NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES C.57

CHEMICAL CLEANING OF NEW PIPING

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

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INDEX

SEC TITLE PAGE

1.0 SCOPE OF SPECIFICATION 3

1.1 Introduction 3
1.2 Scope of Supply 3
1.3 Other NOC Specifications 4

2.0 DEFINITIONS 4

2.1 Technical 4
2.2 Contractual 4

3.0 CODES AND STANDARDS 5

4.0 MATERIALS 5

4.1 Introduction 5
4.2 Chemical Solution Composition 5
4.3 Volume of Solutions Required 6
4.4 Equipment Requirements 7

5.0 PREPARATION AND SAFETY 7

6.0 CLEANING PROCEDURE 8

6.1 General Details 8

6.2 Approval of Cleaning Procedures 8

7.0 TREATMENT RECORDS 9

8.0 ALKALINE DETERGENT DEGREASING WASH 9

9.0 ACID SOLVENT WASH 10

9.1 Carbon Steel Piping Only 10

9.2 Stainless Steel Piping Only 11

10.0 PASSIVATION OF CARBON STEEL 11

11.0 ABRASIVE BLAST CLEANING 12

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1.0 SCOPE OF THE SPECIFICATION

1.1 Introduction

1.1.1 This specification covers the minimum requirements for the chemical cleaning, rinsing and passivating of
the interior of field or shop fabricated process and utility pipework ONLY where specified in drawings or
equipment specifications, e.g. compressors.

1.1.2 This specification applies to equipment for refineries, onshore oil and gas installations and processing
facilities including items purchased either directly or as a part of a package.

1.1.3 The Vendor/Contractor shall comply fully with the requirements laid down in this specification. Any
exception must first be authorised in writing by the Owner.

1.1.4 In the event of any conflict in this specification, the Data Sheets or any of the applicable Codes and
Standards, the Vendor/Contractor shall inform the Owner in writing and receive written clarification before
proceeding with the work.

1.1.5 This General Engineering Specification forms part of the Purchase Order/Contract.

1.2 Scope of Supply

The Vendor/Contractor shall be responsible for obtaining all necessary approvals, permits, licences and
certificates required by the Vendor/Contractor, Owner, Statutory Authority, Local Ordinances or other
Regulatory Authorities covering the Scope of Work.

The Vendor/Contractor shall supply all labour, plant, equipment, chemicals, materials (including their
disposal) and additional safety facilities, but excluding any items, specified separately and in writing as
being supplied by the Owner, necessary to execute the scope of work in accordance with the drawings and
specifications.

The Vendor/Contractor shall be required to supply electricity generating facilities to provide electrical
heating and pumping facilities for the solutions used, if sufficient electrical facilities are not available on
site.

The internal chemical cleaning processes detailed in this specification are generally performed in
conjunction with the pressure testing of piping and plant (hydrotesting) and shall therefore be included in
the full program of pressure testing to minimise the need to duplicate treatment stages.

WARNING Once started the complete process of chemical cleaning shall be carried out. At no time shall
the piping be left for extended times with any acid or acid residues beyond the time needed for the
treatment. All chemical residues must be thoroughly flushed and neutralised from the system.

Before the start of any cleaning process the Vendor/Contractor shall submit to the Owner a written proposal
and receive a written approval of how used or spent chemical solutions from the cleaning process plus any
heavily contaminated rinse/flushing water shall be disposed of, in a manner that satisfies the Owner, and
any statutory waste disposal requirements and regulations.

The Vendor/Contractor shall be totally responsible for the disposal of all chemical waste including any
chemicals supplied by the Owner.
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1.3 Other NOC Specifications

The following NOC General Engineering Specifications are an integral part of this specification and any
exception shall be approved in writing by the Owner.

GES C.58 Chemical Cleaning of Steam Equipment and Piping Systems

GES H.09 Emergency Showers and Eyewash Facilities

GES X.01 Surface Preparation and Painting Application

2.0 DEFINITIONS

2.1 Technical

Pipework/pipework system or pipework spool pieces

All pipework to be cleaned.

Passivation

To produce a very thin protective film on the pipe surface to deter rusting.

Inhibitor

A chemical to be added to the acid solvent wash to minimise attack upon bare carbon steel.

Hygroscopic

A chemical that absorbs water from the surrounding atmosphere. Caustic Soda and Ammonium Bi-fluoride
are hygroscopic chemicals used in the cleaning process.

Recirculation

One recirculation of cleaning solution means the total volume of solution used in the particular stage of the
cleaning process being passed once through the pipework to be cleaned.

2.2 Contractual

The commercial terms used in this specification are defined as follows:

Owner

The oil or gas company, an associate or subsidiary, who is the end user of the equipment and facilities.

Vendor

The company supplying the equipment and material.

Contractor

The main contractor for a defined piece of work

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Sub-Contractor

A company awarded a contract by a Contractor to do part of the work awarded to the Contractor.

Inspection Authority

The organisation representing the Owner or Vendor/Contractor that verifies that the equipment and
facilities have been designed, constructed, inspected and tested in accordance with the requirements of this
specification and the Purchase Order/Contract.

Inspector

A qualified individual representing the Owner, Vendor/Contractor or the assigned Inspection Authority,
who verifies that the equipment and facilities have been designed, constructed, inspected and tested in
accordance with the requirements of this specification and the Purchase Order/Contract.

3.0 CODES AND STANDARDS

The chemical cleaning of new piping shall comply with this specification and the following Codes and
Standards.

ASME - American Society of Mechanical Engineers

ASME B31.3 Process Piping

ASTM - American Society for Testing and Materials

ASTM D2790 Methods of Analysis of Solvent Systems Used for Removal of Water Formed
Deposits

4.0 MATERIALS

4.1 Introduction

4.1.1 The Vendor/Contractor shall supply proper protective clothing and equipment for weighing, measuring and
handling chemicals and suitable carboy or other pumps for handling the chemicals.

4.1.2 Chemical solutions may be prepared off site and transported to site in chemically resistant containers. At
all locations where chemicals are prepared, the Vendor/Contractor shall ensure Owner and Statutory Safety
Regulations are adhered to.

4.1.3 The following chemical solutions are required for the cleaning process:

- Alkaline Detergent Degreasing Wash

- Acid Solvent Wash
- Neutralising Wash
- Post Cleaning Passivation

4.2 Chemical Solution Composition

All percentages expressed by weight unless specified otherwise.

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4.2.1 Alkaline Detergent Degreasing Wash

This solution, used to produce an oil free, water wetting surface consists of 3% Caustic Soda (Sodium
Hydroxide), 1% Sodium Metasilicate, 1% Trisodium Phosphate, 0.1% non ionic detergent in potable water.

4.2.2 Inhibited Hydrochloric Acid Solvent Wash for Carbon Steel Only

This solution, used to dissolve oxide and/or rust films from the pipe surface consists of 6% by volume
concentrated Hydrochloric Acid in potable water to which has been added 0.25% Ammonium Bi-fluoride
and 0.2% by volume Corrosion Inhibitor (Armohib 28, Rhodine 213 or similar).

WARNING Ammonium Bi-fluoride is a white crystalline salt that is hygroscopic and will cause severe
fluoride burns to the skin which heal very slowly. Protective overalls, long gloves and goggles must be
worn when handling this salt.

4.2.3 Acid Solvent Wash and Passivating Solution for Stainless Steel Piping Only

This solution, used to dissolve surface discoloration and to passivate stainless steel piping only, consists of
50% by volume concentrated Nitric Acid in potable water. Protective overalls, long gloves and goggles
shall be used whilst handling acid solutions.

4.2.4 Flash Rust Prevention Wash for Carbon Steel Only

This mildly acidic solution is used to minimise flash rusting of pipe surfaces if there is extended time
between acid solvent washing and neutralising alkaline wash. The solution consists of 0.1% Citric Acid in
potable water.

4.2.5 Neutralising Alkaline Wash

This solution, used to neutralise acid residues, consists of 1% Soda Ash (Sodium Carbonate) in potable
water.

4.2.6 Post Cleaning Passivation Solution for Carbon Steel Only

Two solutions are used to passivate the cleaned pipe surface to prevent rusting prior to commissioning.

The first consists of 3% by volume Ortho-phosphoric acid in potable water, to generate a phosphate film on
pipe wall surfaces.

The second consists of 1% Caustic Soda (Sodium Hydroxide) in potable water, to which 0.5% Sodium
Nitrite has been added.

4.3 Volume of Solutions Required

The volume required is the same for all solutions and will depend upon the diameter and lengths of
pipework spool pieces to be cleaned. It is necessary to calculate the actual internal volume of the total
system through which the solutions are to be circulated. To this calculated volume must be added the
volumes of the feed pipes to and from the reservoir tank, the volumes of filters and pumps plus at least 500
litres in the reservoir tank from which the pump is fed.
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4.4 Equipment Requirements

4.4.1 The Vendor/Contractor shall supply all equipment required, which shall include but not be limited to,
flanges, plugs, fittings, pipe spools, pumps, tanks and valves etc., to ensure that the pipework is cleaned in
accordance with this specification.

4.4.2 Equipment supplied by the Vendor/Contractor for transporting, mixing, holding, pumping and piping shall
be inert to the chemical solutions used in the cleaning process and be of acceptable pressure rating and size
to adequately perform the procedures. The Vendor/Contractor shall ensure that all of the equipment shall be
inspected by a suitably qualified third party Inspection Authority, approved by Owner, prior to
commencing the work.

4.4.3 Reservoir tanks for each solution shall be free from all oil, grease and solid debris and be in a good state of
repair with a liner unaffected by the type and temperature of the solutions to be used in the cleaning
operation. The reservoir tanks shall be sized to hold 110% of the volume of liquid to be circulated through
the pipework, as calculated in Section 4.3.

4.4.4 The tanks shall possess heaters in order to raise the cleaning solutions to a working temperature of 170°F
(77°C) where specified. The heating system shall be submerged under all operating conditions and shall
ensure that the correct operating temperature is maintained.

4.4.5 The cleaning solution shall be pumped from the reservoir tank, through a filtering system fitted with a
10 micron filter medium. The filter medium and filter shall be of suitable materials, not affected by the
type and temperature of the solution being pumped. The filter medium shall be changed between each
solution change or when blocked. The pump shall be sized to give a minimum of three complete
recirculations of solution per half-hour.

4.4.6 The Vendor/Contractor shall supply an adequate number of pressure indicating gauges and temporary
safety valves required to safeguard the piping to be cleaned. Any damage to the system shall be the
responsibility of the Vendor/Contractor. The Vendor/Contractor shall provide calibration certificates for all
pressure gauges, safety valves and ancilliary equipment.

5.0 PREPARATION AND SAFETY

All personnel shall be competent and fully conversant with the plant, machines, equipment and safety
requirements utilised in the cleaning process and the handling of chemicals. All personnel shall possess
pertinent documentation which shall include, but not be limited to, any current applicable licences,
statutory qualifications and training certificates.

The preparation of piping systems for pressure testing, flushing and chemical cleaning requires particular
attention to detail and to the safety of personnel and plant. The work shall be performed in a safe manner in
accordance with the safety rules and regulations of the Owner, Vendor/Contractor and any statutory or
local authority safety standards and regulations.

The lifting and handling of piping, spool pieces and equipment, the erection of scaffolds, platforms, staging
and rigging shall be carried out by competent personnel to the applicable standards of the Owner,
Vendor/Contractor and statutory or other applicable regulations.

All systems to be chemically cleaned shall be suitably prepared for the cleaning operation. All sensing
probes shall be removed and all threaded outlets, orifices or flanges blanked off and adequately sealed. The
Vendor/Contractor shall ensure that all valves shall be temporarily replaced with either blank spool pieces
or with chemically resistant valves during the cleaning process. All brass and stainless steel components
shall be removed from the system to be cleaned. The Vendor/Contractor shall ensure that the correct
circulation of the cleaning solutions is
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attained under all cleaning conditions and note that it may be necessary to insert additional spool pieces
and/or air valves to prevent "dead legs" or air bubbles, to permit the proper filling and draining of the
system.

All pipework not to be cleaned which is part of a total system shall be physically isolated from that to be
cleaned, to ensure no cleaning chemicals leak into and accumulate in such pipework. Any damage shall be
the responsibility of the Vendor/Contractor.

Prior to the circulation of chemicals throughout the pipework and to test the integrity of the prepared
chemical circulation circuit to the satisfaction of the Owner, the pipework shall be filled with potable water
and pressure tested to a minimum of 25% above the maximum operating pressure. The water shall
subsequently be pumped around the system for 30 minutes at a pressure no greater than 10% above the
maximum operating pressure. No leaks shall be allowed. The pipework shall then be drained and inspected
by a third party Inspection Authority. A work permit shall be issued to the Vendor/Contractor, prior to
proceeding with the chemical cleaning.

6.0 CLEANING PROCEDURE

6.1 General Details

6.1.1 Chemical cleaning shall only be performed on that section of pipework specifically detailed in the
drawings, schedules or specifications and carried out as part of a pressure testing activity (hydrotest)
sequence of operations in preparing the pipework for commissioning.

6.1.2 The following cleaning sequence shall be applicable for carbon steel only. The alternative methods for
cleaning of stainless steel piping are as indicated:

Section 8.0 Alkaline detergent degreasing wash;

Section 9.0 Acid solvent wash for carbon steel piping; (Section 9.2 Acid solvent wash for stainless
steel piping);
Section 10.0 Post cleaning passivation (caustic soda solution only for stainless steel piping);

Potable water rinses shall be used between each process to prevent cross contamination of chemicals
reducing the effectiveness of each stage of the cleaning process.

6.1.3 The Owner or Vendor/Contractor shall visually inspect, where possible, such cleaning to ensure the
achievement of the specified results. The Owner's written approval shall be obtained by the
Vendor/Contractor that the pipework is clean prior to reinstatement.

6.1.4 The acceptance criterion for cleaned pipework is that the internal surface shall be free from any rust, mill
scale deposits or loose debris. After passivating and drying the steel shall possess a uniform white grey
appearance.

6.2 Approval of Cleaning Procedures

6.2.1 Fourteen days prior to the commencement of the cleaning operation, the Vendor/Contractor shall submit to
the Owner for approval, a detailed specification of the proposed procedure describing the actual equipment
to be used, methods of control, the names and experience of personnel supervising and monitoring the
cleaning procedure and proposed safety precautions.

6.2.2 Alternative proprietary cleaning processes may be proposed, other than those in this specification,
providing the Owner can be assured that the alternative process will perform the same function.
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6.2.3 Each proposed proprietary process shall be described in a detailed procedure which shall include but not be
limited to:

- Proprietary chemical name and proposed concentration (maximum, minimum and working)
- Method of mixing, injecting/introducing and pumping of the chemicals
- Operating temperature
- Circulation rate in terms of the numbers of complete recycles
- Contact times and duration
- Details of inhibitors used
- Effectiveness of inhibitor against corrosion
- Solution sampling, testing procedures and schedule

6.2.4 Each procedure proposed for approval shall detail the safety precautions, first aid procedures and facilities
to be adopted and available thoughout the cleaning programme.

7.0 TREATMENT RECORDS

The Vendor/Contractor shall submit a documented log book to the Owner after each chemical
treatment/cleaning process performed on each pipework section.

The log book shall include but not be limited to, the chemicals and the formulation used, cleaning solution
temperatures, concentrations, circulation rates, contact times, etc. The log book shall include for 12-hour
progess reports for the period or cleaning operation and shall be available at all times for review by the
Owner.

Complete records of all activities shall be submitted to the Owner on completion of each section of
pipework.

The records shall include but not be limited to:

- Chemicals used and formulation

- Solution temperature record
- Solution concentrations and analysis records
- Circulation rates
- Contact times and duration
- Results of any tests

The Vendor/Contractor shall be responsible for recording, compiling, collating and submission to the
Owner, all certificates and documents applicable to the completed work.

8.0 ALKALINE DETERGENT DEGREASING WASH

All new piping contaminated by oil and greases shall be chemically degreased to produce a water-wet
surface as follows. Heavy oil or grease deposits must be removed manually or by the use of an organic
solvent (Trichloro-ethylene) wash as part of preparing the pipework for cleaning.

If free from heavy hydrocarbon deposits, the pipework system shall be filled with an alkaline detergent
degreasing wash solution prepared as described in Section 4.2.1. The degreasing solution shall be heated to
a working temperature of 170°F (77°C).

Ensure the pipework has no "dead legs" or trapped air bubbles that would prevent solution contact or
circulation.
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Circulate the cleaning solution through the system for 30 minutes in each hour for a total of 6 hours. There
should be at least three recirculations of solution through the system during each 30-minute pumping
period.

Drain the piping system to an approved waste disposal tanker.

Flush with potable water until the effluent when tested is less than pH 8. The pipework is then ready for
the next stage of cleaning.

9.0 ACID SOLVENT WASH

9.1 Carbon Steel Piping Only

9.1.1 Inhibited Hydrochloric Acid solvent wash shall be performed to remove adherent rust and mill scale to
ensure the system is cleaned to bare metal. This treatment is not suitable for systems containing stainless or
high alloy steels. Protective overalls, long gloves and goggles shall be used while handling acid solutions.

9.1.2 Before filling the system to be treated, the acid solvent wash solution, prepared as described in Section
4.2.2, shall be tested to ensure it has been properly inhibited. An acceptable test is to heat a small quantity
of the acid solvent wash to 170°F (77°C) and immerse a cleaned coupon of steel, 25 mm x 25 mm x 3 mm,
of similar composition to the pipework to be cleaned. The concentration of inhibitor is acceptable if, after
30 seconds following immersion of the coupon, hydrogen bubbles stop rising from the surface of the
coupon.

9.1.3 Following acceptance by the Owner of the coupon inhibitor test, the bulk acid solvent wash shall be heated
to 170°F (77°C) and the piping system filled. High points in the piping system shall be vented in a manner
similar to that adopted for hydrostatic pressure testing. Particular attention is directed to the acidic nature
of the solution being vented and approved safety precautions shall be implemented. Any vented acid shall
be diluted by water washing.

9.1.4 When the system has been filled the solution shall be maintained at 170°F (77°C) and circulated for 30
minutes in each hour for a minimum of 6 hours or until the treatment is complete as defined in Section
9.1.8. There shall be at least three recirculations of solution through the pipework system during each 30-
minute pumping period.

9.1.5 Samples of the acid cleaning solution shall be taken every hour, immediately following the completion of a
pumping period, when the acid solution is thoroughly mixed. The Hydrochloric Acid concentration shall be
tested using a simple titration and maintained at not less than 3% and not more than 5% expressed as
concentrated Hydrochloric Acid.

9.1.6 Each solution sample shall be tested immediately for ferric iron and total iron and both results shall be
plotted on a graph against time. A ferric iron content greater than 0.4% or a total iron content greater than
1.5% combined with an increased slope on either of the plotted graphs shall indicate excessive corrosion
activity due to poor concentration control on the acid solution make up, the solution shall be removed
immediately and the system neutralised as in Section 9.1.11.

9.1.7 When the treatment is aborted in accordance with Section 9.1.6 the acid cleaning solution shall be
reconstituted to conform to Section 4.2.2 and tested in accordance with Section 9.1.2. If this is not
possible, a new solution shall be prepared and the treatment shall recommence.

9.1.8 Cleaning shall continue until the iron and the acid concentrations reach an equilibrium condition, which
exists when there is no change in either of the plotted iron concentrations and the available Hydrochloric
Acid concentration remains constant.
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9.1.9 Drain the piping system to an approved waste disposal tanker.

9.1.10 Flush all the piping system with a Citric Acid solution, prepared as described in Section 4.2.4, to reduce
flash rusting. Flushing shall be accomplished by recirculating the flushing solution at least three cycles of
the system before being discharged. Checks using a simple titration shall be made to ensure the rinse water
has less than 25ppm of chloride. If not, flushing with clean water shall continue until this is achieved.

9.1.11 Neutralise the piping system by recirculating for at least three cycles of the system, a 1% Soda Ash solution
prepared as described in Section 4.2.5.

9.1.12 The piping system shall be drained, opened and inspected for acceptance of the cleaning quality by the
Owner.

9.1.13 If accepted and the pipework is to be commissioned immediately, the complete piping system shall be dried
by blowing through with dry, oil free, compressed air. If there is a delay before commissioning then the
pipework shall be passivated as in Section 10.0.

9.2 Stainless Steel piping only

9.2.1 A Nitric Acid solvent wash shall be performed to remove adherent oxide scale and clean the piping system
to bare metal. Protective overalls, long gloves and goggles shall be used whilst handling acid solutions.

9.2.2 Fill the pipework with a solution of Nitric Acid, prepared as described in Section 4.2.3.

9.2.3 When the system has been filled the solution shall be maintained at 120°F (50°C) and circulated for 30
minutes in each hour for a minimum of 6 hours. There should be at least three recirculations of the solution
through the pipework system each 30-minute pumping period.

9.2.4 Samples of the acid cleaning solution shall be taken every hour, immediately following the completion of a
pumping period, when the acid solution is thoroughly mixed. The Nitric Acid concentration shall be tested
using a simple titration and maintained at not less than 40% and not more than 53%, expressed as
concentrated Nitric Acid.

9.2.5 Drain the piping system to an approved waste disposal tanker.

9.2.6 Flush the piping system with low chloride (less than 25ppm), potable water or water approved by the
Owner. Flushing shall be accomplished by recirculating the flushing water at least three cycles of the
system before being discharged.

9.2.7 Neutralise the piping system by recirculating for at least three cycles of the system, a 1% Soda Ash solution
prepared as described in Section 4.2.5.

9.2.8 The piping system shall be drained, opened and inspected for acceptance of the cleaning quality by the
Owner.

9.2.9 If accepted the complete pipework system shall be dried by blowing through with dry, oil free, compressed
air.

10.0 PASSIVATION OF CARBON STEEL

When the time between cleaning in accordance with this specification and commissioning exceeds 3 days
then passivation treatment shall be performed.
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Post cleaning passivation shall be performed after chemical cleaning to prevent long term flash rusting of
the cleaned carbon steel surfaces.

Recirculate a dilute Phosphoric Acid solution, prepared as described in Section 4.2.6, maintained at 170°F
(77°C) for at least three cycles of the system for at least one hour.

Drain the system then rinse with low chloride (less than 25ppm) potable water.

Recirculate a Caustic Soda solution prepared as described in Section 4.2.6, maintained at a temperature of
170°F (77°C), at a rate of three cycles of the system per hour for at least two hours.

After completing the passivation treatment the piping system shall be completely drained and dried by
blowing through with dry, oil free, compressed air.

Passivation treatment shall be immediately followed by replacing all probes, valves, etc, plugging and
sealing all openings in the piping system and pressurising with dry nitrogen at 5 to 10psig (35 to 70kPag).

11.0 ABRASIVE BLAST CLEANING

Large diameter pipes, the interior surfaces of vessels or plant where access is possible and where specified
to be cleaned to remove loose or adherent rust/mill scale films, are best cleaned by abrasive blasting to bare
metal.

Abrasive blasting to surface finish SA 2.5 shall be performed in accordance with GES X.01.

Where the piping configuration or accessibility is such that the performance and assessment of abrasive
blasting may be doubtful, the chemical cleaning process given in this specification shall be used but may
require large volumes of chemicals in proportion to the surface area of steel to be cleaned.