Saep 1662

Engineering Procedure
SAEP-1662 31 January 2005

Cleaning of Heat Exchangers
and Unfired Plant Equipment
Materials and Corrosion Control Standards Committee Members
Al-Anezi, Mohammed A., Chairman
Al-Rumaih, Abdullah M., Vice Chairman
Abdulhadi, Abdullatif I.
Al-Anizi, Salamah S.
Al-Gahtani, Moraya S.
Al-Ghasham, Tawfiq Y.
Al-Ismail, Abdulmajid A.
Al-Mugbel, Wajdi M.
Al-Nabulsi, Khalid M.
Al-Sannaa, Muhsen S.
Balhareth, Nasser M.
Bash, Fahad M.
Burgess, Brian W.
Choi, Ho J.
Cruz, Ivan C.
Dias, Olavo C.
Jones, Stan B.
Kermad, Abdelhak
Lobley, Graham R.
Mehdi, Mauyed S.
Moore, Mark A.
Morrow, Michael J.
Palmer, Robert E.
Stark, Gregory D.
Tems, Robin D.
Previous Issue: 28 January 2004 Next Planned Update: 1 February 2010

Revised paragraphs are indicated in the right margin Page 1 of 51
Primary contact: Abdullah M. Al-Rumaih on 873-4398
Document Responsibility: Materials and Corrosion Control SAEP-1662
Issue Date: 31 January 2005 Cleaning of Heat Exchangers
Next Planned Update: 1 February 2010 and Unfired Plant Equipment
Saudi Aramco DeskTop Standards

Table of Contents
1 Scope............................................................. 3
2 References..................................................... 3
3 Purpose.......................................................... 3
4 Responsibilities.............................................. 4
5 Introduction to Cleaning................................. 6
6 Preparations for Chemical Cleaning............... 6
7 Criteria for Cleaning....................................... 9
8 Chemical Cleaning Treatment Selection...... 10
9 Alkaline Treatments...................................... 13
10 Acid Cleaning and Neutralization................. 16
11 Passivation................................................... 26
12 Evaluating Cleaning Performance
by Inspection........................................ 28
13 Equipment Lay-Up....................................... 28
14 Corrosion Control, Water and
Chemical Treatment Subcommittee..... 29
Appendix 1 - Definition of Terms........................ 30

Appendix 2 - Contractor Submittals.................... 31
Appendix 3 - List of Approved Inhibitors
and Manufacturers................................ 33
Appendix 4 - Chemical Cleaning Log Sheet....... 34
Appendix 5 - High Pressure Water
Jetting (HPJ)......................................... 35
Appendix 6 - Onstream Cleaning
of Heat Exchangers.............................. 37
Appendix 7 - Heat Transfer Coefficients
and Fouling Factor................................ 42
Appendix 8 - Economic Evaluation
TFRE Concept...................................... 44
Appendix 9 - Safety Hazards
with Chemical Cleaning........................ 47
Appendix 10 - Cleaning Chemical
Compatibility Chart for Materials.......... 51
Page 2 of 51
1 Scope
This procedure defines the responsibilities of the various departments involved in the
pre commission and operational cleaning. It outlines methods to determine the need for
cleaning, the criteria for selecting specific cleaning procedures, and steps involved in
various cleaning procedure alternatives.
The use of high pressure water jetting is covered in Appendix 5 and on-stream cleaning
in Appendix 6. Advice is available from Materials Engineering & Corrosion Control
Division/Consulting Services Department (ME&CCD/CSD) to draft detailed
procedures for cleaning specific equipment.
The procedures listed herein are applicable to clean undesirable deposits in heat
exchangers and other unfired plant equipment such as piping, columns, vessels,
Multiple Effect Distillation (MED) units, etc.
For evaluation and recommendation of alternative cleaning procedures not listed herein
contact ME&CCD/CSD.
2 References
Saudi Aramco Engineering Procedure

SAEP-327 Disposal of Wastewater from Cleaning, Flushing,
and Dewatering Pipelines and Vessels
Saudi Aramco Engineering Standard

SAES-B-069 Emergency Eyewashes and Showers
3 Purpose
It is necessary to clean a new equipment initially and periodically thereafter for its
efficient operation, corrosion control and prevention of fouling related failures.
Cleaning is accomplished by a combination of (not necessarily in the sequence listed):
• Mechanical cleaning
• High pressure water jetting (HPJ)
• Hot alkaline treatment
• Acid cleaning and Neutralization
• Passivation
• Cleaning with Solvents
Page 3 of 51
For some equipment it may not be necessary to use all of the above steps since the
degree of contamination will vary from unit to unit. Scale severity, and its analysis,
tube failures, inspection and consultation with the various departments outlined in
Section 4 will determine the exact procedure to be used. This procedure does not
override an equipment manufacturer's cleaning recommendations, especially where
warranty rights are involved. Differences shall be questioned and resolved by the
proponent.
4 Responsibilities
4.1 The Project Construction Agency is responsible for cleaning new equipment.
4.2 The Facility Operating Department is responsible for cleaning commissioned

equipment.
4.2.1 Maintenance
• Prepares the equipment mechanically.
• Provides maintenance support during the cleaning operation.
• Coordinates cleaning and obtains approved contractor services.
4.2.2 Operations Engineering

• Prepares necessary operation procedures, advises the foreman of the
plant during the chemical cleaning of the equipment.
• Acts as a technical representative to facility operator during the
chemical cleaning.
• Ensures adequate safety procedures and precautions are taken.
Notifies Loss Prevention Department to review safety during
cleaning.
• Coordinates and obtains the approval of chemical cleaning
procedures and formulations from the ME&CCD/CSD and the
Research and Development Center (R&DC).
• Requests the presence of specialist personnel from ME&CCD/CSD if
this service is desired.
4.2.3 Operations Inspection

• Has the responsibility for inspection before and after cleaning.
• Is responsible to get and keep the corrosion monitoring records from
the contractor.
Page 4 of 51
• Maintains history of equipment chemical cleaning. Incorporates

relevant reports and data into permanent plant records.
4.3 Loss Prevention Department

• Audits cleaning operations and permits
• Advises on field safety precautions on request.
4.4 Research and Development Center (R&DC)

• Evaluates new chemical cleaning procedures and new corrosion inhibitors.
• Provides specialist/consultant advice on request.
4.5 Regional Laboratories

• Perform scale density, solubility, and chemical analysis, inhibitor
effectiveness testing and analyses during actual cleaning operations on
request.
• Verify the purity of acids and chemicals used for chemical cleaning on
request.
4.6 Chemical Cleaning Contractor
The chemical cleaning contractor is selected from the Consulting Service

Department's approved list of chemical cleaning contractors. Contractor
responsibilities are stated in the contract. Usually this includes: submittal of
procedures and documents per Appendix 2; supply of all chemicals, inhibitors
per Appendix 3, auxiliary pumping and heating equipment as required, and the
necessary personnel for chemical cleaning, including a qualified chemist for
chemical analysis during the chemical cleaning; on line monitoring and control
of corrosion rates; disposal of all waste water and chemical solutions as
provided in SAEP-327; and cleaning the equipment to meet or exceed the
acceptance criteria outlined in Section 12.
4.7 ME&CCD/CSD
• Reviews and approves the cleaning procedures and subsequent changes
necessitated by the field conditions.
• Provides specialist/consultant advice on request.
• Witnesses the cleaning operation on request.
Page 5 of 51
5 Introduction to Cleaning
The cleaning process may involve a combination of several stages. Plan the stages of
cleaning in advance.
5.1 Mechanically remove, using power brushes or reamers as much of the deposits
as possible from the equipment.
5.2 Remove deposits if access is available with high-pressure water jetting. See
Appendix 5 for details.
5.3 Clean on-stream with acid slugging. See Appendix 6.
5.4 Remove oil, grease, and organic deposits and to neutralize pyrophoric material
with hot permanganate, alkaline treatment, or surfactants.
5.5 Removal of tarry and polymerized deposits by cleaning with organic solvents
such as heavy aromatic naphtha (HAN), kerosene, diesel, gas oil, or proprietary
solvents.
5.6 Acid clean to chemically remove, mill scale, mineral deposits from water,
process side deposits and corrosion products.
5.7 Neutralize acids and passivate to form a strongly adherent protective oxide layer
on the wetted metal surface.
6 Preparations for Chemical Cleaning
6.1 General
1. Install all necessary temporary piping, sacrificial valves and pressure,

temperature and level instruments. Do not connect equipment with
dissimilar metals into one system for circulation of acids.
2. Isolate the equipment from the process side by blinds. Install vents and
adequately sized temporary valves to permit draining acids with in 30
minutes. Use temporary plugs or slip blinds to isolate sections that do not
require cleaning.
3. Store all chemicals needed for the procedure on-site prior to commencing
cleaning, including emergency neutralizing agents and nitrogen as well as
wet lay-up chemicals.
4. Ensure that an adequate supply of water is available for flushing and

cleaning.
Page 6 of 51
5. Ensure that instrument connections (except those temporarily installed) are

disconnected before acid cleaning stage.
6. Install fittings for liquid sampling, flow elements, temperature probes, pipe
spools with on-line access fittings for corrosion monitoring probes.
7. Provide adequate lighting at all operating points.
8. Plan for the disposal of wastewater and spent chemical solutions per
SAEP-327.
9. Perform checks on valve lineups as required for flushing and reversing

circulation.
10. Notify ME&CCD/CSD and the Regional Laboratories of intention to

chemically clean. Request the presence of ME&CCD/CSD personnel
during any stage of chemical cleaning for consultations as necessary.
11. Ensure utility water is available, or provide a temporary supply

connection.
12. Ensure sufficient supply of nitrogen at 80 psig to quickly drain using

nitrogen pressure any acid in the equipment.
13. Check and ensure that the flow design includes: flow reversal manifold
and valves, control valves and bypass to control circulation within
specified limits, blend filling of corrosive chemicals (acids and chelants)
without exposure to the atmosphere.
14. Test the cleaning circuit hydrostatically at 1.25 times the dead head
discharge pressure of the circulating pump, after installation of all
temporary piping and connections, prior to chemical cleaning.
15. Ensure that an external heat source is available to maintain the cleaning
fluid temperature, within the limits specified.
16. Ensure spare pumps are available in case of a pump failure to maintain
circulation, and nitrogen pressure connection to drain the acid within
fifteen minutes in case of an emergency. Ensure sufficient holding tank
capacity is available for draining and neutralizing cleaning solutions if
necessary.
17. Ensure, using standard samples, that on-site chemical analytical

procedures and laboratory analytical procedures yield results within ±10%.
18. Ensure inhibitor is selected from Appendix 3.
Page 7 of 51
19. Determine the volume of the equipment by filling with water and draining
it through a flow meter.
20. Be aware of the safety hazards (see Appendix 9) associated with chemical
cleaning and take adequate safety measures.
21. Ensure chemical feed lines are a minimum of 1/12th the diameter of the
vessel or exchanger; drains and vents are clear.
22. Ensure that the chemical cleaning contractor is on-site with mixing tanks,
chemicals, flow meter, corrosion monitoring equipment, pH and
temperature probes, and pumping equipment to blend fill and circulate
chemicals.
23. Flush the equipment with water until it runs clear to remove all loose and
soluble deposits.
24. Use commercial grade quality for all chemicals except where austenitic
materials are present in the equipment to be cleaned. In this case, the total
chlorides of all the chemicals in the mixture must not yield a final solution
containing greater than 50 mg/L as chloride.
25. Install at least one corrosion probe in the circulating loop for on line
monitoring and control of corrosion rates.
6.2 Cleaning Record
1. Cleaning temperatures, time, dates of cleaning process, chemical additions,

and results of chemical cleaning analysis are recorded in a logbook by
Operations Engineering.
2. Typical log sheets include what is shown in Appendix 4, contractor's log

sheets and the on line corrosion monitoring results.
3. Operations Inspection Unit is to collect and keep as permanent plant

records, these log sheets on completion of the cleaning operation.
6.3 Safety Precautions
1. Close all instrument connections and disconnect to protect instruments

from exposure to corrosive solutions.
2. Keep operational and tested, permanent or temporary eye wash fountains

and safety showers per SAES-B-069, within 15 meters and accessible in
10 to 15 seconds of the work site, prior to initiation of chemical cleaning.
Page 8 of 51
3. Adhere to the work permit procedures. Vent flammable gases when

corrosive chemicals are used in the cleaning operation. A "Release of
Flammable Gas" Work Permit will be required. Therefore, do not permit
welding, burning, or running of welding machines or generator sets within
a 5 meter radius from the vents of the systems being cleaned. A hot work
permit will be required to operate pumps. Nitrogen is a non-toxic gas that
will not support life. Entrance by personnel into the equipment will be in
accordance with the requirements in the CONFINED SPACE ENTRY
permit procedures including oxygen tests, combustible gas tests, use of
lifelines if required, etc.
4. Keep hoses connected to an operable water supply adjacent to the

equipment being cleaned to dilute any chemical spills.
5. Rope off the area where the blending and heating of chemical solutions is
performed and post "DANGER" signs. Do not let unauthorized personnel
enter the roped off area.
6. Keep at cleaning site chemical hazard bulletins on various chemicals or

materials from the Environmental Protection Department. These bulletins
provide information on storage, handling, and protective measures for
these chemicals.
7. Ensure all nitrogen cylinders if in use, have individual regulators and are
adequately secured. Also, ensure the nitrogen manifold has a safety relief
valve attached.
8. Ensure all personnel handling chemicals wear protection equipment

required by the chemical hazard bulletins of the materials involved.
9. Ensure the contractor is equipped with adequate portable fire extinguishers

for its equipment.
10. Be aware and prepared for safety hazards with equipment deposits, noted
in Appendix 9.
7 Criteria for Cleaning
Use any one of the following criteria to determine when to schedule cleaning.
1. Inspection: On every T & I, check inside the tubes and shell for corrosion and
scale. Note down the location and amount of scale buildup and check tube ends
for pits, and deposit. Scrape off deposits to determine its composition. Low flow
rate areas, boots, drains are particularly susceptible to heavy deposit buildup.
Visual inspection will indicate the condition of the equipment and will be one of
Page 9 of 51
the primary factors in determining the need for cleaning. Inspect tubes inside and
on shell side for total blockage. Blocked tubes cannot be chemically cleaned until
a flow path is made for chemical circulation.
2. Clean whenever the actual heat transfer coefficient ( Uactual) drops to 60 % of the
Udesign at heat exchanger design operating conditions. (See Appendix 7).
3. Clean when the ten-day average Rf reaches twice of Rfdesign value. Rf is

independent of the fluctuations in the flow rates during the service period. (See
Appendix 7).
4. Clean when the total fouling related expenditure (TFRE) is at the minimum. (See
Appendix 8).
5. Clean whenever the drop in heat duty is unacceptable to Plant Operations.
6. Clean during T&I or unplanned shutdown to take advantage of down time.
7. Using scale monitoring or based on recorded rate of scale or corrosion products

build up, schedule cleaning before fluid flow is obstructed inside or outside the
tubes.
8 Chemical Cleaning Treatment Selection
8.1 General Criteria
8.1.1 Primarily select chemicals that: a) are safe to use, b) are compatible with
the materials of construction (see Appendix 10), c) will remove > 70% of
the undesired deposits, d) will achieve the desired degree cleaning.
8.1.2 With these criteria satisfied, make the final selection, with due reference
to other constraints including cost, environmental restriction on disposal
of waste solutions, and cleaning time available. Responsibility for the
final procedure of the treatment(s) is defined in Section 4. For on stream
cleaning see Appendix 6. Off stream chemical cleaning will involve one
or more of the following steps: Hot alkaline degreasing (see section 9),
acid cleaning (see section 10), followed by neutralization and passivation
treatment (see section 11). Laboratory analyses of deposit samples will
determine the above sequence.
8.1.3 High pressure water jetting (HPJ) may precede or follow to remove
loosened scale (see Appendix 5). HPJ is very effective to remove most
brittle deposits. The use of HPJ is recommended alone, or before
chemical cleaning.
8.2 Analysis of Scale
Page 10 of 51
8.2.1 General - Fouling composition, quantity, and distribution, will vary

considerably between one equipment and another, or even within the
same equipment at various time intervals during its life. It is therefore
necessary in each case, to select a specific treatment, or series of
treatments, which will be most effective in achieving thorough and safe
cleaning, to restore its operational efficiency. Determine the
composition of the scale or deposit and the suitable acids or organic
solvents to remove them before any chemical cleaning. Take a sample
or samples carefully representative of the deposit.
8.2.2 Solubility in Dilute HCl - This figure represents the weight percent of the
deposit, which will dissolve in boiling 7.5% wt., inhibited hydrochloric
acid.
8.2.3 Loss on Ignition - This figure represents the weight percentage of the
deposit that can be removed by heating the insoluble residue from 8.2.1
above to 315°C in a laboratory furnace. The result is indicative of the
organic content of the deposit in the forms of oil, grease, degraded
polymers and carbon. If the figure is high (greater than 10%) further
definition of the organic content can be determined by refluxing the
sample with a suitable organic solvent, which will indicate the relative
proportions of oil and grease, and carbon. These proportions assist in the
selection of a suitable hot alkaline or permanganate treatment.
8.2.4 Insoluble Residue - This figure represents the insoluble complexes of

other cations and, if the quantity is significant (i.e., greater than 2%)
further treatments with more concentrated hydrochloric acid may be
required to render the material soluble.
8.2.5 Metals - The metal ions present in the deposit, are analyzed for iron (Fe),
copper (Cu), calcium (Ca), magnesium (Mg), nickel (Ni), zinc (Zn),
manganese (Mn) and sodium (Na). These results are useful to determine
the number of cleaning stages that are likely to remove all the deposits
from the system.
8.2.6 Anions - Phosphate, sulfate, carbonate and sulfide are also determined in
the scale. This information is useful to determine the need for
sulfate/sulfide conversion treatment or the need to suppress the evolution
of H2S during acid cleaning.
8.3 Hot Alkaline Treatment Selection
8.3.1 Where oil, grease, carbon, or other organic compounds are present, these
must be removed during cleaning. Selection depends on the degree of
contamination. Use hot alkaline treatment only when organic deposits
Page 11 of 51
interfere with acid cleaning. If solubility of deposits is >70% in acid

with or without addition of surfactants then a separate alkaline stage is
not required.
8.3.2 Soda ash (Na2CO3) degreasing is a mild treatment used where

contamination is primarily light oil and grease, with less than 5% organic
contamination. See Section 9.1.
8.3.3 Caustic degreasing (NaOH) is the treatment used for all new equipment,
and where mill scale is present, or organic contamination is 5% to 25%.
See Section 9.2.
8.3.4 Permanganate (KMnO4) degreasing is used where organic contamination

is heavy (> 25%) and carbonized. This treatment should only be
employed where fouling type and quantity render it necessary, since
costs, and complication of subsequent acid cleaning, are greater than in
the case of the alternatives. See Section 9.3.
8.4 Acid Cleaning Selection
8.4.1 Hydrochloric Acid: Inhibited hydrochloric acid is the most widely used
acid since it produces good solubility with a wide variety of scales, is
economic, and easy to handle. It exhibits good corrosion characteristics
when correctly inhibited and the process is controlled within the
accepted limits. The process is flexible and can be modified to enhance
silica removal by the addition of ammonium bifluoride, or to remove
organics by addition of surfactants. It is not compatible with stainless
steels.
8.4.2 Citric Acid: Citric acid is compatible with stainless steels, and presents
good handling, safety, and corrosion characteristics. It is less aggressive
in its attack of some iron oxide scales and therefore usually requires
higher temperatures or longer contact times. It has little effect on
calcium salts present in deposits. In general it is more expensive than
hydrochloric acid treatment. The normal reasons for its selection are: a)
presence of austenitic materials of construction. b) rust removal,
neutralization and passivation can be carried out using a single solution,
thereby considerably reducing cleaning time by eliminating the need to
drain, flush, and refill the equipment between stages.
8.4.3 EDTA: Disodium or tetra sodium EDTA salts, are used to remove
calcium sulfate deposits. Corrosion rates are low under controlled
conditions.
Page 12 of 51
8.4.4 Sulfuric acid: Sulfuric acid is an effective acid for iron oxides, iron
sulfides and is lower in cost than hydrochloric acid. It is also compatible
with stainless steels. However, it is dangerous to handle. In its
concentrated form, it is aggressive to organic material, and contact with
the skin or eyes are extremely dangerous. Its use is not recommended
where scales contain significant calcium, due to the formation of
insoluble calcium sulfate.
8.4.5 Sulfamic acid: Sulfamic acid has the advantage of being a crystalline
solid, which is simple, to store, handle, and mix. It is frequently sold
mixed with an inhibitor and a color indicator to show effective acid
strength. It is compatible with stainless steels and is a moderately
aggressive acid for iron oxide and calcium carbonate. Due to its
relatively high cost, it is mainly used on low volume equipment. It is not
recommended to clean copper alloys due to their susceptibility to stress
corrosion cracking.
8.5 Neutralization and Passivation
Following acid cleaning it is essential that the equipment be thoroughly

neutralized. This is either achieved by neutralization alone, usually with 0.5%
sodium carbonate, or during the passivation treatment (see Section 11), where
the process requires pH values of 7 or greater.
The selection of passivation treatment is sometimes governed by the selection of

the acid. Where citric acid or EDTA processes have been used, these are
extended to effect neutralization and passivation by a suitable pH adjustment
and the addition of an oxidizing agent. It can also be achieved by the
nitrite/phosphate treatment (see Section 11).
9 Alkaline Treatments
9.1 Alkaline Degreasing with Soda Ash
9.1.1 Control Parameters
Sodium carbonate 0.5 to 1.0% by weight

Sodium metasilicate 0.5 to 1.0% by weight
Trisodium phosphate 0.5 to 1.0% by weight
Surfactant 0.1 to 0.2% by volume
Anti foam (if required) 0.05 to 0.1% by volume
Temperature Limits 85°C to 95°C
Circulation Rate 1 to 2 volumes / hour
Residence Time 2 to 3 hours
Page 13 of 51
9.1.2 Testing
Determine every hour the phosphate and M-alkalinity values. If the

M-alkalinity and phosphate concentrations have dropped to half the
original values, add chemicals to restore the original concentration.
9.1.3 Safety Hazards
The solution can react violently with acids. Heating the solution will
expand its volume. Be prepared to open drain valves to maintain desired
levels.
9.1.4 Procedure
1. Verify volume of equipment to appropriate level by filling and
draining through a flow meter.
2. Dissolve the chemicals externally and blend fill through the
chemical feed connection. Open vent and fill the equipment from
the bottom to ensure adequate contact of degreasing solution with
the contaminated metal surfaces.
3. Provide external heating to control temperature.
4. Circulate for 2 to 3 hours reversing flow every 30 minutes.
5. Drain the solution quickly with air pressure (5 psig max) into a
holding tank.
6. Fill the equipment with water heated to 77°C and drain quickly to
rinse.
7. Inspect
8. If no further cleaning is required, then reconnect all instrument
lines.
9. Replace all hand and manhole covers, using new gaskets.
10. Remove blinds, temporary piping and instruments.
11. Place the equipment in service.
9.2 Caustic Degreasing
9.2.1 Control Parameters:
Sodium hydroxide 1.0 to 2.0% by weight

Trisodium phosphate 0.5 to 1.0% by weight
Page 14 of 51
Anti foam (if required) 0.05 to 0.1% by volume

Circulation Rate 1 to 2 volumes/hour
9.2.2 Testing
Determine every hour the phosphate and M-alkalinity values. If the

M-alkalinity and phosphate concentrations have dropped to half the
original values, add chemicals to restore the original concentration.
Sodium hydroxide reacts exothermically with water. Therefore, never

add water to it. Add sodium hydroxide, either liquid or solid, into water
slowly with constant stirring. Heating the solution will expand its
volume. Be prepared to open drain valves to maintain desired levels.
9.2.4 Procedure
The procedure is same as in Section 9.1.4.
9.3 Permanganate Treatment
This procedure is also good to convert pyrophoric iron sulfides to soluble

sulfates and to eliminate H2S liberation if HCl is used subsequently.
Sodium hydroxide 1.0 to 3.0% by weight

Potassium permanganate 1.0 to 3.0% by weight
9.3.2 Testing
Take samples at one-hour intervals. Monitor M-alkalinity, permanganate

concentration, and temperature. If permanganate strength drops below
1.0%, do not add permanganate to increase its concentration. Drain the
equipment into a holding tank, add fresh degreasing solution and
continue circulation.
Page 15 of 51
Handle carefully potassium permanganate as it is a strong oxidizing

agent. Add slowly with constant stirring to dilute sodium hydroxide in
water.
9.3.4 Precautions
Do not use any antifoam or surfactant as they will react with

permanganate and deplete its strength. This treatment frequently results
in the deposition of manganese dioxide. If this treatment is to be
followed by hydrochloric acid stage, chlorine may be liberated with a
consequent increase in corrosion rates and safety hazards (see Section
10.2.6 commentary note).
9.3.5 Procedure
1. Verify volume of equipment to appropriate level by filling and
draining through a flow meter.
2. Dissolve the chemicals externally and blend through the chemical
feed connection. Fill the equipment from the bottom to ensure the
cleaning solution wets all contaminated surfaces.
3. Provide heat externally to bring to desired temperature range.
4. Circulate for 2 to 4 hours reversing flow every 30 minutes.
Monitor until permanganate concentration stabilizes.
5. Drain the solution quickly under air pressure (5 psig max) into a
holding tank.
6. Fill the equipment with water heated to 77°C and drain quickly to
rinse. Inspect.
7. If no further cleaning is required then reconnect all instrument
lines.
8. Replace all hand and manhole covers, using new gaskets.
9. Remove blinds, temporary piping and instruments.
10. Place the equipment in service.
10 Acid Cleaning and Neutralization
10.1 General
Following removal of organic material, acid cleaning is carried out to remove

iron oxides, sulfides, water borne scales, and silica. The acids are selected as
noted in Section 8.
Page 16 of 51
Although the acid concentrations listed encompass most cleaning operations,

some times higher acid, inhibitor and ammonium bifluoride concentrations may
be beneficial. Extended contact times may be required than those specified for
removing certain heavy and hard to remove deposits. Changes to the specified
procedures below require prior approval from .
Commercial grade quality for all listed chemicals is adequate. The concentrated
acid must not contain greater than 100 mg/L of iron. Where austenitic materials
are present in the system to be cleaned the total chlorides of all the chemicals in
the mixture must not yield a final solution containing greater than 50 mg/L as
chloride.
Perform a hydrostatic pressure test of the cleaning circuit at 1.25 times the dead
head pressure of the circulating pump before acid addition.
10.2 Hydrochloric Acid
10.2.1 Do not use this procedure in equipment with mixed metallurgy or with
stainless steel. More than one acid cleaning cycle may be required to
clean.
Hydrochloric acid 3.5 to 7.5% by weight

0.2 to 0.3 % by volume or as
Inhibitor recommended by manufacturer
Ammonium bifluoride 0.0 to 1.0% by weight
Oxalic acid (See Note) 1.0% by weight
Residence Time 2 to 4 hours.
Corrosion Rates < 600 mpy
Total dissolved Iron 10,000 mg/L max.
10.2.3 Testing
Prior to commencement, test the inhibitor for effectiveness. During

circulation monitor the solution for acid, total iron concentration,
corrosion rate, temperature, and inhibitor effectiveness. Take samples at
30 minute intervals, or more frequently. Perform analyses as rapidly as
possible and preferably on-site.
Page 17 of 51
Hydrochloric acid is a strong mineral acid. Handle with suitable

precautions, particularly in the concentrated state. Oxalic acid is highly
toxic.
10.2.5 Precautions
Review materials of construction to ensure that they are compatible with

high chloride solutions. Austenitic stainless steels are prone to stress
corrosion cracking in such environments and must not be present in
systems to be cleaned by hydrochloric acid. Do not use HCl to clean
equipment with ferrous and non ferrous metals that are not electrically
isolated. Corrosion rates are controlled by a number of variables. These
include temperature, circulation velocity, residence time, acid
concentration, inhibitor concentration and concentration of dissolved
ions. Control these variables within their limits unless approved by
ME&CCD/CSD.
10.2.6 Procedure
1. Replace all permanent valves, which will come in contact with

acid, with sacrificial valves or protect them with blinds. If
sacrificial valves are not available, keep new valves on hand for
replacing all valves contacted by acid during the cleaning
procedure.
2. Fill the equipment from the bottom with water to the top
eliminating all air in the system. If the water is sufficiently hot,
circulate by chemical cleaning pumps to achieve uniform metal
temperatures throughout the equipment, and adjust to 70-82°C. If
the water is not at a high enough temperature, use an external heat
exchanger, or inject steam, to raise and adjust temperature by
circulation.
3. Strip dissolved oxygen in the inhibited acid by sparging nitrogen at

1M³/hr using a PVC pipe into the acid containers for at least 1
hour.
4. Use nitrogen to drain back sufficient volume of water to

accommodate inhibited acid addition. Check inhibitor
effectiveness in the acid on-site. As quickly as possible, blend fill
the equipment with inhibited acid solution. Blend a slightly higher
concentration during the beginning of the fill than at the end
because the initial acid entering the equipment is consumed to
some degree during the fill. Ammonium bifluoride may be added
in concentrations up to 1.0% by weight to assist in the removal of
Page 18 of 51
silica. In the absence of silica, the ammonium bifluoride

concentration shall not exceed 0.5% by weight when it is added to
assist in the removal of iron.
5. Circulate solution using chemical cleaning pumps. Reverse flow

direction every hour using flow reversal manifold. Take samples
from the various locations and monitor temperature, acid strength,
iron concentration, and inhibitor effectiveness. During circulation,
temperatures will gradually decay from 82°C. This is acceptable to
65°C. If, it becomes necessary to raise the temperature, use an
external heat exchanger. Do not inject steam into the acid solution.
If the acid strength falls below 3.0%, or if the total iron exceeds
10,000 mg/L, drain the equipment immediately into a holding tank
under nitrogen pressure of 70 to 10 to 50 psig and go to step 2.
6. Continue circulation, taking test samples every 30 minutes.

Continue cleaning until the acid solution and total iron
concentration approach equilibrium.
7. Check for acid leaks in the circulation system, and if the leaks
cannot be contained drain as in step 8.
8. Drain the acid into a holding tank under a positive nitrogen

pressure of 10 psig. Drain as fast as possible, using the maximum
number of drain valves consistent with maintaining a positive
nitrogen pressure. Introduce nitrogen into the equipment through
the vent line.
9. Fill to the top of the equipment with hot water mixed with 2 to 3 %
of soda ash. Drain the equipment under nitrogen as before and
refill with water, for a second rinse. Drain the second rinse under a
positive nitrogen pressure. Soda ash may have to be added to the
solution drained directly into the sewer, to ensure that its pH is
above 7. When no repeat acid cleaning is required about 0.1% by
weight of citric acid should be added to the second rinse to assure
more thorough rust removal.
10. If the acid is drained because of any one of the three reasons cited
in step 6,or 7 above, water flush to clear drains and repeat steps
from 2.
Commentary Note:
Where a permanganate treatment is used, the residual scale will probably

be contaminated with manganese dioxide. This will liberate chlorine in
contact with hydrochloric acid and 1.0% of oxalic acid must be added to
Page 19 of 51
the hydrochloric acid to prevent this. The liberation of chlorine gas in the
low pH HCl environment will result in accelerated corrosion in the form of
severe pitting attack.
10.3 Citric Acid
10.3.1 More than one acid cleaning cycle may be required to remove all the
rust. Citric acid is not effective to remove water scales or iron sulfides.
Citric acid 2.5 to 5% by weight

Sodium Hydroxide To pH 4.0 to 4.5 during rust removal,
9.0 to 9.5 during passivation
Sodium nitrite 0.5% by weight
10.3.3 Testing
Take samples at 30 minute intervals. During rust removal monitor

corrosion rate, temperature, iron concentration, free citric acid
concentration, and pH.
Handle carefully sodium nitrite as it is a strong oxidizing agent.
10.3.5 Precautions
Corrosion rates are controlled by a number of variables. These include

temperature, circulation velocity, residence time, acid concentration and
concentration of dissolved ions. Control these variables within their
limits unless approved by ME&CCD/CSD.
10.3.6 Procedure
temperatures throughout the equipment, and adjust to 93°C. If the
Page 20 of 51
water is not at a high enough temperature, use an external heat

exchanger or inject steam to raise and adjust temperature by
circulation.

the equipment with premixed inhibited citric acid with sufficient
sodium hydroxide to adjust pH to 4.0 to 4.5.

direction every 30 minutes using flow reversal manifold. Take
sample and monitor temperature, free citric acid strength, iron
concentration, inhibitor effectiveness, and pH. If the free citric
acid strength falls below 1.0%, add citric acid to maintain 1.0%
level. During circulation, temperatures will gradually decay from
the original levels. The temperature drop to 70°C is acceptable at
the completion of this phase. If, however, it becomes necessary to
raise the temperature, use an external heat exchanger. Do not inject
steam into the acid solution.
4. Continue circulation, taking test samples every 30 minutes, and

until the acid solution and total iron concentration approach
equilibrium.
5. Check for acid leaks in the circulation system. If the leaks cannot
be contained, or if the total iron exceeds 10,000 mg/L, drain the
equipment immediately into a holding tank under nitrogen pressure
of 10 psig, rinse the equipment with water, water flush to clear
drains and repeat steps from 1.
6. Ensure free citric acid concentration is 1.0%. If not, add further

citric acid to achieve this level. Add caustic to adjust pH to 9.5.
7. Add 0.5% sodium nitrite. Continue circulation for 2 hours

minimum.
8. Drain under air and fill the equipment with hot water to the top.
Drain the equipment under air as before and refill with water, for a
second rinse. At this point the equipment is both neutralized and
passivated.
10.4 EDTA (Ethylene Diamine Tetra Acetic Acid) salts
Use this procedure to remove sulfate deposits.
Page 21 of 51
Tetra or disodium EDTA 3 to 10.0% by weight for sulfate removal

pH > 9.5
10.4.2 Testing
Prior to commencement, test the inhibitor for effectiveness. Take

samples every 30 minutes. Monitor pH, EDTA concentration, corrosion
rate, and temperature.
10.4.3 Procedure
1. Fill with hot water inject concentrated premixed solution of EDTA

with inhibitor to provide a 10.0% solution in the equipment.
2. Do not allow the temperature to decay below 80°C. Monitor

EDTA concentration and pH. Maintain pH above 9.5 by adding
caustic if necessary. If free EDTA concentration drops below
1.0%, inject more EDTA to restore concentration to 3.0%.
3. Drain the solution with air pressure into a holding tank. Fill and
drain, twice with water.
4. Open equipment and inspect. Use hydrojetting to remove loose

sulfate deposits.
10.5 Sulfuric Acid
More than one acid cleaning cycle may be required to remove all the rust. Do
not use H2SO4 to clean exchangers with ferrous and nonferrous metals that are
not electrically isolated.
Sulfuric acid 4.0 to 8.0% by weight

Inhibitor 0.2 to 0.3 % by volume or as
recommended by manufacturer
Page 22 of 51

Total Residence Time 2 to 4 hours
Dissolved Iron 10,000 mg/L max.
10.5.2 Testing
Prior to commencement, test the inhibitor for effectiveness. During

circulation monitor the solution for acid, total iron concentration,
corrosion rate, temperature, and inhibitor effectiveness. Take samples at
30 minute intervals. Perform analyses as rapidly as possible and
preferably on-site.
Sulfuric acid is a strong mineral acid, and must be handled with care,
particularly in the concentrated form. Considerable heat is evolved
during dilution. Never add water to concentrated sulfuric acid. Add the
acid slowly to water mixing thoroughly.
10.5.4 Precautions

inhibitor concentration, temperature, circulation velocity, residence time,
acid concentration and concentration of dissolved ions. Control these
variables within their limits unless approved by ME&CCD/CSD.
10.5.5 Procedure
1. Replace all permanent valves, which will come in contact with

acid, with sacrificial valves. If sacrificial valves are not available,
keep new valves on hand for replacing all valves contacted by acid
during the cleaning procedure.
circulation.
Page 23 of 51
3. Strip dissolved oxygen in the inhibited acid by sparging nitrogen at

1 m³/hr using a PVC pipe into the acid containers for at least 1
hour.

the equipment with inhibited acid solution. Blend a slightly higher
concentration during the beginning of the fill than at the end
because the initial acid entering the equipment is consumed to
some degree during the fill.

direction every 30 minutes using flow reversal manifold. Take
samples and monitor temperature, acid strength, iron concentration,
and inhibitor effectiveness. During circulation, temperatures will
gradually decay from the original figure of approximately 82°C.
This is acceptable to 60°C. If, it becomes necessary to raise the
temperature, use an external heat exchanger. Do not inject steam
into the acid solution. If the acid strength falls below 3.0%, or if
the total iron exceeds 10,000 mg/L, drain the equipment
immediately into a holding tank under nitrogen pressure of 10 psig
and go to step 2.

7. Drain the acid into a holding tank under a positive nitrogen

pressure of 10 psig. Drain in as short a time as possible, using the
maximum number of drain valves consistent with maintaining a
positive nitrogen pressure. Introduce nitrogen into the equipment
through the drum vent line.
8. Fill the equipment with hot water mixed with 2 to 3 % of soda ash
to the top. Drain the equipment under nitrogen as before and refill
with water, for a second rinse. Drain the second rinse under a
positive nitrogen pressure. Soda ash may have to be added to the
solution drained directly into the sewer, to ensure that its pH is
above 7. When no repeat acid cleaning is required about 0.1% by
weight of citric acid should be added to the second rinse to assure
more thorough rust removal.
10.6 Sulfamic Acid (H2NSO3H)
Page 24 of 51
More than one acid cycle may be required to clean. Do not use sulfamic acid to
clean exchangers with copper alloys due to possibility of stress corrosion
cracking. Approximately 1 kg of sulfamic acid will dissolve 0.5 kg of CaCO3.
Sulfamic acid 5.0 to 10.0% by weight

NaCl* 2.5% by weight
Inhibitor 0.1 to 0.2 % by volume or as
recommended by manufacturer
pH < 1.5
* add to enhance rust removal only in carbon steel systems
10.6.2 Testing
Prior to commencement, test the acid for inhibitor effectiveness. Take

samples at 30 minute intervals, or more frequently. Perform analyses as
rapidly as possible and preferably on-site. Monitor acid and iron
concentrations, corrosion rate, temperature and inhibitor effectiveness.
10.6.3 Precautions

temperature, circulation velocity, residence time, concentration of acid,
inhibitor, and dissolved ions. Control these variables within their limits
unless approved by ME&CCD/CSD.
10.6.4 Procedure
circulation. Use nitrogen to drain back sufficient volume of water
to accommodate inhibited acid. Check inhibitor effectiveness in
the acid on-site. As quickly as possible, blend inhibited acid
Page 25 of 51
solution into the equipment. Blend a slightly higher concentration

during the beginning of the fill than at the end because the initial
acid entering the equipment is consumed to some degree during the
fill.

direction every 30 minutes using flow reversal manifold. This is
essential in order to achieve good cleaning, reduce corrosion, and
maintain uniform temperatures and concentrations. Take samples,
and monitor temperature, acid strength, iron concentration, and
inhibitor effectiveness. During circulation, temperatures will
gradually decay. This is acceptable to 60°C. If, it becomes
necessary to raise the temperature, use an external heat exchanger.
Do not inject steam into the acid solution. Check for leaks in the
circulation system. If the leaks cannot be contained or, if the acid
strength falls below 1.0%, or pH raises above 1.5, or if the total
iron exceeds 10,000 mg/L, drain the equipment immediately into a
holding tank under nitrogen pressure of 10 psig and go to step 1.

4. Drain the acid under a positive nitrogen pressure of 10 psig into a

holding tank. Drain in as short a time as possible, using the
maximum number of drain valves consistent with maintaining a
positive nitrogen pressure. Introduce nitrogen into the equipment
through the vent line.
5. Fill the equipment from the bottom with water to the top. Drain the
equipment under nitrogen as before and refill with water, for a
second rinse. Drain the second rinse under a positive nitrogen
pressure. Soda ash may have to be added to the solution drained
directly into the sewer, to ensure that its pH is above 7. When no
repeat acid cleaning is required about 0.1% by weight of citric acid
should be added to the second rinse to assure more thorough rust
removal.
11 Passivation
11.1 General
Immediately after cleaning with mineral acids and rinsing of the equipment, the
final step is passivation of the freshly cleaned steel surfaces. Passivation is not
required after hydro jetting, or for equipment made of non-ferrous alloys or
Page 26 of 51
stainless steels. Use commercial grade quality for listed chemicals except where
austenitic materials are present in the system to be cleaned, the total chlorides of
all the chemicals in the mixture must not yield a final solution containing greater
than 50 mg/L as chloride.
11.2 Inspection
Following the neutralization step, visually inspect equipment to determine

whether another acid stage or high pressure water jetting is required. Also,
inspect following the high pressure water jetting to determine its effectiveness in
removing the scale and if more jetting is required.
Page 27 of 51
11.3 Control Parameters
Sodium nitrite 0.5% by weight

Monosodium phosphate 0.25% by weight
Disodium phosphate 0.25% by weight
Sodium hydroxide Adjust pH to 7
Circulation Rate 1 to 2 volumes / hour
11.4 Testing
Monitor and maintain pH by adding caustic if necessary
11.5 Safety hazards
Sodium nitrite is a strong oxidizing agent. It must be handled with care.
11.6 Procedure
1. Blend fill the equipment to the top, and circulate by chemical cleaning
pumps.
2. At the end of the six hours, drain the equipment under air pressure.
3. Open vents, drain and inspect internals for completion of work.
12 Evaluating Cleaning Performance by Inspection
Plant Inspection, Operations, Operations Engineering and the cleaning contractor are to
inspect after the cleaning, to ascertain that the job has been successfully completed.
Visual and video boroscope inspections are carried out to determine the effectiveness of
cleaning. No visible traces of water, loose or adherent deposits inside the equipment are
acceptable.
13 Equipment Lay-Up
If the startup of the equipment after cleaning is likely to be delayed by more than five
days, dry it with nitrogen to a dew point of 1°C and store it under a positive pressure of
nitrogen for corrosion protection.
Page 28 of 51
14 Corrosion Control, Water and Chemical Treatment Subcommittee
Ivan Cruz Coordinator

Mark Moore Member
Olavo Dias Member
Robin Tems Member
Abdulatif Abdulhadi Member
Abdelhak Kermad Member
Mike Morrow Member
Robert Palmer Member
Brian Burgess Member
Tawfiq Al-Ghasham Member
Revision Summary
31 January 2005 Revised the "Next Planned Update". Reaffirmed the contents of the document, and
reissued with editorial changes.
Page 29 of 51
Appendix 1 – Definition of Terms
Austenitic Stainless Steels: Chromium and nickel bearing ferrous alloys noted for
their resistance to corrosion.
Blend (Filling): A method of filling a vessel with chemical acid in which the chemical
concentrate in liquid form is metered into the filling line at such a rate as to maintain the
desired concentration level in the liquid entering the vessel.
Flushing: Cleaning a surface by the application of copious supplies of water under

pressure.
Inhibitor: A compound that retards or stops an undesired chemical reaction such as

corrosion or oxidation.
M-Alkalinity: Methyl orange alkalinity, which exists above the pH range of 4.2 to 4.4.
Mill Scale: A layer of iron oxide consisting of magnetite (Fe3O4) on the surface of hot
rolled steel.
Mils Per Year (mpy): A measurement of corrosion penetration in one thousandths

(0.001) inch per year.
Passivation: A treatment for steel surfaces to give greater resistance to corrosion by

shifting the normal electrochemical potential of the metal with a thin film of oxide.
pH: A value between 0 and 14 taken to represent the acidity or basicity of an aqueous
solution.
Sacrificial Valve: A substitute valve used in a chemical cleaning operation in place of

the regular valve to prevent corrosion damage to that valve.
Surfactant: A compound, when dissolved in water, reduces interfacial tension between

the liquid and a solid.
Water: Good quality water having a conductivity of less than 1000 microsiemens.
Page 30 of 51
Appendix 2 – Contractor Submittals
Submittals for review and approval shall include the following:
Equipment details
1. Location, fill volume, materials of construction of shell and tubes or plates and
gaskets
2. Components isolated, blinded, plugged, or removed
3. Scale composition and solubility in the proposed solvent
Selected treatments for cleaning

4. High pressure water jetting
5. Hot alkaline treatment
6. Acid
7. Passivation
Materials and Quantities

8. Water volume for each stage of cleaning
9. Nitrogen volume for each stage of cleaning
10. Chemicals and quantities
11. Inhibitor name and quantity
Equipment details
12. Pumps and capacities
13. Piping, fittings, and valves
14. Tanks and capacities
15. Power source
Control parameters
16. Circulation rate, temperature limits, chemical concentrations, pH, M-alkalinity,
iron, corrosion
17. Sketch of circulation path, showing locations of: pumps, control valves, chemical
injection, flow and temperature instruments, vents, drains, blinds, plugs, etc.
18. Waste disposal plan and approvals, Chemical Hazard Bulletins.
19. Chemical analysis procedures
Page 31 of 51
20. Contractor safety manual

21. Contingency plans to handle piping leaks, pump failures, rescue from confined
spaces
22. Corrosion control methodology
23. Quality assurance and control procedures
24. Personnel assigned and their qualifications
25. Schedule of activities, start and end dates
Page 32 of 51
Appendix 3 – List of Approved Inhibitors and Manufacturers
Saudi Aramco Approved Commercial Corrosion Inhibitors for Chemical Cleaning
MANUFACTURER OR DISTRIBUTOR
(1) (2) (3) (4)
Acid & Max. Corr. Henkel AKZO HALLIBURTON NAVDEEP
Max. Rate (7) at suggested suggested suggested conc. % suggested conc. %
Conc. Max. Temp. conc. % (6) conc. % (6) (6) (6)
HCl, 300 mpy Rodine213 Armohib 28, HAI 50**, 0.2% v/v Nevamine CP 20,
6 % v/v at 82°C or 426, 0.2% v/v 0.2% v/v
0.2% v/v
H2SO4, 200 mpy Rodine 95 Armohib 31, OSI-1A , 0.2% v/v Nevamine CP 20,
8 % v/v at 82°C or 31A, 0.2% v/v 0.2% v/v
0.2% v/v
Citric, 200 mpy Rodine 31A, Armohib 31, OSI-1A , 0.2% w/w None
5 % v/v at 93°C 0.2% w/w 0.2% w/w
Sulfamic 200 mpy Rodine 95, Armohib 31, OSI-1A , 0.2% w/w None
10 % v/v at 65°C 0.2% w/w 0.2% w/w
Na-EDTA 50 mpy Rodine 241, None OSI-1A , 0.2% w/w None
10 % w/w at 95°C 0.2% w/w
MANUFACTURER
Application Concentration Maximum Henkel (1) (6) Sharp (5) (6)
Protection
HPJ 0.001% to 0.003 % 3 days Flash Rust inhibitor Flash Shield 2000 A/B
Notes:
** Surfactant must also be added
(1) Henkel Surface Technologies, U.S.A., http://www.hstna.com, phone: 800-235-2172, Fax: 248 588-4383.
(2) Akzo Chemicals Inc, Chicago, Ill. U.S.A., http://www.surface.akzonobel.com, phone: 312 906-7500.
(3) Halliburton Services, Dhahran, Saudi Arabia, 31932, http://www.halliburton.com, phone: 03 856-1616/-
1544, Fax: 03-856-1591.
(4) Navdeep Chemicals, Bombay, India, http://www.navdeep.com, phone: 009122-261-3855/-7715/-2804,
Fax: 009122-286-2735.
(5) Sharp Performance Products, 5921 Plainview Street, Houston, phone: 713-641-110, Fax: 713-641-9898
(6) Suggested concentrations are shown. Adjust the actual concentration such that the maximum corrosion rate
is not exceeded. Also refer to manufacturer's recommendations for flash rust inhibitor concentrations.
(7) Use the corrosion rates shown here to check inhibitor effectiveness in static solution. While cleaning the
circulation rate, temperature and the inhibitor concentration are adjusted such that the maximum corrosion
rate does not exceed 600 mpy in acids and 50 mpy in Na-EDTA.
Page 33 of 51
Appendix 4 – Chemical Cleaning Log Sheet
Plant Location Chemicals Used
Equipment No. Date / Time Started
Equipment Type Date / Time Finished
PO43- /
Date Time Temp Acid Total iron pH CO32- Corrosion rate Remarks
°C % mg/L mg/L mpy
Page 34 of 51
Appendix 5 – High Pressure Water Jetting (HPJ)
HPJ Application for Equipment Cleaning
Use HPJ either alone or to supplement chemical cleaning if inspection reveals deposits are
present in the equipment after acid cleaning and neutralization.
Introduction
High Pressure Jetting (HPJ) is a highly effective and adaptable cleaning technique, using
specialized equipment capable of developing 8,000 psig or more. During high pressure
jetting the fouling is stripped from the equipment being cleaned by a combination of
mechanisms. The direct impact of the jet provides a shattering effect, and hydraulic
pressure produces a disruptive shearing force. The shearing force may be applied in two
ways; firstly, by the penetration of water between the fouling and metal surface to break the
bond between them, and secondly, by penetration of the water into a porous foulant to
cause the break up of the foulant mass.
In high pressure jetting the total cleaning action is a function of the available energy and the
efficiency with which it is applied. The cleaning energy is related to the pressure and
volume of the water, whereas the efficiency is determined by the nozzle design and angle of
impingement of the water jet to the fouling.
When attempting to remove thin oils from metal surfaces, the water jet may drive these
films across the surface without detaching them; or if the oil is removed, it may well spread
to an adjacent surface. An emulsifier or detergent will assist in removing and sequestering
the fouling.
Advantages and Limitations
HPJ is usually successful if chipping, scraping or wire brushing can remove the deposit.
Some tarry or gummy deposits smear when impacted by a water jet and are not removed.
HPJ is not effective with certain types of firmly bonded nonporous scales that usually occur
in equipment, and scales deep inside the heat exchanger tubes that cannot be reached by the
high pressure water jet. Then chemical or solvent cleaning is essential.
Though HPJ leaves a clean surface, flash rusting of carbon steel equipment will occur due
to the moisture and oxygen present. Chemical additives are available to minimize flash
rusting. (See Appendix 3)
Line friction is another factor to consider when jet cleaning and much of the effective pump
pressure is lost when pumping through a long hose and lance. Special organic polymers to
reduce the friction losses by as much as 90% are added to the water. In addition, some
Page 35 of 51
polymers make the water more cohesive; that is, they maintain the water in tight cylindrical
jet that strikes the target with much more force than untreated water at the same pressure.
By reducing the tendency of the water to fan out or spray, the effective cleaning distance
between the nozzle and the target is increased. Thus impact stress and cleaning power are
increased.
Polymers are typically added at a concentration of 0.3 % by volume based on water flow.
The polymers should be injected into the water flow directly before the high pressure pump.
Recirculation is not practical because the shear stress at the nozzle destroys the polymer.
Do not attempt HPJ unless a fail safe system is used, since controlling the pressure by
shutting down the pump takes too much time in case of an accident. High pressure jetting
is a skilled operation. Use only a trained crew and supervise the work to carry out HPJ
safely and effectively.
Equipment Specification
Pump Capacities 750 kW, 10,000 psig; 1500 kW, 20,000 psig
Water Volume 30 L/minute to 50 L/minute
Nozzle orifice diameter 0.8 to 2.4 mm
Number of Nozzles & Orientation 4 each, facing 45° rearwards, and 90° to
the direction of lance advancement
Maximum distance between nozzle tip and surface to be 25 mm
cleaned
Flexible Hose diameter 19 mm minimum
Water for jetting Cold steam condensate
Additives Concentration
Polymer 0.3% by volume
Surfactant 0.1 to 0.2 % by volume
Flash rust inhibitor 0.001 to 0.005 % by volume
Recommended pressure range to remove deposits

DEPOSITS WATER PRESSURE*
Phosphates, Resins, Calcium Carbonate, Coke, Fly Ash, Drilling 20,000 psi-
Mud, Silicates, Water Scale, Lime, Polymers 10,000 psi
Mastics, Cement, Barnacles, Rust, PVC 7,000 psi
Sediments, Paraffin, Wax, Grease, Hard Clay, Soft Carbon, 3,000 psi
Crude Residues
Dirt, Mud, Grease, Algae, Vegetation, Scum, Bird droppings, 2,000 psi-
and other soft deposits 1,000 psi
* While cleaning aluminum fins in fin-fan coolers keep the HPJ pressure below 700 psig and use the lowest effective pressure
necessary to clean with out damaging the fins.
Page 36 of 51
Appendix 6 – Onstream Cleaning of Heat Exchangers
Offstream cleaning requires that at least a part of the plant be shutdown during the operation.
Since downtime costs money, there is a lot of incentive to perform as much cleaning as is
possible without shutdowns. Several onstream techniques have been developed as follows:
Acid Slugging with HCl
This method is effective to remove scales soluble in HCl. The treatment consists of injecting
inhibited acid into the cooling water at relatively low concentration for a short time period
while the cooler remains in service.
If the fouling is predominantly scale the cooling water flow is reduced and the acid
concentration is kept about 0.5% acid in the effluent for hardness deposits or about 3% for iron
oxides. If the fouling contains appreciable quantities of mud and weed, the cooling flow is
maximized and acid concentration reduced. Acid slugging is a rapid method of cleaning, and
most bundles can be cleaned in 20 minutes to 1 hour. Preparation work is minimum and often
consists of providing only 1½" valve connection at a cooler inlet. Sampling connections and
temperature monitors are required for good control of the cleaning.
In general, acid slugging cleans once-through cooling systems, particularly where salt water is
used as the cooling medium. Onstream cleaning has been extended to include recirculated
systems, but the effluent acid must be diverted to the sewer or neutralized to avoid upsetting the
cooling tower operation.
In all cases where chemical injection is used, precautions must be taken to ensure that the
injected cleaning agent and dissolved fouling are not allowed to remain in the system in any
form which will be incompatible with the water treating chemicals, etc. The pH for instance,
must be readjusted to a normal level as soon as possible after acid injection. Inhibitor dosage
should be increased to passivate metal surfaces. The materials of construction must be checked
before adding any cleaning agent. Inhibited hydrochloric acid has little or no action on carbon
steel or the majority of copper alloys at temperatures up to 80°C but can lead to stress cracking
on 300 series stainless steels. The metal surface temperatures may be considerably higher than
the temperature of the circulating water and that materials such as the cast iron in compressor
jackets are liable to be attacked more readily than carbon steel.
An alternative to acid slugging for the onstream cleaning of coolers is a modification of the
circulation procedure used offstream. This procedure requires care to ensure that temperature
guidelines are not exceeded but has the advantage that the effluent cleaning solvents are
discharged to the sewer and, therefore, will not interfere with closed circuit cooling water
corrosion control. Procedure requires the installation of tees in the cooling water inlet and
return lines that can be connected via hoses to conventional pump and chemical cleaning tank
facilities. In addition, connections from the firewater system must be made with sewer
connections on both the inlet and outlet. Cleaning volumes should be as large as practical in
Page 37 of 51
order to provide as large a heat sink as possible because the idea is to circulate the cleaning
solution during normal cooler operation.
Firewater is used to backflush the system to the sewer and to make up the solutions because it
is higher pressure and cold. Unit is circulated from bottom to top until unit is clean or solution
temperature rises to 80°C. If temperature reaches 80°C, stop the chemical pump and use
cooling water to displace the acid back to the tank with additional flushing to the sewer.
Ensure that process side temperatures and pressures will not exceed allowable. Units with high
process temperatures will permit short contact times before solution temperatures reach the
allowable maximum and should be cleaned only with extreme caution.
Sulfuric Acid for Scale Removal
Sulfuric acid, is much cheaper and more readily available, to periodically reduce the pH of the
system or segment of a system to about 1.5 to 2.0 for a period of 6 to 8 hours or until the acid is
no longer being consumed. At this pH the calcium carbonate hardness deposits, which are the
primary foulants in the salt water system, are readily dissolved. If substantial iron oxide were
present, a lower pH would be required for adequate removal.
Chemical cleaners for the offstream removal of calcium hardness deposits have not used
sulfuric acid because the resultant calcium sulfate is not soluble in the acid solution and the
reaction quickly stifles itself. However, calcium sulfate is soluble up to about 1500 mg/L in
fresh water at 60°C. In the onstream once through treatment with dilute acid the concentration
of calcium sulfate is so low that the solubility is not exceeded. However, it has been
established that calcium sulfate is more soluble in high ionic strength seawater than it is in fresh
water. Therefore, the scheme is more applicable to salt water systems than to fresh water
systems.
Onstream Removal of Mud, Silt and Microbiological Fouling
Onstream cleaning of an entire recirculating system has been attempted in areas where a
shutdown was intolerable by reducing the pH with acid while adding polyelectrolytes. The
technique can be successful if carefully executed but is employed as a last resort. It probably
will not be very effective on deposits high in iron oxide, but can be effective if iron oxide is
bound by mud, silt, etc. For best results, the cleaning encompasses several days as is illustrated
in the following typical procedure:
1st day Chlorinate and /or use nonoxidizing biocide.
2nd day
1. Shot feed polyelectrolyte to obtain desired concentration in system
(usually about 25 mg/L)
2. Add dispersant continuously to compensate for that lost in blowdown
3. Decrease pH to range of 5.0 to 5.5
Page 38 of 51
4. Increase blowdown to lower cycles of concentration to 2.0

5. Air bump or backflush critical heat exchangers every 2 hours
3rd day Continue
4th day
1. Maintain dispersant concentration at recommended level
2. Decrease pH to 4.0 for eight consecutive hours; otherwise maintain
range of 5.0 to 5.5.
3. Maintain cycles of concentration to 2.0
4. Air bump or backflush, as above
5th day
1. Discontinue feed of dispersant and raise pH to normal range
2. Decrease blowdown to normal level
6th day Triple the feed rate of corrosion inhibitor to passivate system metals
Onstream Removal of Oil from A Cooling Water Circuit
The procedure below has been found to work well in several locations in minimizing the
adverse affects of process contaminants that have just leaked into the cooling water system.
The procedure is not effective for removing deposits from old or persistent leaks.
1. Locate and shut off leaking equipment immediately after leak are observed. This
is a crucial step. The following techniques may be useful to locate leaks:
- Sample water from outlet of equipment, headers, gas traps, etc.
- Check loss of chlorine residual across suspect exchanger or other areas
- Measure oil-in-water content daily
- Use GC analysis to identify possible sources of oil
2. If visible fouling exists clean wooden members at top distribution deck of tower
with steam lances. Clean structural and demister chevrons from basin level using
water hoses.
3. Skim oil at top distribution deck and at cooling tower basin. During this time:
- Change to non-chromate treatment.
- Maintain normal dosage of phosphate or other non-reducible inhibitor.
Page 39 of 51
- Ensure 2 mg/L free tolyltriazole copper inhibitor if brass bundles are present.
- Add an initial 100 mg/L (as product) shock dosage of non-ionic surfactant
(polysiloxane and polyoxyalkylene, fatty acid alkylamines, or polyoxylated
ethylene and alkoxylated phenol).
- Maintain normal blow down rate.
- Chlorinate continuously to 0.2-0.5 mg/L free residual (if attainable). Evaluate

impact of the quantity chlorine fed on carbon steel and brass corrosion
monitoring devices and on recirculating water pH depression.
- Add biocide (chloromethylsulphone or equivalent) for sulfate reducing

bacteria twice per week.
- Perform oil-in-water and chlorine residual daily.
4. Blowdown system for 3 - 4 days at highest rate possible and at as many different
points as possible (cooling tower hot return, basin, and at pump cooling jackets,
etc.):
- Operate spare pump at cooling tower to increase velocity.
- Operate oil skimmer at cooling tower pump suction bay (if available)
- Do not add surfactant during this period.
- Increase dosage rate of corrosion inhibitor to compensate for higher blowdown

rate (maintain same concentration).
- Perform oil-in-water and chlorine residual daily.
5. Reduce blowdown to normal level and add surfactant:
- Maintain 100 mg/L of surfactant product for 4 days.
- Operate spare pump at cooling tower for 4 days.
- Chlorinate continuously to 0.2 to 0.5 mg/L free chlorine residual if attainable.
- Examine corrosion coupons (preferably located in an equipment bypass) and

test equipment twice per day for oil, and continue to add dispersant until
coupons clear up.
- Perform oil-in-water analysis daily.
Page 40 of 51
6. Reduce blowdown to minimum possible and passivate exchanger surfaces by

increasing corrosion inhibitor concentration 2.5 - 3X for 5 days.
- Maintain necessary pH to avoid any precipitation of inhibitor or waterborne

salts.
- Maintain 100 mg/L surfactant product for one week.
- Continue to add biocide twice a week.
7. Return to normal operation:
- Shutdown spare pump.
- For two days per cell, shut off one cooling tower cell in sequence so that flow
is maximized through other cells (to flush oil off structures).
- Maintain normal concentration of corrosion inhibitor.
- Chlorinate continuously (0.1 - 0.3 mg/L residual) or once per day to 0.5 to 1.0
mg/L free chlorine residual.
Page 41 of 51
Appendix 7 – Heat Transfer Coefficients and Fouling Factor
Uactual = Q/(Ao.ΔTLMTD.F)
Where,
Uactual = the actual heat transfer coefficient of the exchanger at operating conditions,
based on the outside heat transfer surface area
Q = the quantity of heat transferred
Ao = the total outside area of tubes for heat transfer
ΔTLMTD = the log mean temperature difference = [(T1-t2)-(T2-t1)] / ln[(T1-t2)/(T2-t1)]
T1 = the hot stream inlet temperature, T2 = the hot stream outlet temperature
t1 = the cold stream inlet temperature, t2 = the cold stream outlet temperature
F = the temperature correction factor based on the geometry of the exchanger
(number of shell and tube passes) and obtained from TEMA charts
Uclean = 1/ {[1/(hi.Ai/ Ao)] + Ao [ln(D0/Di) / (2.π.Kw.L)] + [1/(ho)]}

Where,
hi = the film heat transfer coefficient of tube side
Ai = N. π. Di.L = heat transfer area of inside of the tubes, and Ao = N. π. D0.L,
the tube outside heat transfer area, D0 = the tube outer diameter, Di = the
tube inside diameter
Kw = the thermal conductivity of the tube material
ho = the film heat transfer coefficient of the shell side
N = the number of tubes, L = the tube length, π = 3.14159
ho & hi are obtained from heat transfer reference books
Definition of Udesign:
Udesign = 1/{(1/Uclean) + Rfdesign}
Fouling factor definitions:

Rfdesign = a value specified by the manufacture in the Heat Exchanger TEMA
Specification Sheet
Rf = actual fouling factor realized during service period.
Ideally after each clean up of the heat exchanger Rf should be ≤ Rfdesign
Page 42 of 51
The fouling factor actually realized in the heat exchanger is given by:
Rf = (1/Uactual) – (1/Uclean)
Note: The Rf is independent of the fluctuations in the flow rates during the service period.
Use at least a ten day average value of Rf for decision criteria.
Page 43 of 51
Appendix 8 – Economic Evaluation TFRE Concept
Calculate the total fouling related expenses (TFRE) and clean when TFRE is at a minimum.
TFRE = (Qloss x Meq + Ed + Ei) x (n)
where: TFRE = Total Fouling-Related Expense, SR/yr.

Qloss = Energy loss per cycle due to fouling.
Meq = Monetary equivalent per unit of energy loss.
Ed = Direct expenses of cleaning.
Ei = Indirect expense, such as lost production per cycle.
n = Number of months since last cleaning.
Graph 1 illustrates the concept of Total Fouling-Related Expense (TFRE) to optimize the
cleaning cycle for a fictitious unit. Note that TFRE (SR/yr) is plotted as a function of months
since cleaning. The onstream energy loss and the associated process debits both increase
directly as the time between cleaning are extended. The cleaning costs and the offstream
energy loss are reduced as the cleaning interval is extended. Summing all of these costs helps
in selecting an optimum cleaning frequency to minimize cost for this unit.
Graph1: TOTAL FOULING RELATED EXPENSE

( Graph shows least expensive option is around 4.5 months between cleanings)
100000
90000
80000
70000
Qloss x Meq.x n
60000
(Ed+Ei(offstream))12/n
Costs
50000 Ei(onstream) x n
40000 TFRE (total of above)
30000
20000
10000
0
1 2 3 4 5 6 7 8 9 10 11 12
Months since cleaning (n)
Page 44 of 51
To determine the TFRE from operating and maintenance cost data:
Step A For each value of n = 1 to 12 , calculate the TFRE by adding the costs for:
• Energy loss due to fouling.
• Direct expenses of cleaning
• Indirect costs of lost production during cleaning
• Indirect costs of lost production due to fouling (process debit)
Plot this on a graph.
Step B Determine the optimum cleaning interval by picking the minimum in the TFRE curve.
In order to construct a graph of the costs needed to determine TFRE:
Step 1 Obtain from plant operations and maintenance personnel the costs associated
with:
• Energy loss due to fouling (Qloss).
• Monetary equivalent per unit of energy loss (Meq).
• Direct expenses of cleaning (Ed).
• Indirect costs of lost production during cleaning (Ei offstream).
• Indirect costs of lost production due to fouling (Ei onstream).
• Number of months since cleaning (n = 1 to 12)
• Number of cleanings per year N =12/n (n = 1 to 12)
Step 2 Establish a graph representing for a one year period "Cost" on the Y-axis and
"Months Since Cleaning" on the X-axis. On this graph, plot the following
lines per the instructions given:
• Cumulative cost of lost energy at n month intervals:
Cost after n months = Qloss x Meq x n
• Cumulative cost of onstream production loss:
Cost after n months = Ei onstream x n
• Cost of offstream production loss (i.e., during cleaning):
Cost after N cleanings = Ei offstream x (number of days for cleaning)
x 12/n
• Direct expense of cleaning:
• Cost after N cleanings = Ed x 12/n
Page 45 of 51
For example, Graph I is obtained using the above steps given the following
information.
• Qloss x Meq = $3,000 per month.
• Ed (cost of cleaning) = $4,000 chemical + $1,000 mechanical.
• Ei onstream (production loss) = $1,000/month.
• Ei offstream (production loss) = $1,000/day.
• Cleaning time = 2 days.
Page 46 of 51
Appendix 9 – Safety Hazards with Chemical Cleaning
Provided for information only. Contact Saudi Aramco Industrial Hygiene Services, Preventive
Medicine Services Division, Dhahran (phone: 877-8222) to determine the need for the
precautions and develop procedures.
Safety
Chemical cleaning is potentially dangerous, and careful control is essential in avoiding

unpleasant accidents.
Plan for safety in the operation at all stages. Material Safety Data Sheets are required for the
transport and handling of chemicals. Review the data sheets before any cleaning jobs using
solvents or additives is undertaken.
Principal Hazards
The principal hazards associated with chemical cleaning include:
• Chemical burns - caused by contact with the chemicals, fouling or their products.
• Toxicity effects - caused by skin contact, ingestion or inhalation of the chemicals,

fouling or their products.
• Flammability and explosion - this may be caused by fouling, chemicals or their

products.
• Pressure - caused by gas generation or overheating in a closed system. Additional

hazards exist with high pressure jetting.
Chemical burns
Chemical burns are associated with acids or caustic and usually occur during
transportation and mixing of the concentrated chemicals. Less frequently, incidents
occur due to a leak developing during the cleaning operation.
Take steps to protect personnel eyes, face and hands with the correct clothing. Insist on
gloves and goggles as a minimum when handling any chemical irrespective of its
corrosive nature.
Control loading and transportation of corrosive chemicals and use suitable containers.
Check these to ensure that they are in good condition, firmly secured, labeled clearly,
leak proof and that there are no loose stoppers. Transfer of concentrated liquids, etc.,
by a small pump rather than by manually pouring from containers, and exercise caution
during mixing and dilution.
Page 47 of 51
Some chemicals, particularly concentrated sulfuric acid and caustic soda, evolve heat
when diluted. Dilute gradually by adding the chemical to water in order to dissipate the
heat and avoid fuming, spitting and boiling. Stir continuously during dilution, as dense
materials may sink to the bottom of the mixing tank. Add acids to water. For
concentrated solution's, (5% or more), monitor temperature while mixing. Use a
metered pump to add the acid and minimize heat evolution by controlling the flow of
acid during mixing.
Toxicity
Toxicity incidents with chemicals are relatively rare providing the toxicity limits are
known and handling is supervised. There is, however, a real risk that during the
cleaning operation new toxic compounds may be formed by reaction between the
cleaning chemicals and the fouling. The most common case is the production of
hydrogen sulfide gas by dissolving sulfide scales in acid. This and other gases can be
deadly and anticipate their formation prior to the cleaning operation. Plans adequately
all operations for the safe disposal of gases formed and the disposal of spent cleaning
chemicals. This is particularly important where cleaning may be carried out in confined
spaces. Keep suitable gas testing equipment and breathing apparatus in the event of an
emergency.
Flammability and explosion
Flammability and explosion problems usually arise from gas production by overheating
the solvent, gas given off from the fouling or gas evolved by chemical reaction during
the solution of the fouling, e.g., hydrogen evolved by metal dissolving in acid. There
are also certain cases where the fouling itself may be pyrophoric or even explosive.
Pressure hazards
Pressure hazards are due to the evolution of large volumes of gas or overheating of a
closed system with out vents. Provide adequate venting to eliminate this problem.
Remember that vents can become blocked by loose scale, and install a pressure gage in
the system if this could occur.
Procedures for Equipment Safety
Follow safety procedures to safeguard equipment on every chemical cleaning job. Hydrogen is
liberated by the cleaning reaction and, under certain conditions it is possible to confine the
hydrogen and set up an explosive mixture in the vessel. Venting the vessels permits the escape
of most of the hydrogen from the system as fast as it is formed.
PRECAUTIONS FOR PERSONNEL SAFETY
Take precautionary procedures to avoid toxic hazards, which may occur during chemical
cleaning operations. These hazards sometimes include the cleaning agent itself, for example
Page 48 of 51
when a concentrated sulfuric acid, a strong caustic, etc., is being used. In such cases, adhere to
recommended handling practices and wear proper protective clothing.
Guidelines for the safe handling of chemicals are covered on specific chemical hazard bulletins,
and available from Environmental Protection Department.
Liberation of Dangerous Gases

Hydrogen sulfide. hydrogen cyanide, arsine, phosphine, phosgene, nitrogen dioxide
Many of the deposits encountered in the refinery contain sulfide, cyanide, arsenide, and
fluoride scales that will liberate large quantities of dangerous gases such as H2S when
exposed to acidic solvents. Provision should be made to dispose of these lethal gases.
One way to limit the amount of H2S released by contact with acids is to first circulate
water, then slowly add acid to build up concentration. This prevents rapid gas
evolution.
One way to dispose of H2S gas is to discharge into the flare system to burn the gas in
the flare to form SO2, which is toxic but less dangerous than H2S if no vents are high
enough in the air. If no wind exists and large quantities are liberated, however, there is
the possibility of the heavier-than-air gas settling around the equipment. A preferred
technique is to scrub out the H2S by bubbling the gas through a sparger into a drum
containing caustic. Caustic volume is 80 L of 25% NAOH to every 400 L acid 10%
H2SO4. A typical scrubber for a large job is 1.4 meter diameter by 2.3 meter height. A
minimum height of 1.3 meters is recommended.
Caustic concentrations of 50% have resulted in plugged spargers. Therefore, keep the
sparger off the bottom of the drum, containing relatively large diameter sparger holes.
Maintain a caustic concentration of 25% to prevent serious plugging. The resultant
sodium sulfide reaction product is a precipitate. Dispose it in an approved land farm or
disposal pond where it cannot later react to regenerate the hydrogen sulfide, (i.e., by
contacting acid). At the completion of the job, sparge nitrogen into the spent acid to
strip H2S out of the acid and push it into the scrubber.
Another new technique for suppressing H2S is by adding formaldehyde to sulfuric acid.
The reaction product formed is trithiane, which can form a flocculent, and precipitate on
metal surfaces, especially when heavy sulfide deposits are present.
Spent acid contains dissolved H2S, which can be released upon entry into a vacuum
disposal truck. Since vents on vacuum trucks are at ground level, there is the possibility
of flooding the area with H2S. A caustic scrubber can be installed on the exhaust line
from the vacuum truck, or formaldehyde can be added to the truck (1 L per 1000 L
capacity) prior to the entry of spent sulfuric acid.
Page 49 of 51
Hydrogen cyanide, arsine, phosgene, phosphine, nitrogen dioxide
Other gases may be liberated during the cleaning cycle including hydrogen cyanide in
units containing cyanide deposits such as Vapor Recovery Units. A/C units, FCCU,
Catalytic Light Ends, Coker, and Sour Water Strippers may also have fluoride, cyanide-
containing deposits. A caustic wash can be employed to remove the salt. Arsine and
phosphine are other gases, which have been found in vent gases from acid cleaning
jobs. Generally, precautions for hydrogen sulfide will also take care of the other gases
formed.
Other toxic gases that can be produced during acid cleaning include nitrogen dioxide
and hydrogen cyanide.
Toxicity Limits for Solvents
Occasionally, it may be necessary to use various hydrocarbon or chlorinated solvents to remove

oily or polymeric materials. All are toxic to some extent and some are flammable as well.
Whenever solvents are used for cleaning periodic and sometimes continuous monitoring with
gas testing equipment is required.
Page 50 of 51
Appendix 10 – Cleaning Chemical Compatibility Chart for Materials
Citric Ammonium
Materials H2SO4 HCl Sulfamic EDTA Alkalies
+NH3 biflouride
Aluminum Alloys NR NR A A C NR
Austenitic C NR C C A C NR
Stainless Steels
Brasses A A C A C C NR
Carbon steels (cs) A A A A A C C
Cast irons C C A C C A C
Ferritic C C C C A C C
Stainless Steels
Low Alloy Steels C C A C C A C
Titanium C C A C A C NR
Zinc (including NR NR NR C NR NR NR
Galvanized steel)
Galvanic Couples:
cs / brass C C C C C A NR
cs / ferritic ss A C A A A C C
cs /austenitic ss C NR C C A C NR
A = Acceptable under normal range of concentration and temperature

C = Acceptable only under certain conditions, some corrosion may occur under ideal conditions
NR = Not recommended
If material is not listed above, contact ME&CCD/CSD for advice.
Page 51 of 51

Saep 1662

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Saep 1662

Uploaded by

Copyright:

Available Formats

Engineering Procedure

SAEP-1662 31 January 2005

Previous Issue: 28 January 2004 Next Planned Update: 1 February 2010

Saudi Aramco DeskTop Standards

Appendix 1 - Definition of Terms........................ 30

Saudi Aramco Engineering Procedure

Saudi Aramco Engineering Standard

4.2 The Facility Operating Department is responsible for cleaning commissioned

4.2.2 Operations Engineering

4.2.3 Operations Inspection

• Maintains history of equipment chemical cleaning. Incorporates

4.3 Loss Prevention Department

4.4 Research and Development Center (R&DC)

4.5 Regional Laboratories

4.6 Chemical Cleaning Contractor

The chemical cleaning contractor is selected from the Consulting Service

5.3 Clean on-stream with acid slugging. See Appendix 6.

6 Preparations for Chemical Cleaning

1. Install all necessary temporary piping, sacrificial valves and pressure,

4. Ensure that an adequate supply of water is available for flushing and

5. Ensure that instrument connections (except those temporarily installed) are

7. Provide adequate lighting at all operating points.

9. Perform checks on valve lineups as required for flushing and reversing

10. Notify ME&CCD/CSD and the Regional Laboratories of intention to

11. Ensure utility water is available, or provide a temporary supply

12. Ensure sufficient supply of nitrogen at 80 psig to quickly drain using

17. Ensure, using standard samples, that on-site chemical analytical

18. Ensure inhibitor is selected from Appendix 3.

6.2 Cleaning Record

1. Cleaning temperatures, time, dates of cleaning process, chemical additions,

2. Typical log sheets include what is shown in Appendix 4, contractor's log

3. Operations Inspection Unit is to collect and keep as permanent plant

6.3 Safety Precautions

1. Close all instrument connections and disconnect to protect instruments

2. Keep operational and tested, permanent or temporary eye wash fountains

3. Adhere to the work permit procedures. Vent flammable gases when

4. Keep hoses connected to an operable water supply adjacent to the

6. Keep at cleaning site chemical hazard bulletins on various chemicals or

8. Ensure all personnel handling chemicals wear protection equipment

9. Ensure the contractor is equipped with adequate portable fire extinguishers

7 Criteria for Cleaning

3. Clean when the ten-day average Rf reaches twice of Rfdesign value. Rf is

5. Clean whenever the drop in heat duty is unacceptable to Plant Operations.

6. Clean during T&I or unplanned shutdown to take advantage of down time.

7. Using scale monitoring or based on recorded rate of scale or corrosion products

8 Chemical Cleaning Treatment Selection

8.1 General Criteria

8.2 Analysis of Scale

8.2.1 General - Fouling composition, quantity, and distribution, will vary

8.2.4 Insoluble Residue - This figure represents the insoluble complexes of

8.3 Hot Alkaline Treatment Selection

interfere with acid cleaning. If solubility of deposits is >70% in acid

8.3.2 Soda ash (Na2CO3) degreasing is a mild treatment used where

8.3.4 Permanganate (KMnO4) degreasing is used where organic contamination

8.4 Acid Cleaning Selection

8.5 Neutralization and Passivation

Following acid cleaning it is essential that the equipment be thoroughly

The selection of passivation treatment is sometimes governed by the selection of

9.1 Alkaline Degreasing with Soda Ash

9.1.1 Control Parameters

Sodium carbonate 0.5 to 1.0% by weight

Determine every hour the phosphate and M-alkalinity values. If the

9.1.3 Safety Hazards