
pressurized water and hammering, or rapid draining water
filled.Hammering shall, however, not be performed for
austenitic stainless steel pipe, copper pipe and aluminum
pipe.
4.2.2.3.b. Partial water flushing shall be performed for each assembled
piping, and overall water flushing shall be performed for
whole of the piping system connected to the apparatus. For
those parts, where water flushing is inapplicable, air flushing
shall be employed.
4.2.2.3.c Where instruments are included in the piping system to be
flushed, the instruments shall, as a rule, be removed and spool
pipe (distance piece) shall be inserted of the instrument. When
flushing is carried out in the condit ion with control valve
connected, the procedure shall be as follows.
??Disconnect the companion flange at upstream side of the
control valve and cover opening of the control valve.
??Flush the piping of upstream side.
??Connect the control valve with piping of upstream side
after completion of the flushing.
??Close the control valve, open bypass valve, and then flush
the piping of downstream side. Where bypass valve is not
installed, temporary strainer shall be inserted.
4.2.2.3.d Temporary strainer with 80 mesh x #38 shall be used.
Flushing shall be performed until no foreign matter comes to
the temporary strainer.
4.2.2.4 Drying after Flushing
After flushing, drying of inside of pipe shall be carried out with
compressed air or by natural drying. Drying with superheated steam shall
be carried out only if so instructed by COMPANY.

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4.2.3. Air Flushing

4.2.3.1 Degree of Flushing
Air flushing shall be performed till there remains no scale in the piping,
COMPANY personnel in charge shall make judgement of whether the
result of the flushing is satisfactory or not.
4.2.3.2 Procedure of Air Flushing
?? Air flushing shall be performed in the method of blowing pressurized
oil (vapor) - free air and hammering. If preparing of pressurized oil
(vapor) - free air is difficult, pressurized non-oil-free air may be used
under the permission by COMPANY, except for piping of oxygen
system. Hammering shall, however, not be performed for austenitic
stainless steel pipe, copper pipe and aluminum pipe.
?? Partial air flushing shall be performed for each assembled piping.
?? Overall air flushing shall, as a rule, be performed for each piping
from equipment to adjacent equipment. Whether the equipment is to
be included in the piping or not shall be determined, considering the
shape, internal construction and packing of the equip ment and also
according to the overall flushing plan.
?? Treatment of instruments and handling of temporary strainers shall
conform to the requirements specified in Section 4.2.2.3.c and
4.2.2.3.d.
4.2.4. Steam Flushing
4.2.4.1 Execution of Steam Flushing
Steam flushing shall be performed after completion of pressure test and
insulation work.
4.2.4.2 Preparation for Steam Flushing
4.2.4.2.a. Following preparation work shall be carried out according to
planning of the steam flushing
??Temporary piping work
??Countermeasure for safety
??Coordination procedure and assignment of man concerned
??Prevention of public nuisance
??Cooperation with operator
??Judgement criteria of flushing
??Treatment of piping accessories
??Setting of spring hanger, etc.
??Confirmation of support (slide or fix)
4.2.4.2.b. Support shall be attached to exhaust piping to prevent accident
caused by the reaction force during flushing.
4.2.4.3 Procedure of Steam Flushing
4.2.4.3.a. Procedure of steam flushing shall be in accordance with
Flushing plan. In general, following items are required.

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??Removal or opening of steam trap, vent and drain

??Warming up for piping (to be blown gradually with
cooperation by operator)
??Checking for expansion joints, spring hangers, etc. caused
by thermal expansion.
??Steam flushing temperature (Flushing shall be performed at
the temperature near to the operating temperature
considering operating condition of boiler)
??Cooling down (To remove the scale effectively by
temperature change, it is required to perform flushing and
cooling cyclically, having temperature difference as large
as possible between flushing and cooling period)
4.2.4.4 Judgement Criteria of Steam Flushing
4.2.4.4.a. Judgement on result of steam flushing shall generally be done
by checking color or quantity of the foreign material present
in the drain sampled.
4.2.4.4.b. If necessary, especially for suction line of steam turbine, etc.
result of flushing shall be judged by observing whether scratch
was produced or not on the test piece made of iron, copper or
brass.
4.2.5. Acid Cleaning
4.2.5.1 Piping to be Acid-cleaned
Acid cleaning shall be applied to oil piping system for metallic packing,
cylinder, etc. of rotating machinery, unless otherwise specified in
Specific Job Requirements.
4.2.5.2 Procedure of Acid Cleaning
Procedure of Acid Cleaning of piping shall be as follow.
4.2.5.2.a. Prior to acid cleaning, degreasing with alkaline solution shall
be done to remove oil on pipe inside.
4.2.5.2.b. As a rule, 6% hydrochloric acid solution or 10% sulfuric acid
solution at temperature of 30 - 40C shall be used. The piping
shall be pickled in the solution for 1 - 6 hours.
4.2.5.2.c. After pickling, the piping shall be washed with water flow for
1 hour or more or by filling the pipe with water 3 times or
more (Total holding time with water filled in shall be 6 hours
or more)
4.2.5.2.d. After washing with water, 1% caustic and 0.5% sodium nitrite
at temperature of 80F shall be used for neutralization. The
piping shall be neutralized in the solution for at least 2 hours.
4.2.5.2.e. Then, inside of piping shall be washed with water flow or by
dipping in water. Outside of pipe shall be washed with water
too.

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4.2.5.2.f. The piping shall be well dried with superheated steam or dry
air and then the inside of oil piping system shall be given a
coat of oil of the same quality as the specified service oil for
the oil piping.
4.2.5.2.g After completion of cleaning, it shall be checked that no
foreign matter is present on temporary strainer screen of 100
mesh x #42 or, if necessary, of 200 mesh x #47

4.3. Identification of Cleaned Item

?? Provide and install metal tag for cleaned items at all valves and connections to avoid
subsequent contamination and to identify potential hazard. Tag will read as follows:
WARNING:
INTERNALLY CLEANED AND PRESSURIZED;
KEEP SEALED UNTIL COMMISSIONING.
(DATE)
?? Tag will be yellow with black letters and at least 8 inches (200 mm) by 10 inches (250
mm), secured with 14 gage stainless steel wire.

5. ATTACHMENTS
Attachment : A
Service Index With Assigned Cleaning Procedures
Attachment : B
Cleaning Procedures Before Installation : Cleaning Procedure No. 1, Near white Metal Blast
Cleaning Of Internal Carbon Steel Piping
Attachment : C
Cleaning Procedures After Installation : Cleaning Procedure No. 2, Cleaning And Water
Flushing
Attachment : D
Cleaning Procedures After Installation : Cleaning Procedure No. 3, Air, Nitrogen And Steam
Cleaning
Attachment : E
Cleaning Procedures After Installation : Cleaning Procedure No.4 , Water Flushing And
Disaffection.
Attachment : F
Cleaning Procedures After Installation : Cleaning Procedure No. 5, Water Flush of Precleaned
Systems
Attachment : H
Cleaning Procedures After Installation : Cleaning Procedure No. 7, Alkaline Detergent Wash
For Oil And Grease Removal Carbon Steel Pipe Only
Attachment : I
Cleaning Procedures After Installation : Cleaning Procedure No. 8, Alkaline Detergent Wash
For Oil And Grease Removal Stainless Steel Pipe Only

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Attachment : J
Cleaning Procedures After Installation : Cleaning Procedure No. 9, Solvent Cleaning For Rust
And Mill Scale Removal (Pickling) Carbon Steel Pipe Only
Attachment : K
Cleaning Procedures After Installation : Cleaning Procedure No. 10, Post-Cleaning
Passivation Carbon Steel Pipe Only.
Attachment : L
Piping Engineering Form : 000.250.F0401 : Pipe Cleaning Inspection Record.

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