037-Procedure For Cleanliness PDF
037-Procedure For Cleanliness PDF
037-Procedure For Cleanliness PDF
Project
Shell Project No: HP-3000-QAT
Project Document Number: T- 4.250.930
2MH127
Tag/Item Number(s):
N/A
Unit(s):
ASU
PCWBS:
LINDE ENGINEERING
Page 2 of 19
5887
10.12.2007
BR
AU/MC
ZG
ICC
22.11.2007
BR
AU/MC
ZG
IFR
20.11.2007
BR
AU/MC
ZG
IIR
Date
Description
GAMA
Rev.
No.
Project
Rev
No.
Status
Document Title:
Contractor
LOC470
GAM
PRO
QAC
GTL
037
Org.
Code
Doc.
Type
Disc.
Code
Geogr.
Area
Seq.
No
Rev.
No
Vendor Code
Rev No: O
Q A T A R
Doc. Title
GAM-PRO-QAC-GTL-037
PROCEDURE FOR CLEANLINESS
Date
10.12.07 Rev. C
TABLE OF CONTENTS
1.
PURPOSE _____________________________________________________________________6
2.
SCOPE________________________________________________________________________6
3.
HSSE _________________________________________________________________________6
4.
REFERENCES _________________________________________________________________6
5.
DEFINITIONS __________________________________________________________________6
6.
RESPONSIBILITY ______________________________________________________________7
6.1.
6.2.
6.3.
6.4.
SITE ENGINEER__________________________________________________________________7
6.5.
SITE SUPERVISOR/FOREMAN_____________________________________________________7
6.6.
QC ENGINEER ___________________________________________________________________8
6.7.
QC INSPECTOR __________________________________________________________________8
6.8.
6.9.
7.
General _________________________________________________________________________________8
7.1.
7.2.
7.3.
Flushing __________________________________________________________________________9
7.4.
Medium/Quality __________________________________________________________________10
8.
9.
Pre-Cleaning _____________________________________________________________________12
9.2.
10.
10.1.
Direct inspection________________________________________________________________13
10.2.
10.3.
11.
12.
12.1.
General _______________________________________________________________________17
12.2.
T-4.250.930 REV-O
Page 4 of 19
Q A T A R
Doc. Title
GAM-PRO-QAC-GTL-037
PROCEDURE FOR CLEANLINESS
Date
10.12.07 Rev. C
12.3.
12.4.
Marking_______________________________________________________________________17
13.
14.
QUALITY ASSURANCE______________________________________________________18
15.
ATTACHMENTS ____________________________________________________________18
T-4.250.930 REV-O
Page 5 of 19
Q A T A R
Doc. Title
GAM-PRO-QAC-GTL-037
PROCEDURE FOR CLEANLINESS
Date
10.12.07 Rev. C
1. PURPOSE
The purpose of this Procedure defines internal cleanliness requirements, cleaning
methods, inspection for piping systems at C2 ASU Pearl GTL Project by Gama Qatar
located inside the Ras Laffan Industrial City in Qatar.
2. SCOPE
This procedure ensured that all cleaning activities on C2 ASU Pearl GTL project
will be carried out with adequate cleaning and testing methods to the degree required in
this Procedure
3. HSSE
All works shall be in compliance with the State of Qatar laws and regulations, Ras
Laffan Industrial City and International standards, codes, LINDE ENGINEERING AG and
QSGTL and/or its PMC requirements and instructions.
In addition all employees and GAMA subcontractor employees on site will have through
LINDE ENGINEERING AG Site Safety Induction and GAMA Qatar Safety induction for site
safety, health, environmental and security prior to work activities. Other training courses will
be attended as required by LINDE ENGINEERING AG or QSGTL and/or its PMC as
required.
4. REFERENCES
T-4.234.542
T-13.377.360
T-4.096.688
T-13.371.359
70.10.80.11
Cleaning of Equipment
5. DEFINITIONS
Company
Contractor
: LINDE ENGINEERING AG
Sub Contractor
: GAMA QATAR
T-4.250.930 REV-O
Page 6 of 19
Q A T A R
Doc. Title
GAM-PRO-QAC-GTL-037
PROCEDURE FOR CLEANLINESS
Date
10.12.07 Rev. C
Contract
CS
: Construction Supervisor
ITP
QCR
QCP
QCE
QCI
QA/QC
TPI
6. RESPONSIBILITY
6.1.
SITE MANAGER
The site manager will provide inputs to the project execution plan to ensure that lifting
strategies & philosophy are addressed.
6.2.
CONSTRUCTION MANAGER
The construction manager is responsible for the overall management of the project
construction team to ensure that safe and effective operations are conducted and
properly documented.
6.3.
EQUIPMENT MANAGER
The equipment manager will be responsible for the transporting equipments availability
and good order.
6.4.
SITE ENGINEER
6.5.
SITE SUPERVISOR/FOREMAN
Shall report to Site Engineer
T-4.250.930 REV-O
Page 7 of 19
Q A T A R
Doc. Title
GAM-PRO-QAC-GTL-037
PROCEDURE FOR CLEANLINESS
Date
10.12.07 Rev. C
6.6.
QC ENGINEER
Shall report to Manager (QA/QC) and shall be responsible for overall implementation,
monitoring and control of QC activities.
6.7.
QC INSPECTOR
Shall report to QC Engineer
Shall be responsible for attending all Inspection Stages as required by ITP
Shall be responsible of performing all checks and shall prepare necessary
Inspection Reports
6.8.
HSSE MANAGER
Shall report to Project Manager and shall be responsible for over all control and
Inspection of HSSE issues.
6.9.
HSSE OFFICER
Shall report to HSSE Manager
Shall be responsible for all safety aspects for this procedure
7.1.
STEAM BLOWING
The purpose of steam blowing is to remove debris, loose scale and rust from
recently welded steam lines applicable only for steam turbine operation. The
effectiveness depends on the steam velocity, the change of temperature in time
and the number of blows.
Line cleaning should not commence until all related piping and process equipment
are fully installed, the system has been checked for conformance with the piping
and instrumentation diagrams, and the piping systems have been hydro tested.
Temporary piping and silencers for depressurizing to atmosphere shall be properly
anchored. All restrictions in the piping such as orifice plates, flow measurement
tubes and thermo wells shall be removed prior to steam blowing, openings to be
blinded.
Control valves shall be replaced with spool pieces. Steam should be blown from a
clean system to unclean systems. In order to thermally shock the piping to remove
T-4.250.930 REV-O
Page 8 of 19
Q A T A R
Doc. Title
GAM-PRO-QAC-GTL-037
PROCEDURE FOR CLEANLINESS
Date
10.12.07 Rev. C
mill scale, the steam valve controlling the blow down should be of the quarter turn
type (quick opening).
The valve should be located well upstream of the piping to be cleaned. At the inlet
flange of the silencer, a target strip of polished copper or aluminum shall be
clamped to judge the finished cleanliness.
Blows should first be made at low pressures to remove large objects in the piping,
gradually raising the pressure during later blows to the maximum operating
pressure. Between the blows there should be a cool down period of at least 60
minutes for UN insulated pipes and 240 minutes for insulated pipes.
A system is considered to be acceptably clean when the target plate has less than
a predetermined number of impact pock marks. The following requirements apply
for blowing steam lines:
Steam flow during blowing shall be at least three times the maximum flow rate
during operation;
There shall be not more than one total particle count (pock mark) per square
centimeter of target plate surface if not otherwise specified by manufacturer
There shall be no evidence of embedded material (e.g. weld splatter, sand, etc.).
Target plates shall not show individual rough impressions
The blow shall be of not less than 10 minutes duration, At least 15 blows shall be
made if the piping is not to be put immediately into service; the system shall be
purged with nitrogen to remove any air and should be placed under an inert nitrogen
blanket.
7.2.
AIR BLOWING
The purpose of Air blowing is to remove debris and loose scale. Air is usually
supplied from temporary high-pressure large-capacity air compressors or air filled
vessels.
These rental air compressors have to be supplied with filters to remove oil and
moisture from the compressed air system.
An air reservoir may be available during the blow down process. The piping is then
cleaned by pressurizing the piping system to be agreed with Company and then
opening a temporary quick acting valve to allow depressurization to atmosphere.
7.3.
FLUSHING
The purpose of the activity, flushing, is to remove loose rust, mill scale and
construction debris from piping systems before Erection.
Flushing can be defined as the act of running water, in sufficient quantity and
velocity, through a given section of pipe or piping, completely filling that section of
T-4.250.930 REV-O
Page 9 of 19
Q A T A R
Doc. Title
GAM-PRO-QAC-GTL-037
PROCEDURE FOR CLEANLINESS
Date
10.12.07 Rev. C
pipe or piping, such that the flow of water through the system will forcibly remove any
loose rust, mill scale or construction debris from the system.
There are some basic guidelines which should always be followed when flushing
lines with water:
Flushing shall be carried-out under the supervision of the Gama Piping
Superintend.
Gama/Linde Piping Inspector inspect the cleaned system and sign the Report.
Flushing shall be performed through fully open flanges and/or open pipe ends.
Flushing through smaller openings, such as drains or vents, is not acceptable
Flush from the highest elevation to the lowest, where possible following the
Normal flow Direction of the system.
When flushing is completed, de-water the system and dry as soon as possible.
7.4.
MEDIUM/QUALITY
Stainless steel lines:
Potable/demineralized water, with chloride content < 20 ppm.
Carbon steel and alloy lines:
Potable water/plant water or any other prior approved flushing medium.
The flushing duration for an "open ended" system is such that for a period of > 5
minutes "clear water" (no debris or other foreign materials) must be discharged.
Closed circuit loop flushing until the circulating pump strainer is free of foreign
materials (debris) and the circulating water is clear. The following systems
and/or lines shall not be flushed.
Process lines in which the presence of water would cause operational difficulties.
Instrument air lines: these lines will be service tested and blown with air. The air
used must be free from oil, use existing instrument air supplies where possible or
mobile compressors fitted with oil filtering devices.
Nitrogen systems: these will be service tested after blowing with instrument air.
Steam supply systems: after hydro test the water shall be drained and the system
Blown with steam, when available.
Page 10 of 19
Q A T A R
Doc. Title
GAM-PRO-QAC-GTL-037
PROCEDURE FOR CLEANLINESS
Date
10.12.07 Rev. C
9. CLEANLINESS REQUIREMENTS
This section defines methods which are suited to obtain the cleanliness condition
prescribed for the single pipes or assembled piping system. Usually cleaning methods
are mechanical processes and chemical processes. it is a condition that the items to be
cleaned are either already machined or have, in the state as delivered, a smooth, noncorroded and un scaled surface without painting. Corroded or scaled surfaces shall be
prepared by pickling or grit blasting. This section defines methods which are suited to
obtain the cleanliness condition prescribed for the single pipes or assembled piping
system.
Table 1 Mechanical cleaning
Identification
Code
Method
M1
M2
M3
Vacuum cleaning
M4
M5
Grit Blasting
T-4.250.930 REV-O
Page 11 of 19
Q A T A R
Doc. Title
GAM-PRO-QAC-GTL-037
PROCEDURE FOR CLEANLINESS
Date
10.12.07 Rev. C
9.1.
Method
C1
C2
C3
C4
C5
C6
PRE-CLEANING
All piping materials including, fittings, strainers etc, shall be pre-cleaned prior to final
assembly/site erection. In the majority of cases, this cleaning requirement is part of a
purchase order or shop fabrication.
For Vendor package systems the internal cleanliness of the system components shall
be preserved at least until they are installed in the plant on-site, by means of:
1) Hermetically sealed wrapping, containing desiccant bag, for small items
2) Firmly secured end-caps, plugs or gasketed blind flanges, as appropriate, to
seal all openings on non-hermetically packaged items
3) Desiccant (bags), but not vapor phase inhibitors, attached to the inside of
(temporary) end-caps and blank flanges
All pre-cleaned parts or final assemblies shall be lapelled / marked
T-4.250.930 REV-O
Page 12 of 19
Q A T A R
9.2.
Doc. Title
GAM-PRO-QAC-GTL-037
PROCEDURE FOR CLEANLINESS
Date
10.12.07 Rev. C
If the pre-cleaned condition has been maintained during construction and erection,
and there has been minimal site welding, in-situ cleaning can be limited to blowing the
pipe work out with high (near sonic) velocity, oil-free air, supplemented where
applicable with brush pigs. If the pre-cleaned condition has not been maintained
during construction and erection, pipe work shall be cleaned as specified in the
relevant cleanliness class s, see par.8.3. Any in-situ cleaning required shall be carried
out after any hydrostatic testing and by specialist contractors. A system that is
complete and has received final cleaning, but is not to be put into immediate service,
shall be preserved by pressurizing with clean, dry, oil-free nitrogen.
DIRECT INSPECTION
All surfaces shall be subjected to direct visual inspection where possible, by both
bright white light and ultra-violet light methods.
The inspected surface shall be dry and free from
cleaning agents
Adhered scale, weld spatter, loose particles or fibers
organic substances such as grease, oil, paint, sealants If direct inspection by ultraviolet light is not possible, surfaces shall be wiped with a clean, white, lint-free cloth
that may be dipped in solvent. The cloth shall then be inspected to ensure the
absence of any oil, residue, discoloration, fibers, etc.
10.2.
Page 13 of 19
Q A T A R
10.3.
Doc. Title
GAM-PRO-QAC-GTL-037
PROCEDURE FOR CLEANLINESS
Date
10.12.07 Rev. C
TARGET BLOWING
Position a white sheet covered with petroleum jelly, e.g., Vaseline, at the end of the
line, and blow line with oil-free nitrogen. Dirt picked up by the nitrogen stream will be
visible on the sheet.
Table 3 Inspection Methods
Identification
Method
code
P1
Visual examination at clear daylight, or under bright white light.
P2
P3
P4
P5
P6
T-4.250.930 REV-O
Page 14 of 19
Q A T A R
Doc. Title
GAM-PRO-QAC-GTL-037
PROCEDURE FOR CLEANLINESS
Date
10.12.07 Rev. C
Cleanliness class S2
Fabrication
Sequence
Piping
parts
(pipes,
fittings,
flanges
etc.)
Prefabricat
ed piping
spools
Piping
spools prior
to
installation
Piping after
installation
(precommissio
ning)
DN
Limi
ts
Ferriti
c
Steels
Cleaning
Austenitic
Steels,
Aluminium
Ferritic
Steels
Inspection
Austenitic Steels,
Aluminium
>50
M5
C6 8)
P2
P2 and P3
`>25
and
50
N/A
M6 11)
N/A
P3 4)
Acceptance Criteria
ALL
M2 9)
P2
M4
P1 4)
ALL
Cleanliness class S3
Fabrication
Sequence
Piping parts
(pipes, fittings,
flanges etc.)
Prefabricated
piping spools
DN
Limi
ts
>50
Piping after
installation
(precommissioning)
T-4.250.930 REV-O
Cleaning
Austenitic
Steels,
Aluminium
Ferritic
Steels
M5 or
M2 5)
Inspection
Austenitic Steels,
Aluminium
Acceptance
Criteria
P1
`
>25
and
50
Piping spools
prior to
installation
Ferrit
ic
Steel
s
M2
and
C6 6)
M2 and C6 6)
P1
P1
Free of mill
scale, paint,
dirt and
other debris
ALL
M1 3)
P1
M4 7) or M2
P1 4)
ALL
Page 15 of 19
Q A T A R
Doc. Title
GAM-PRO-QAC-GTL-037
PROCEDURE FOR CLEANLINESS
Date
10.12.07 Rev. C
Cleanliness class S4
Fabrication
Sequence
Piping parts
(pipes, fittings,
flanges etc.)
Prefabricated
piping spools
DN
Lim
its
>5
0
Piping after
installation
(precommissioning)
Cleaning
Austenitic
Steels,
Aluminium
Ferritic
Steels
M1 or
M2 5)
or M5
1) 2)
Inspection
Austenitic Steels,
Aluminium
Acceptance
Criteria
P1
`
>2
5
an
d
5
0
Piping spools
prior to
installation
Ferritic
Steels
AL
L
AL
L
M2
M1 or
M2 5)
P1
M1 3)
M2
P1
Free of mill
scale, paint,
dirt and
other debris
P1
P1 4)
T-4.250.930 REV-O
Page 16 of 19
Q A T A R
Doc. Title
GAM-PRO-QAC-GTL-037
PROCEDURE FOR CLEANLINESS
Date
10.12.07 Rev. C
12.4. MARKING
The packing of a cleaned component or plant equipment shall be marked punching or
by means of an undetectable, durable and well legible label or tag:
Furthermore, a note shall be attached for the receivers informing on vacuum packing
or inert gas filling or on susceptive bags to be removed (position and number of bags
to be stated!).
Page 17 of 19
Q A T A R
Doc. Title
GAM-PRO-QAC-GTL-037
PROCEDURE FOR CLEANLINESS
Date
10.12.07 Rev. C
15. ATTACHMENTS
GAM-QCR-QAC-GTL-070
T-4.250.930 REV-O
Page 18 of 19
Q A T A R
Item Location
Area:
Isometric No:
Item Description:
sub system:
Form No:
sheet
Cleanliness
class
Spool
Cleaning
Method
GAM-QCR-QAC-GTL-070
Inspection
method
Inspection Result
Pre Fabrication
Erection
Report No:
Inspection Date
GAMA QATAR
Signature
Date
LINDE
Signature
Signature
Date