INTERNAL CLEANING FOR PIPING PROCEDURE | METHOD STATEMENT

1. PURPOSE
2. SCOPE
3. APPLICABLE DOCUMENTS
4. RESPONSIBILITY
5. MANPOWER
6. TOOLS & EQUIPMENT
7. METHODS / PROCEDURES
8. QUALITY CONTROL
9. SAFETY PRECAUTION

INTERNAL CLEANING FOR PIPING PROCEDURE | METHOD STATEMENT

1.0 PURPOSE

1.1. This method statement shall provide minimum guidelines to carry out the internal cleaning for Piping activities, procedures for Plants and Refineries, In accordance with contract scope of work and project specification.

2.0 SCOPE

2.1. This Method Statement covers the procedure of internal cleaning for piping.

3.0 APPLICABLE DOCUMENTS

3.1. Project Specification and Standard

3.1.1. S-000-3160-001 Construction Specification for Piping Work at Prefabrication Shop

3.1.2. S-000-3160-002 Specification for Piping Construction Work in Field
3.1.3. S-000-3160-004 Piping Pressure Test Procedure
3.1.4. S-000-3160-006 Sample of Piping Work Punch Items
3.1.5. S-000-3160-007 Piping Internal cleaning Procedure
3.1.6. S-000-3160-009 Bolt Tensioning Procedure
3.1.7. S-000-3160-100 Piping Spool Drawing Preparation and Weld Joint Registration Procedure
3.1.8. S-000-3160-102 ISO/Spool Drawing and Data Handling Procedure

3.2. Saudi Aramco Standard

3.2.1. SAES-L-350 Construction of Plant Piping
3.2.2. SAEP-13  Project Environmental Impact Assessments
3.2.4. SAES-A-004  General Requirements for Pressure Testing
3.2.3. SAEP-302  Instruction on obtaining a waiver of a mandatory Saudi Aramco Engineering requirements
3.2.5. SAES-G-116  Cleanliness Standards for lube oil/seal oil Fluid Power System

3.2.6. SATIP Saudi Aramco Typical Inspection Plan
3.2.7. SAIC  Saudi Aramco Inspection Checklist

3.3. Industry Codes Standard

3.3.1. ASME B31.3 Process Piping
3.3.2. ASME B31.4 Pipeline Transportation System for Liquid Hydrocarbons and Other Liquid

3.4. Applicable SATIP/SAIC/SATR

3.4.1. SAIC-L-2017 Piping / Equipment Internal Cleaning Inspection
3.4.2. SATR-A-2007 Pre-Test Punch List Form
3.4.3. SATR-A-2008 Internal Cleanliness Report (Piping Systems & Equip)

3.5. Standard Drawing / Latest Revision Documents

3.5.1. Piping and Instrument Drawing (P&ID)
3.5.2. Piping General Arrangement Drawing
3.5.3. Pipe Support Detail Drawing
3.5.4. Isometric Drawing (Full Isometric)
3.5.5. Spool Drawing (Spool Generated)

4.0 RESPONSIBILITY

4.1. Construction Manager responsible for implementing HSE shall study, analyze and schedule all construction activities with his department to include manpower and equipment line up as well as other possible resources required for the successful implementation of the construction work activities. He shall study all aspects of work procedure as per JGC/DEC Technical Scope of Work.
4.2. Piping Superintendent shall study and review all necessary documents for the installation works to include, technical scope of work, specification, bill of quantities, planned milestone dates and construction procedure in support to his supervisor. He shall monitor the availability of materials in accordance with construction schedules. He shall directly report to construction Manager.

4.3. Piping Supervisor shall directly report to the Piping Superintendent and be responsible for the implementation and control of all site activities per Technical Scope of Work and latest approved construction drawings. He shall coordinate with other disciplines to visualize possible conflicts in the drawing as well as in the schedule to provide other options to prevent unnecessary delays and obstructions.
4.4. QC Inspector shall be responsible for inspection and monitoring the work and ensure that the work is performed and properly documented in accordance with Project requirements.

4.5. Safety Supervisor shall be responsible in monitoring safety aspects and ensuring that the work is done in accordance with Safety Standard Procedure. He shall discuss to the Supervisor’s the characteristics of related materials and status of work area giving reminders as an additional point to work safely.

5.0 MANPOWER
5.1. The Piping Superintendent shall control the overall activity of Piping Aboveground Installation Works. The basic manpower under him shall consist of but not limited to the following:

5.1.1. Piping Supervisor
5.1.2. Piping Foreman
5.1.3. Pipe fitters
5.1.4. Crane Operator (ARAMCO Certified)
5.1.5. Riggers (ARAMCO Certified)
5.1.6. Permit Receiver
5.1.7. Helpers

5.2. Safety Engineer/Officer

6.0 TOOLS AND EQUIPMENT

6.1. Tools and equipment needed should be in good condition and must be checked by Piping Supervisor / Safety Officer prior to use in the construction area. These include but are not limited to:

6.1.1. Tools, Jigs, Instruments& Equipments
6.1.1.1 Air Compressor
6.1.1.2 Water tank
6.1.1.3 Air Receiver tank or manifold
6.1.1.4 Pressure Hose
6.1.1.5 Wrenches
6.1.1.6 Mobile Crane
6.1.1.7 Rags

7.0 INTERNAL CLEANING FOR PIPING PROCEDURE | METHOD STATEMENT

7.1. General Instruction

7.1.1. Pipe internal cleanliness and end protection shall be maintained during all phases of construction activities including material receiving and storage at warehouse, transportation, piping fabrication, erection, and so on. All concerned persons for piping work shall be responsible for maintaining pipe internal cleanliness.

7.1.2. Pipe internal cleaning shall be carried out in accordance with piping construction cleaning work flow shown in Attachment-1 of S-000-3160007. Internal cleaning method shall be defined by piping service/material/size.
7.1.3. The cleaning and flushing method related to pre-commissioning activities such as chemical cleaning, steam blowing, lube oil flushing and lay-up method is defined by pre-commissioning specification.

7.2. Cleaning during pre-fabrication and storage (by others)

7.2.1. Upon receiving any material at warehouse, all pipes and pipe fittings shall have end protection.
7.2.2. All piping components should be visually inspected for internal cleanliness (no presence of loose particle/flakes or debris) prior to welding to adjacent component.
7.2.3. Upon completion at shop, fabricated spools shall be cleaned using an air compressor, if cleanliness is not acceptable by the QC inspector of client.

7.2.4. After visual inspection by QC inspector for internal cleanliness at shop, provide end protection for all open ends. It should be maintained during sandblasting, painting, storage & even in transportation.
7.2.5. End protection should not be removed by unauthorized personnel.
7.2.6. In case of internal lining spool, same procedure will be applied prior to and after lining work.

7.3. Cleaning during pipe installation (field welding)

7.3.1. Prior to pipe installation at site, all pipe spools shall be visually checked for internal cleanliness by QC inspectors. Using air compressor, pipe spools or pipe lines shall be cleaned by air blowing.
7.3.2. During assembly and erection, ensure that no foreign materials such as welding consumables, lumber, gloves etc. are left inside any piping component and spools.
7.3.3. During spool fit-up or flange connecting, internal cleanliness shall be officially inspected by both client and SAACO QC inpector as hold point in accordance with SATIP-L-350-01.
7.3.4. All pre-fabricated pipe spools shall be visually inspected in accordance to SAIC-L-2017, and all foreign material shall be removed from the inside. SAACO QC inspector shall prepare SATR-A-2008 and sign off on pipe surface on each pipe spool and mark up inspection date plus name of inspector.
7.3.5. After inspection, the piping end covers shall be returned and maintained until making the joint to the adjacent spool or components.
7.3.6. After welding of field joints, if any back welding or welding repair is required for RFI shall be raised to check internal cleanliness and ensure removed of debris after the completion.

7.3.7. At interface points, client and SAACO shall ensure that cleanliness check shall be carried out by other contractor as well prior to tie-in.
7.3.8. End cover protection shall be checked by client and SAACO QC inspector at the end of daily work and inspected by company if required.

7.4. Cleaning of Pipe system before/after the pressure test

7.4.1. All piping such as Instrument air, Nitrogen and Lube oil shall not be flushed with water. Internal cleaning shall not be flushed with water. Internal of these should be define by piping service/material/size.
7.4.2. After piping installation is complete, prior to pressure test, internal cleaning by water drain out shall be conducted until internal cleaning of piping system is acceptable. If the first drain out is not successful, another drain out will be repeated until accepted. Internal cleaning shall be conducted for each test package.
7.4.3. After pressure test is completed, all lines shall be thoroughly cleared of dirt, loose scale and debris at flange connections such as test limit or subsystem limit and reinstate in-line items such as control valve.
7.4.4. For in-line valves, removal of valve cavities is done by blowing out the water inside using high pressure air until water is removed. If moisture is still present apply approved corrosion-resistant lubricants as per valve manufacture instruction. Verify water removal effectiveness randomly(next day)

7.4.5. After drain out of test fluid from piping systems require to dry lay-up

7.4.5.1 All stainless steel lines
7.4.5.2 Instrument air system (refer to SAES-A-007 para.7.9 & SAES-J901 Sec. 5)

7.4.5.3 Nitrogen system

7.4.5.4 The water to be used for cleaning shall be treated water or raw water. Fire water may be used where process water is not available. Sea water is not acceptable.
7.4.5.5 When cleaning stainless steel line, the chloride ion content shall be less than 50mg/L. After cleaning, the piping systems shall be completely drained, and dry-layup shall be applied.

7.4.5.6 In case of piping system requires pneumatic test, air blowing using by dry air shall be carried out in order to ensure the cleanliness of piping system prior to pneumatic test.
7.4.5.7 No lines should be cleaned through vessels, all vessel nozzles shall be blinded prior to cleaning.

8.0 QUALITY CONTROL

8.1. QC personnel shall be assigned to ensure the quality control and assurance requirement of the project.
8.2. QC Inspector shall coordinate with other inspector to conduct inspection as required in SATIP.
8.3. QC Inspector shall be responsible to conduct all required inspections/documentations and to ensure that all applicable requirements, codes, and standards are complied with.

8.4. Contractor has to utilize the applicable SAIC for every activity.
8.5. Calibration shall be done as required for all machines and tools going to be used in the work in accordance with schedule Q.

9.0 SAFETY PRECAUTION

Obtain the approval of the work permit from the concerned JGC/DEC Representative before starting any work.
9.1. Watchman shall be available at working area to avoid the entry of unauthorized  personnel and incase mechanical cleaning by manual of pipe size 24” and larger.
9.2. All electrical tools shall be checked and color-coded.
9.3. Continuous monitoring and inspection shall be done by Piping supervisor and Safety supervisor and it shall be continuously implemented to detect and correct unsafe practices while performing the work activities.
9.4. Provide warning sign and sufficient barricade on working area and only assigned personnel will be allowed in the area.
9.5. Safety harness with double lanyards shall be used all the time when working at elevated temporary platforms 1.8 meters high and above.
9.6. Man lift users shall be trained and certified to operate and use the equipment.
9.7. Piping Supervisor shall monitor the work activities to help and to protect all assigned workers against exposure to safety hazards. He shall ensure that Personal Protective Equipment (PPE’s) are supplied and used and comply with applicable standards. HSE will assist in giving advice.

9.8. All rigging equipment shall be in good condition and possess a valid certification from authorized certifying and inspection department inspection and color coding shall be done in accordance will inspection guideline.
9.9. Toolbox meeting shall be conducted by Piping Supervisor daily so as work activities will be properly coordinated to all concerned and all safety infractions will be acted immediately.
9.10. All necessary personal protective equipment (PPE) shall be provided and to be worn at all times.
9.11. Housekeeping shall be maintained and working area shall be kept in a clean and tidy manner.
9.12. Job Safety Analysis Record (JSAR) of this method statement shall be disseminated and explained to workers prior to start of work.

10.0 ATTACHMENT

10.1. Job Safety Analysis