ALGIERS REFINERY

REHABILITATION AND ADAPTATION PROJECT

METHOD OF STATEMENT-PIPEWORK CLEANING GUIDELINES

Document Class : CLASS1 Project N° - Unit Doc Type Material Code Serial Number Rev. Page

9952T-000 MS 9000 0001 0 1/10

METHOD OF STATEMENT
PIPEWORK CLEANING GUIDELINES

Modifications: pages 6 & 7

Fabien Ruez
2012.12.13
15:36:03
+01'00'
Cristian Niculescu
2012.12.12 13:16:42 Cristian Niculescu
2012.12.12 13:17:01
0 12/DEC/12 Issued for Execution C.NICULESCU
+01'00' C.NICULESCU
+01'00'
F.RUEZ
A 27/MAR/12 Issue for review C.NICULESCU C.NICULESCU F.RUEZ
Rev Date STATUS WRITTEN BY CHECKED BY APPROVED BY
DD/MMM/YY (name & visa) (name & visa) (name & visa)

DOCUMENT REVISIONS

Sections changed in last revision are identified by a vertical line in the margin
 ALGIERS REFINERY
REHABILITATION AND ADAPTATION PROJECT

METHOD OF STATEMENT-PIPEWORK CLEANING GUIDELINES

Document Class : CLASS1 Project N° - Unit Doc Type Material Code Serial Number Rev. Page

9952T-000 MS 9000 0001 0 2/10

CONTENTS

1. PROJECT SCOPE............................................................................................................................................................. 3
1.1 GENERAL OUTLINES ...................................................................................................................................................... 3
1.2 PURPOSE .................................................................................................................................................................... 3
1.3 DEFINITION ............................................................................................................................................................... 4
1.4 REFERENCE ............................................................................................................................................................... 4
2. GENERAL OVERVIEW OF PIPE CLEANING .............................................................................................................. 4

3. CLEANING METHODS..................................................................................................................................................... 5
3.1 HYDRAULIC PRESSURE FLUSHING ................................................................................................................................ 5
3.2 POWER FLUSHING ......................................................................................................................................................... 5
3.3 AIR BLOWING ............................................................................................................................................................... 5
3.4 STEAM BLOWING .......................................................................................................................................................... 5
3.5 CHEMICAL CLEANING ................................................................................................................................................... 5
3.6 OIL FLUSHING ............................................................................................................................................................... 6
3.7 MECHANICAL CLEANING .............................................................................................................................................. 6
3.8 HAND CLEANING .......................................................................................................................................................... 6
4. GENERAL GUIDELINES OF CLEANING ..................................................................................................................... 6

5. PIPE CLEANING CLASSIFICATION TABLE ............................................................................................................... 7

 ALGIERS REFINERY
REHABILITATION AND ADAPTATION PROJECT

METHOD OF STATEMENT-PIPEWORK CLEANING GUIDELINES

Document Class : CLASS1 Project N° - Unit Doc Type Material Code Serial Number Rev. Page

9952T-000 MS 9000 0001 0 3/10

1. PROJECT SCOPE
1.1 General outlines
SONATRACH RAFFINERIE D’ALGER, Algiers Refinery Algeria (OWNER) is presently operating a
2.7 MMTPA petroleum refinery at Algiers, Algeria having various units such as Crude Distillation
Unit, Gas Plant, Catalytic Reformer unit and associated auxiliary units including utility & offsite. The
plant is situated at Sidi- Arcine, located east of Algiers Refinery is approximately 10 km from
Algiers Airport and 15 km from the Algiers Port. Algiers Refinery was built in 1964 with a capacity of
1.6 MMTPA for processing of Hassi Messaoud crude oil capacity of Algiers Refinery was increased
to 2.7MMTPA in the year of 1970.

As part of “Rehabilitation & Adaptation Project” of Algiers Refinery, OWNER intends to revamp
some of the above units and also add a few new units. Engineers India Ltd. (EIL), New Delhi,
INDIA has been retained as PMC by SONATRACH for Rehabilitation & Adaptation Project of
Algiers Refinery. Under the Rehabilitation Project, the crude processing capacity of the Refinery
shall be increased by 35%. The revamp of existing units in the refinery and associated Utilities and
Offsite facilities shall be enhanced / modified under Rehabilitation part.
OWNER has also planned to produce fuels conforming to the Euro-2009 specifications.
Accordingly, OWNER has planned to implement a project under Rehabilitation part to increase the
capacity from the complex including modernization of existing utilities and offsite facilities. Electrical
modernization and Instrument modernization including new DCS and central control room are also
part of Revamp plan.

Under the Adaptation project SONATRACH intends to maximize diesel and minimize fuel oils. For
this matching new Utilities, Offsite facilities and an Effluent Treatment Plant (ETP) with Biological
treatment plant to cater to the requirement of the refinery have been planned. New Residual
Fluidized Catalytic Cracking Unit (RFCCU), Sulfur Block containing Sulfur Recovery unit (SRU),
Amine treatment Unit (ARU), Sour water stripper unit (SWS), Fuel Gas treating unit (FGATU) and a
new MS Block containing Naphtha Hydrotreater unit (NHTU), Light Naphtha Isomerisation Unit
(LNISOM),Continuous Catalytic regeneration Unit(CCRU) have also been planned under the
Adaptation Project.
Under instrumentation modernization work, all existing pneumatic instruments in existing plants,
revamped or otherwise, shall be replaced with electronic instruments with all associated
accessories. A central control room (blast resistant) with a new DCS control system which will
control, monitor the Refinery. Both Rehabilitation and Adaptation area plants, Utilities and Offsite
have been planned along with a number of Satellite rack rooms. Fire and gas detection and
monitoring system of the refinery is also part of Project.
Under electrical modernization work, a new 63 kV grid power receiving and distribution terminal
along with a number of new and revamp of substations have been envisaged. This will also include
addition and replacement of existing transformers, switchgears etc. New plant communication, Fire
alarm, telephone systems in plant and few of non plant buildings are also part of the Project.
As part of Fire water system up gradation, a new fire water network along with pump station and
other fire water systems like foam, water monitors have been planned.
1.2 PURPOSE
This Method Statement describe the basic requirements and classification of methods applied in
the cleaning of the pipes/equipment (hereinafter referred to as “the system”) of the plants
constructed for Algiers Project and will serves as a guidelines for Contractor/Sub-Contractor teams
during the construction , pre-commissioning & commissioning activities.
 ALGIERS REFINERY
REHABILITATION AND ADAPTATION PROJECT

METHOD OF STATEMENT-PIPEWORK CLEANING GUIDELINES

Document Class : CLASS1 Project N° - Unit Doc Type Material Code Serial Number Rev. Page

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1.3 DEFINITION
OWNER/CLIENT: SONATRACH
EPCC CONTRACTOR: TECHNIP FRANCE
CSU: Commissioning and Start up Team
MS: Method Statement
PC&C: Pre-commissioning and Commissioning

1.4 REFERENCE
9952T-0000-MS-9000-0002-Cleaning Hydraulic Pressure Flushing
9952T-0000-MS-9000-0003-Cleaning Power Flushing
9952T-0000-MS-9000-0004-Cleaning Air Blowing
9952T-0000-MS-9000-0005-Chemical Cleaning
9952T-0000-MS-9000-0011-Lube Oil Flushing

2. GENERAL OVERVIEW OF PIPE CLEANING

• Trash or construction debris inside the system arising from erection or construction processes,
as well as internal scale will be removed before operation starts. After completion of
construction the system will be cleaned to avoid the following troubles which are apt to occur
during start up operations:
ƒ Flow restriction
ƒ Valve malfunction
ƒ Damage to rotate equipment
ƒ Process contamination
• Cleaning operations takes place during construction and pre-commissioning phase and is
performed by Construction team with support from CSU. Construction will develop a clean build
procedure to clean the pipes spools in the fabrication shop and again on site before lifting for fit
up. During commissioning phase it may be possible that CSU team will repeat some specific
cleaning activities (blowing or flushing) using permanent equipments.
• During flushing/blowing activities the instruments as pressure/temperatures gauges,
pressure/temperature/flow transmitters and check valves should be disconnected from the
system.
• The mediums used to perform the cleaning activities are:
ƒ Water(potable, desalt. water)
ƒ Air
ƒ Nitrogen
ƒ Steam
ƒ Oil
ƒ Chemical solution
 ALGIERS REFINERY
REHABILITATION AND ADAPTATION PROJECT

METHOD OF STATEMENT-PIPEWORK CLEANING GUIDELINES

Document Class : CLASS1 Project N° - Unit Doc Type Material Code Serial Number Rev. Page

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• The Method statement will present the cleaning methods that will be taken in to
consideration/applicable for this project:
ƒ Hydraulic pressure flushing
ƒ Power flushing
ƒ Air blowing
ƒ Steam blowing
ƒ Chemical cleaning
ƒ Oil flushing
ƒ Mechanical cleaning
ƒ Hand cleaning
Note: Either one or a combination of the methods will be applied during this project as
applicable dependent upon construction materials used and required level of cleanliness. All
lines cleaned must be protected and as far as possible preserved with nitrogen or dry
instrument air.

3. CLEANING METHODS
3.1 Hydraulic Pressure Flushing
This method is widely used in pipe cleaning and is usually applied where liquids flow during normal
operation. This method is mainly conducted by Sub-Contractor construction group, which in brief
utilizes kinetic energy obtained by source supply, gravity or any means other than pump power.
3.2 Power Flushing
This method is applied to pipes in which water flushing can be done using the pump permanently
installed within the unit/facility concerned. The kinetic energy generated by the pump is used to
flush foreign materials from the pipelines or collect them in the filters/strainers for removal.
3.3 Air Blowing
Air blowing method is widely used for pipe cleaning. Dry oil free air produced by permanent or
temporary air compressor is used in volume equal or greater than the system volume being blown.
Process systems required to be moisture free benefit from this cleaning method. Quick opening
valves (knife valve) shall be used to control the blowing pressure in a safe manner.
3.4 Steam Blowing
Steam blowing is applied to the cleaning of steam supply pipes. Since steam flows inside the pipes
with high velocity and temperature during blowing, this method is effective in removing foreign
materials and mill scale. Special safety measures shall be taken during steam blowing activities
special for HP steam.
3.5 Chemical Cleaning
This method utilizes chemical reaction to remove rust, mill scale, oil grease, etc. from pipes and
equipment surface where applicable.
™ Acid Cleaning
This method utilizes the properties of some acids to chemically dissolve and remove rust
,slag or mill adhering to base metal and is applied to systems for which very fine clearance
are required as:
 ALGIERS REFINERY
REHABILITATION AND ADAPTATION PROJECT

METHOD OF STATEMENT-PIPEWORK CLEANING GUIDELINES

Document Class : CLASS1 Project N° - Unit Doc Type Material Code Serial Number Rev. Page

9952T-000 MS 9000 0001 0 6/10

-Reciprocating compressors suction

-Lube oil/seal gas pipe of compressors
Note: Contractor will discuss with Vendor’s equipment the requirement for chemical
cleaning of the anti-surge lines and will apply the recommendation as required.

™ Alkaline Cleaning
This method utilizes the properties that biological oil can be hydrolyzed and dissolved in
the solution and torn off from the metal surface to be suspended in the solution. The
chemicals normally used are: Tri/Di- sodium phosphate, caustic soda and soda ash. The
systems requiring alkaline boiling are:
-Steam producing boilers
-Amine systems
3.6 Oil Flushing
Oil flushing is applied to the cleaning of hydraulic lube oil lines, lube oil and seal oil for rotating
machines and powered equipment. Foreign materials such as rust, weld slag, and mill scale are
caught by filters installed in the oil flushing loop and later removed.;
3.7 Mechanical Cleaning
The cleaning by this method is done by rubbing, beating or wiping the pipe surface by special tools
or equipment.

3.8 Hand Cleaning

This method is applied to equipment, large bore pipe (24 inches and above), ducting to which
access is available to safely carry out such work. Especially compressor strainer downstream line
and anti surge valve inlet line would be hand brushed to remove all loose rust.

Note: Precaution must be taken for personnel safety. A confined entry permit should be applied for
big bore pipe entry. To facilitate fast and safe inspection a boroscope can be used. Third party
contractor may be hire to take care of steam blowing activities or chemical cleaning. The
procedures for these activities will have to be approved by Contractor and Company and will have
to fulfil all project rules. The 22” lines diameter and less will be visually inspected after hydro test,
flushing and drying to assure that line is clean.

4. GENERAL GUIDELINES OF CLEANING

All piping already cleaned and inspected must be isolated from non cleaned piping and open end of
pipes to be covered and protected.
Steam lines will be pressurized with steam or maintained under dry air positive pressure if not put
immediately in service after cleaning.
Lines that need to be dried (gas lines, cryogenic lines, rundown lines) must be preserved with
nitrogen or dry air if the drying can not be performed after cleaning.
Blinds used to protect equipment during flushing need to be rated for service.
Water piping special for cooling water system shall be filled with water and if required rust inhibitor
added if lines will not be in service after cleaning.
Lube oil lines after lube oil flushing will be preserved with oil as per vendor recommendations.
Instrument or valves that can be plugged/ damaged by debris during flushing or blowing will be
isolated or by passed (temporary spool installed) from lines subject of cleaning. Special care will be
 ALGIERS REFINERY
REHABILITATION AND ADAPTATION PROJECT

METHOD OF STATEMENT-PIPEWORK CLEANING GUIDELINES

Document Class : CLASS1 Project N° - Unit Doc Type Material Code Serial Number Rev. Page

9952T-000 MS 9000 0001 0 7/10

taken for ball valves mostly in process system where if the valves can not be removed will be kept
full open during cleaning activities. Instruments such FE, RO TE, have to be better dropped rather
than bypassed for cleaning activity.
During cleaning operation the main header will be cleaned first, then each lateral header or branch
in the same manner.
Any lines not accessible to water or lines which will trap water in such way that it could not be
drained out, must be blown with dry air.
Note: low point drains provided by Construction for hydro test medium drain are shown in the
isometrics.
During flushing/blowing of the lines connected to equipments (vessels, exchangers, pumps,
compressors) the circuit shall be diverted to avoid flush debris into equipment. The equipment shall
be protected by blinds and temporary lines shall be installed to bypass these equipments.
Flushing blowing shall be conducted with use of permanent equipment installed in order to obtain
the proper velocity. Where this equipment is not available or not ready for service, temporary
arrangement can be used for cleaning operations (temporary pump and connections).
Before starting and during cleaning activities (water flushing, air and steam blowing) the following
HSE measures will be on place:
• Area of flushing/blowing barricaded off with HSE signs on place
• PTW and JSA prepared and signed by all parties involved
• PIDs showing lines to be blown marked up and attached to PTW
• All risks and measures identified
• All temporary equipments verified and in place for cleaning operation
• All responsible persons to perform the cleaning operation in place (toolbox talk done with HSE
Construction/Commissioning representative).
• HSE representative on place to supervise the cleaning operations.

5. PIPE CLEANING CLASSIFICATION TABLE

Cleaning methods are classified in the attached table based Contractor experience and Oil & Gas
norms. The recommended method herein may be changed at site based on the site conditions and
availability of cleaning medium.
 ALGIERS REFINERY
REHABILITATION AND ADAPTATION PROJECT

METHOD OF STATEMENT-PIPEWORK CLEANING GUIDELINES

Document Class : CLASS1 Project N° - Unit Doc Type Material Code Serial Number Rev. Page

9952T-000 MS 9000 0001 0 8/10

 ALGIERS REFINERY
REHABILITATION AND ADAPTATION PROJECT

METHOD OF STATEMENT-PIPEWORK CLEANING GUIDELINES

Document Class : CLASS1 Project N° - Unit Doc Type Material Code Serial Number Rev. Page

9952T-000 MS 9000 0001 0 9/10

ATTACHMENT-PIPING CLEANING CLASSIFICATION TABLE

CLEANING BY KYNETIC ENERGY CHEMICAL CLEANING REMARKS

MECHANICAL
CLEANING
HYDRAULIC POWER STEAM AIR OIL ACID ALKALINE HAND
PRESSURE FLUSHING BLOWING BLOWING FLUSHING CLEANING CLEANING CLEANING
FLUSHING

1.GENERAL CLASSIFICATION
WATER O O
DEMIN/BFW O O
COOLING WATER SUPPLY/RETURN O O O
HOT WATER O O
POTABLE WATER O O
STEAM O
STEAM CONDENSATE O O
CHEMICAL O O O*1 O
INSTRUMENT/PLANT AIR O
NITROGEN O
FUEL GAS O
HYDROCARBON-GAS/LIQUID O*2 O*1 O
REFRIGERANT O O
FLARE O O
BLOWDOWN/WASTE WATER/CLOSE
DRAIN O O
SLOP OIL O O*1
SEWER O
2.SPECIAL CLASIDICATION
RECIPROCATING COMPRESSOR
SUCTION O O
LUBE OIL/SEAL OIL O O*4
 ALGIERS REFINERY
REHABILITATION AND ADAPTATION PROJECT

METHOD OF STATEMENT-PIPEWORK CLEANING GUIDELINES

Document Class : CLASS1 Project N° - Unit Doc Type Material Code Serial Number Rev. Page

9952T-000 MS 9000 0001 0 10/10

CLEANING BY KYNETIC ENERGY CHEMICAL CLEANING REMARKS

MECHANICAL
CLEANING
HYDRAULIC POWER STEAM AIR OIL ACID ALKALINE HAND
PRESSURE FLUSHING BLOWING BLOWING FLUSHING CLEANING CLEANING CLEANING
FLUSHING

SEAL GAS O O*4

HYDRAULIC OIL O O
COMBUSTION AIR DUCT O*3
FLUE GAS DUCY O
LARGE BORE O O
COLD SERVICE O O
AMINE SYSTEMS O
NOTE: *1 AIR BLOWING APPLIED AFTER FLUSHING *2 NOT FOR LNG OR REFRIGERANT *3 USING COMBUSTION AIR FAN *4 FOR COMPRESSOR