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How to Clean Natural Gas Piping with Gas Blows

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How to Clean Natural Gas Piping with Gas Blows
POWER MAGAZINE 03/01/2020 | Michael F. Czyszczewski, PE

Prior to placing newly installed natural gas piping and valves in service, systems must
be properly cleaned to remove potentially damaging foreign material that is inherently
left behind during construction. The process is more complicated than it sounds,
requiring accurate cleaning force calculations and detailed sequencing steps to ensure
all debris is removed. Here’s how to do it right.

Before new fuel gas piping can be connected to a combustion turbine (CT), it must be
cleaned by “decompression” gas blows.

The Process
The pipe to be cleaned is connected at one end to a gas reservoir. This can be a tank or
upstream section of clean empty piping. At the other end, a temporary exhaust pipe and
valve is installed. The reservoir is pressurized to less than half the design pressure. When
the blow valve is rapidly opened, the pressurized gas violently rushes through the piping
and out the exhaust pipe (Figure 1).

1. A typical configuration of gas blow piping components is shown here. Courtesy:

Michael F. Czyszczewski, PE

POWER Magazine March 2020 1

As the gas moves through the pipe, debris and liquids are picked up and blown out. When
the reservoir depressurizes to a level where no more cleaning is effectively taking place,
the valve is closed. The process is then repeated over and over (10 to as many as 100
times) until the pipe is judged clean.

If a large enough compressor is available, small diameter (less than 4 inch) piping or small
lengths of pipe could alternatively be cleaned by a “continuous blow” technique. This
could speed up the process by eliminating the pressurization cycles.

What Gas Should You Use?

The first choice for cleaning gas has been to use the operating gas. However, after a
deadly 2010 explosion occurred while using natural gas, the industry re-evaluated this
practice. The Chemical Safety Board (CSB) investigating the accident recommended that
natural gas not be used for pipe cleaning. The CSB also urged the governing code and
standard organizations to ban the use of flammable gas and to publish guidelines for
cleaning with alternative gases.

In response, the National Fire Protection Association (NFPA) issued NFPA 56 “Standard
for Fire and Explosion Prevention During Cleaning and Purging of Flammable Gas Piping
Systems” in provisional form in 2011, and final form in 2013. This standard prohibits the
use of flammable gas for pipe cleaning where the system design pressure exceeds 125
psig. In 2011, the Electric Power Research Institute (EPRI) released “Guidelines for Fuel
Gas Line Cleaning with Compressed Air or Nitrogen.” These alternative gases compare as
follows:

 Air. The air must be clean, dry, and oil-free. Gas blows will probably require larger
pressures and flows than are available from the station instrument air compressors. If
necessary, larger or multiple compressors could be rented to get the pressures and flow
rates needed. Accessories such as an air receiver, relief valves, regulators, and air
dryers may also be required.

 Nitrogen. Chemically inert nitrogen is commonly used to purge and provide

blanketing corrosion protection for fuel gas equipment. Nitrogen is nonflammable,
nonexplosive, dry, and free from oil. Nitrogen does pose a potential asphyxiation
safety risk, which must be addressed if used. The gas can be produced on-site in large
volumes (from 3,000 standard cubic feet per minute [scfm] to 15,000 scfm) and very
high pressures (up to 15,000 psig) by rented pumper trucks originally developed for
use in the oil and gas industry. These trucks contain the instrumentation, storage tanks,
pumps, liquid nitrogen, vaporizers, safety valves, and other equipment required to
supply pressurized gas.
The economics of air and nitrogen could be very similar. The gas you choose must be
based on your project-specific requirements.

In its 2016 release, the American Society of Mechanical Engineers (ASME) B31.1 piping
code clarified that it did not provide guidance for pipe cleaning methods, but added in its

POWER Magazine March 2020 2

2018 release that fuel gas pipe cleaning may be subject to the requirements of NFPA 56.
NFPA standards are often adopted as federal, state, or local law.

When Is the Pipe Clean?

A polished metal plate known as a “target” is inserted in the gas path where it will be
struck by debris particles during the gas blows. Pipe cleanliness is based on the number
and size of particle strikes allowed by the CT manufacturer. Blows continue until the
examination of two consecutive plates show no more scoring than allowed by the
acceptance criteria.

The target should be installed on the temporary exhaust “tail pipe,” as close to the segment
of pipe being cleaned as possible to prevent false target readings from debris originating
within the temporary pipe. It should be located away from flow disturbances created by
elbows and tees, and not be installed at the pipe exit, where there should be a shock wave.
The target should be as small as practical to minimize pressure drop. Hard metal plates
will show fewer impacts, therefore, the material, design, and location of the target must be
agreed to by the owner and CT manufacturer.

The majority of cleaning takes place during the initial round of gas blows. As cleaning
progresses, the color of the discharge plume will change from rust orange to clear. Only
after significant cleaning has taken place, should the target be inserted.

What Piping Is Cleaned by Gas Blows?

Manufacturers will identify how the gas inlet piping to their equipment should be cleaned.
Gas blows are primarily performed on the fuel gas supply piping from the outlet of the gas
service meter to the isolation valve inlets at the CT. If stainless steel piping is used
downstream of the fuel gas conditioning skid, it can instead be visually inspected using a
borescope. If debris is found, the stainless pipe should be blast or brush cleaned, as
conditions require.

If the gas equipment piping does not have a specified cleanliness criterion, it may still be
cleaned using gas blows. Non-targeted “service blows” are used, and cleaning continues
until the exhaust plume turns clear. Fuel gas piping to heat recovery steam generator duct
burners is one example. Other secondary systems, such as the gas supply piping to an
auxiliary boiler, can instead be chemically cleaned or blast cleaned followed by a service
blow.

It may not be practical to do gas blows on some complex piping arrangements. Short hard
to reach pipe can instead by cleaned by hydrolazing (high-pressure water blasting).

Identifying Blow Paths

The length of piping that can be cleaned during a gas blow is limited. Flow resistance, and
the location of isolation valves and branch connections, will usually require multiple flow
paths. Each path will need time and resources to prepare and set up. Identifying the
optimum blow paths is critical to having an efficient process and, therefore, requires

POWER Magazine March 2020 3

thoughtful consideration to minimize the number of blows needed.

The process of identifying the blow paths is called “sectioning.” A piping and
instrumentation diagram (P&ID) should be studied and marked to show the direction and
path for each planned blow. This diagram should show the location of the proposed gas
source, target plate, blow valve, block valves, instrument valves, tail pipe, and all
temporary connections to the permanent pipe.

The diagram should also identify any equipment skids, flow nozzles, orifice plates, and
thermal wells that should be removed, replaced with spool pieces, or bypassed to prevent
them from being damaged or to eliminate the pressure drop they would cause during gas
blows. If a valve cannot be removed, it should be fully open during the blows and
occasionally cycled closed and open between blows to shake lose any particulates that
may have gotten caught in the valve. The following is some advice for defining blow
paths:

 A path should always start at a gas source rated for the expected blow pressures, and
with sufficient volume to accommodate reasonable blow times. This source can be a
nitrogen pumper truck, isolatable section of upstream pipe already cleaned, or a rented
pressure vessel.
 A path should end at a temporary tail pipe outlet. For some blow paths, it may be
necessary to relocate the tail pipe. Alternatively, additional tail pipes could be used.
 Long blow paths have high flow resistance and should be avoided. High resistance
will require a higher reservoir pressure and use more blow gas.
 A dirty blow path should not introduce flow into a section of pipe cleaned in an earlier
blow.
 Blow paths can be run in the reverse of the normal flow direction. This is sometimes
necessary when the reservoir volume upstream of the pipe being cleaned is inadequate,
but there is sufficient downstream volume that could be used.
 It must be possible to isolate the flow path. If necessary, temporary valves or spectacle
flanges can be installed to block a branch line. Dead-ended (stagnant) pipe segments
should be avoided, as they can trap debris.

The Blow Valve

The blow valve is critical to successful cleaning. When closed, the blow valve is used as a
stop valve to allow the upstream piping and reservoir to be pressurized. When opened, it
initiates the gas blow cleaning process. Most importantly, the valve must be able to open
quickly. A faster valve will allow more cleaning gas to scour the inside of the pipe at
maximum velocity. A quarter-turn ball valve or knife gate valve that opens in 0.5 to 1
second (or better) is a good choice. An automatic operator is preferred for safety reasons.

The closer the valve is to the tail pipe; the more volume will be available upstream for
pressurization. More volume gives greater stored energy and longer blows. Alternatively,
locating the valve upstream of the piping being cleaned will provide an additional cleaning
benefit when the valve pops open and the pressurized gas impacts the dirty pipe. However,
most importantly, the valve should be installed away from flow disruptions, and if a
manual valve is used, it should be in an accessible and safe location.

POWER Magazine March 2020 4

Because the blow valve will be subjected to high stresses, loads, and debris, it can be
easily damaged. It’s therefore considered good insurance to have a spare.

Rupture disks are sometimes used instead of a blow valve. They are disposable and open
very quickly. However, because they must be replaced after each blow and are
manufactured to a single predefined burst pressure, they may not be suitable when many
gas blows or starting pressures are needed.

Cleaning Calculations

2. Nomenclature

The principle behind gas blow cleaning is to create high gas velocities and drag forces,
which will shear debris off the pipe interior walls. This cleaning force (CF) is defined as
follows:

CF = (mB2 x vB) / (2 x gc x A)

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where mB is the mass flow rate of the blow gas during cleaning, vB is the specific volume
of the blow gas during cleaning, gc is the gravitational constant, and A is the area at the
tail pipe exit. (All variables in equations referenced in this article use customary U.S.
units, such as ft, sec., lb, psia, and F, unless otherwise stated.) CF during the gas blow
must be greater than the maximum CF during operation for effective cleaning to take
place. In other words, the ratio of cleaning to operating CF, known as the cleaning force
ratio (CFR), must be greater than 1.0, as calculated in the following equation:

CFR = CFB / CFM ≥ 1

where CFB is the cleaning force of the blow and CFM is the maximum cleaning force
during operation. Assuring CFRs are greater than 1.0 is the fundamental criteria upon
which the gas blow starting pressures are based. Experience has shown that drag forces
from a CFR greater than or equal to 1.2 will provide acceptable results. Higher CFRs do
not show significantly faster cleaning and are not recommended because more gas is
exhausted. However, a higher CFR margin should be used if required by the equipment
manufacturer.

CFR increases as you move downstream in a constant diameter pipe, therefore, the
majority of the pipe will see CFR’s many times greater than 1.0. Also, the calculations do
not take credit for the dynamic shock that occurs when the blow valve is suddenly opened.
Because of this conservatism, a minimum CFR of 1.0 is considered reasonable and
sufficient for service blows.

To calculate CFR, the mass flow and specific volume is needed along the entire blow path.
Sonic and subsonic velocities, choked flow, and density changes occur, which make the
calculations difficult. Fortunately, compressible fluid flow software greatly simplifies the
effort.

First, construct a software model of the system in its normal operating configuration. Runs
of each operating mode are then used to find the largest values corresponding to the terms
in the denominator of the CFR equation.

Next, modify the model to include any configuration changes that will be made for
cleaning. All temporary pipes, bypasses, the tail pipe, blow valve, and blow path block
valves should be added.

The objective is to use the model to find the blow gas reservoir starting and ending
pressures that will result in acceptable CFR values throughout the length of pipe being
cleaned. This is done by a trial and error process in which different pressures are tested,
and the mass flow and specific volume results are imported into a spreadsheet that
calculates the CFRs. The following is some advice for determining starting pressures

 As the pipe depressurizes (is blown down), gas velocity will decrease. When the
source pressure drops to a point where the CFRs are below 1.0, the gas blow can be
terminated. By not completely depressurizing, the recycle time and quantity of gas
used can be minimized. However, use some judgement. If the blow down times are
very short (less than 10 seconds), complete depressurization will allow more time to
eject the debris.

POWER Magazine March 2020 6

 Increasing the gas mass flow rate or specific volume will increase the CFR. Mass flow
rate can be increased by increasing reservoir pressure. Specific volume can be
increased by decreasing pipe pressure or increasing the temperature.
 When gas flows through a pipe, the pressure drops along the path due to friction. The
pressure drop causes the gas specific volume and velocity to increase. If the sonic
velocity is reached, a shockwave forms. The velocity will no longer increase beyond
the shockwave and the flow is considered “choked.” Sonic choking can occur at
locations where the pipe diameter suddenly increases, at the pipe exit, and at
constrictions such as a reduced bore valve. Ideally, sonic choking should only occur at
the pipe exit and not inside the pipe, where it could cause severe pipe vibrations.
 Increasing the tail pipe diameter will increase the CFR. However, the tail pipe
diameter should be no larger than that of the piping to which it connects to avoid
creating an internal choke point.
Pressure and temperature instrumentation with data recording capability, installed near the
gas inlet and outlet, should be used to confirm that acceptable CFRs are being achieved.
Use a table or chart of gas properties to get the specific volume based on measured
pressure and temperature. Studies have shown that the most reliable method of
determining the mass flow rate (mB) is to base it on a calculation of sonic velocity (c) at
the exit.

mB = A x c / vB

where c is √(k x gC x 144 x PE x vB), k is the ratio of specific heat (about 1.4 for air and
nitrogen), and PE is the pressure at the gas exit.

Noise Control
Gas blows are loud. In fact, sonic shock waves may be visible in the gas plume exiting the
tail pipe. Hearing protection will be required for anyone work

Gas blows are loud. In fact, sonic shock waves may be visible in the gas plume exiting the
tail pipe. Hearing protection will be required for anyone working nearby.

Sound pressure level (SPL) indicates the intensity of the sound at a given point with
respect to a reference level. Measurements are usually expressed in dB(A) units where the
“A” indicates an adjustment for the frequency sensitivity of human hearing. Based on an
Occupational Safety and Health Administration (OSHA) noise limit of 90 dB(A), a
reduction to less than 85 dB(A) at a distance of 3 feet is recommended. SPL can be
estimated with the following expression derived from American Petroleum Institute (API)
Standard 521:

SPL ≅ 20 log (dE / 1000) – 10 log (vB) + 80 log [(4 x vB x mB) / (π x dE2)] – 10 log (2 x π x
r2) – 22.232

where dE is the tail pipe gas exit inner diameter and r is the distance from pipe exit. If the
plant is near a residential area, a silencer will be necessary. When specifying a silencer,
pressure loss at the maximum flow rate should be restricted to no more than about 1 psid.
A high flow resistance will result in higher blow pressures and more blow gas being used.

POWER Magazine March 2020 7

Time and Mass Calculations
When depressurization begins, the pressure differential between the reservoir and the
atmosphere is high, and the exit flow is at sonic velocity. As the differential decreases, the
exit velocity remains constant until a critical pressure is reached and it becomes subsonic.
As the reservoir pressure is reduced further, the volumetric flow and mass flow drop until
the differential pressure reaches zero. Blowdown time (t BD) can be estimated with the
following empirical expression recommended by the American Gas Association (AGA):

tBD ≅ (0.1225 x P1 0.333 x SG0.5 x V x Fc) / dE2

where P1 is the gas reservoir starting pressure, S G is the specific gravity relative to air (1.0
for air and approximately 1.0 for nitrogen), V is the storage volume under pressure
(including tank, reservoir, and piping), and FC is the choke factor (1 for an ideal exit to 1.8
and higher for a typical gate valve). Ensure the blowdown time is sufficiently greater than
the blow valve opening time and the reservoir is not pressurized above the rated pressure
capability of the components.

A positive displacement compressor will fill the reservoir at a relatively constant flow
rate. The time to recharge the reservoir (tCHARGE) can be estimated with the following
expression:

tCHARGE ≅ [V x (P2 – P1) x 60] / (Pa x Q)

where P2 is the gas reservoir ending pressure, Pa is atmospheric pressure (14.7 psia), and Q
is compressor output capacity for filling the reservoir. To estimate the calendar days
needed for cleaning, the number of blows required for each blow path is needed.

Unfortunately, an accurate prediction is nearly impossible. The number can vary from 1 to
100. If there was an emphasis to “build it clean,” fewer blow cycles should be needed.
Whatever number is used, it’s going to be a rough estimate, so add margin. Additional
time should be added to account for gathering and checking instrumentation data,
calculating CFRs, removal and insertion of target plates, and inspecting the target.

Experiencing a shortage of nitrogen during the cleaning process will delay completion. To
estimate the quantity of nitrogen required for a gas blow (q GAS), use the following
expressions based on the perfect gas laws:

qGAS ≅ (2.7 x SG x P1 x V) / T

where T is the gas temperature in Rankine (F + 459.67), or:

qGAS ≅ V / vB

Pressure Testing
ASME B31.1 covers the design and testing of power plant piping systems. ASME B31.3
is used for industrial piping such as at a refinery or chemical plant. ASME B31.8 applies

POWER Magazine March 2020 8

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to gas transportation and distribution piping. The plant owner should identify which codes
to use and where they apply.

Prior to performing gas blows, the piping must be pressure (leak) tested. Normally, water
is used. However, if permitted by the piping code, pneumatic testing could instead be
performed using the cleaning gas. This may be desired in situations where the hydro test
water cannot be easily removed, cannot be tolerated in the pipe, or is not sufficiently
available.

The applicable piping code describes the process for conducting a pneumatic pressure test.
ASME PCC-2 gives a method for determining the distance enveloping the pipe that should
be marked off with caution tape and cleared of people. The decision to perform a
pneumatic test should not be taken lightly. Pneumatic pipe ruptures occur suddenly,
usually without warning; therefore, pneumatic testing is discouraged.

Discharge Force
Much like thrust from a rocket engine, the open discharge will create a static reaction
force at the tail pipe exit. Usually an anchor is required to restrain the tail pipe from
movement. API RP 520-2 provides the following expression which can be used to
estimate the thrust force at the tail pipe exit (F):

F = 9.836 x mM x √{(k x T) / [(k+1) x Mwt ]} + [144 x (PE – Pa) x A]

where mM is the mass flow rate of gas during maximum operation and M WT is the gas
molecular weight (about 28.5 for air and nitrogen). When the blow valve suddenly opens,
the pipe will be subjected to dynamic loads as the gas starts flowing. The dynamic forces
are accounted for by a dynamic load factor (DLF). This factor represents the ratio of the
peak stress from a rapidly applied load to the stress that would occur, if applied slowly.
DLF ranges from 1.1 to 2.0. Typically, a DLF of 2 is used. If a lower value is desired, see
ASME B31.1 for details.

Do the Job Right

In a 2010 CSB-conducted survey on gas blow cleaning, about half of the respondents
stated they did not have a technical basis for determining the gas flows and pressures they
should use. Without the guidance of supporting calculations, it’s likely that more time and
gas will be required for cleaning. An analytical approach to gas blow cleaning will help to
ensure that the process proceeds safely and efficiently.

In sports, a blowout is when one team outperforms another by a large margin. When it
comes to blowout pipe cleaning, preparing a technical basis for the work will make sure
you are on the winning team.

—Michael F. Czyszczewski, PE (mczyszczewski@asme.org) is a mechanical engineer

with 40 years of experience in the power industry.

POWER Magazine March 2020 9