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Pipingandvesselsflushingandcleaningprocedures 150323202530 Conversion Gate01 PDF
Pipingandvesselsflushingandcleaningprocedures 150323202530 Conversion Gate01 PDF
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
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Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
1 Scope
2 Aim/purpose
3 Responsibilities
4 Procedure
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Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
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Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
2.0 Aim/purpose
The purpose of flushing and cleaning lines and vessels is to remove loose
foreign matter, production residues and surface protection substances
from the inside of line and vessels (welding rods, sand, earth, pebbles,
nuts and bolts, tools, rags, oil and greasy films, etc.) in order to avoid line
blockages, damage to sensitive components such as orifice plates,
turbine, compressors, pumps impellers, valve seats and so on.
3.0 Responsibilities
The responsibilities are given in the work instructions to the plant operator,
standard engineering procedures preparation of commissioning, working
step, network cleaning, flushing and purging.
4 Procedure
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b) Quick decompression
This operation will preferably be done using a "quick opening valve" after
having pressurized the network to the desired level of pressure. The
existing valves of the network may not be used for this purpose, except for
special cases.
The quick decompression causes a high velocity of air in the pipes, thus
removing loose material and performing a light erosion on the walls which
eliminate rust and scale. During this operation the reaction forces affecting
the piping shall be considered.
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Line flushing uses water from the normal supply network of the plant, if
available. Water supply could conceivably be from other sources, i.e. city
water lines, supply boat temporary pumps, etc. depending upon the
ongoing situation.
Fill and dump flushing is often used for cleaning vessels. The method
being quite simple, the adequately vented vessel is filled to the desired
level with flush water and then dumped to grade, the flush water
dislodges loose debris and rust and carries it out of the equipment. Note
that some lines connected to the vessel can be flushed by dumping the
water through them. One major problem with this method is the disposal of
the large quantities of water involved which may overload the normal
drain systems.
If there is only dust on the walls of a large vessel, a water spray from a
hose pipe might be sufficient.
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• Whenever possible, the cleaning fluid shall flow from top to bottom.
• The diameter of the outlet pipe may be at least two thirds of the
diameter of the line to be cleaned, and at least as large as the inlet
pipe.
• Main headers shall be cleaned first (i.e., before their connecting lines).
• Large diameter pipes shall be cleaned before small diameter ones.
• Dead ends shall be avoided or, if not possible, cleaned separately.
• Fragile devices included in the network (all flanged valves, turbine-type
flowmeters, orifice restrictions, etc.) shall be removed (see section
4.4).
• Protection of the devices in the vicinity of the network shall be carefully
studied in particular near the water (or air) outlet in order not to
damage electric motors or instruments with water or dirty air (see
section 4.5).
• Existing block-valves on the lines to be cleaned shall not be used to
control an air flow as they could be damaged by erosion (due to the
high velocity of the fluid).
• A special care shall be taken for vessels designed only for an
atmospheric pressure service, in order not to create, during washing, a
high pressure due to a water head.
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During the flushing or the blowing of a line, some particles such as sand,
rust, etc. are carried away at high velocities and may either damage some
devices when an impact occurs, or clog small diameter pipes. Accordingly,
fragile devices have to be removed from the pipe before flushing/blowing.
During flushing and blowing operations, large quantities of dirty water and
dirty air are spread out in the units. This water or air generally contains
sand, particles of rust, etc., and might damage other equipment (for
example: breaking the glass of a pressure gauge). Additionally, the water
itself may damage the insulation materials, the electrical motors, etc.
- Slow velocity:
The water velocity through the pipe is normally only about 3 to 4
m/s, seldom higher, which is much lower than air blowing velocity.
- Weight of water:
For lines designed for gas service, the weight of pipes full of water
may be too heavy for the hangers, supports (this has to be checked
prior to any water flushing).
- Corrosion factor:
Water can cause corrosion due to its chloride content.
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- In liquid process lines and water lines, the velocity shall be the
lowest figure between 3 to 4 m/s and the velocity obtained with 1.3
times the maximum process or water flow. The minimum velocity
shall be 2 m/s.
Estimate the maximum head loss. With the velocity calculated as above,
estimate the head loss for a flow going through the principal piping and
add the static head (if any).
If the flow and the head loss are compatible with the pumps available on
the site, go ahead, otherwise air blowing has to be considered.
The pressure shall be carefully studied and specified in order that the
maximum allowable pressure in the system is never exceeded.
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Although blinds are seldom used for flushing operations, if they are
necessary they will be indicated and numbered with a red color.
A site review shall be done to determine the possible water inlets and
outlets, the water source, the pump(s) location, the additional pipes or
hose pipes layout from the source to the network. The water disposal
problem (flood risk) and the protection of the equipment and people nearly
shall be carefully studied.
The drawings for the additional pipes to be manufactured and erected may
be drawn if required. The required material (pipes, valves, gaskets, etc.)
and the means (monorails, cranes, pulleys blocks, etc.), tools, gaskets,
grease for bolts, nuts, etc. required to carry out the removal and
reassemble, the needs for the dummy spools (flanges, pipes, etc.) will be
determined.
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Whenever possible, good quality water shall be used from the beginning
until the end. However, if the quantities involved are very large, and
except for stainless steel materials, it is allowed to carry out the first
flushing operations on a given network with raw water, and to perform the
last one (rinsing) of the same network with a good quality water.
The quality of the water shall comply with the specification for hydrostatic
test and the design basis for the plant respectively.
4.6.2.9 Safety
- Restricted area:
An area of at least 5 meters around the outlet points will be roped off
during the release of water.
- Work permit:
Any water flushing operation shall be subject to specific work permits
according to the safety procedure.
- Restraints:
Wherever necessary, the pipes at the water outlets shall be rigidly fixed to
avoid damage to the lines, equipment and people nearby.
- Environment protection:
Adequate protection of the devices in the vicinity of the water outlet has to
be installed in order not to damage electric motors or instruments with
water.
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The flow / discharge pressure curve of the pump can also be used to
check the flow rate (make sure the pump runs at its normal speed).
When the main header of the network is deemed clean (see 4.6.4), stop
the water flow and prepare the network to flush the connections and
smaller diameter pipelines.
When the complete network has been flushed satisfactorily, the circuit
shall be rinsed if necessary.
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The duration of the flushing is the time needed for the outlet water to be as
clean as it is at the inlet (take two samples in glass bottles and compare),
and shall also be sufficient to open all the vents, drains, impulse lines
(when the instruments are disconnected) and to obtain clean water at
each of these points.
- Air quality:
For some operations, especially instrument air system, oil free air and/or
dry air might be needed (temporary drier and oil extractor may be
necessary).
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- In the gas process lines, the velocity shall be the lowest figure
between 60 m/s and the velocity obtained at 1.3 time the maximum
process flow rate. The minimum velocity shall be 30 m/s.
The total volume of the network shall be estimated and the time required
to raise the pressure up to 6 bars with the compressor(s) shall be
calculated.
If the quick decompression method is used, the air pressure in the network
shall never exceed 6 bars. It should also be checked that all pipes and
vessels of the network are designed to withstand a pressure of 6 bars.
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A site review shall be made to determine the possible air inlets, the
possible outlets, and the necessary temporary pipes (avoid hose pipes
when possible). Detailed drawings shall be prepared if necessary,
and the required equipment to be supplied and installed (pipes, valves,
gaskets) shall be determined.
Where the quick decompression method has been selected, the pressure
release can be obtained by:
In the first case, the flow rate may be roughly adjusted, if necessary, and
the valve may be closed in case of emergency; in the second case, no
control is possible.
Due to the high velocity involved, the quick opening valve might be eroded
if it is used in an intermediate state (i.e. not completely opened).
Therefore, whenever possible, the valve shall be completely open.
Attention shall be paid to tray manholes and other internals of the vessels
used as air capacities (quick decompression method).
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Due to the high forces generated at the air outlet, the following particular
precautions shall be taken for blowing operations:
- Restricted area:
An area of at least 30 meters around the outlet points will be roped off
during the release of air.
- Work permit:
Any air blowing operation shall be subject to specific work permits
according to the safety procedure.
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- Environment protection:
The large quantities of dirty air released during the flushing carries
particles of sand, rust. welding rods, .etc. which could damage
nearby equipment. Therefore adequate protection has to be
installed.
- Personnel protection:
Protection of personnel carrying out the operation must be ensured
by suitable protective equipment, i.e. ear protection, gloves,
coveralls, goggles as a minimum.
Identical to 4.6.2.10.
- Allow the air flow to enter the network up to the calculated flow rate
(check by difference at the outlet of the compressor, before and after).
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- If a quick opening valve is used, allow the air to enter the network and
carefully check that pressure in the system never exceeds the maximum
allowable pressure. When the required pressure is reached, check that all
safety measures have been adhered to, and open the valve. If necessary,
this operation shall be repeated several times (see cleanliness criteria in
paragraph 4.7.4).
- If a rupture disk is used, after having checked that safety measures have
been taken, allow the air to enter the network; check continuously the
pressure rise, and when the rupture disk blows out, stop the air inlet in the
network. The operation shall be repeated several times (see cleanliness
criteria in paragraph 4.7.4).
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- Color of the air at the exit point. This will roughly indicate whether or not
rust and dirt remain in the piping. This is usually sufficient for the majority
of process and utilities piping.
- The principle differences between air blowing and steam blowing are:
- The main advantage of steam over air is the embrittlement of pipe wall
deposits, especially millscale, caused by temperature changes between
blowings and the subsequent contraction of the piping or equipment
causing a cracking effect on pipe wall deposits.
Very high forces are generated at the steam outlet. Therefore, specific
safety procedures must be closely adhered to; generally steam blowing
operations shall be done when most of the other works in the area have
been stopped, personnel which will stay in the area should be
informed/warned before blowing, hearing protection is mandatory.
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During cleaning operation, the steam velocity shall be the lowest figure
between 60 m/s and the velocity obtained at 1.3 time the maximum
process flow rate. The minimum velocity shall be 30 m/s.
A site review shall be made to determine the possible steam outlets and
the necessary temporary pipes and devices. Detailed drawings shall be
prepared if necessary, and the required equipment to be supplied and
installed (pipes, valves, gaskets) shall be determined.
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The drawings for the additional pipes to be manufactured and erected may
be drawn if required. The required material (pipes, valves, gaskets, etc.)
and the means (monorails, cranes, pulleys blocks, etc.), tools, gaskets,
grease for bolts, nuts, etc. required to carry out the removal and
reassemble, the needs for the dummy spools (flanges, pipes, etc.) will be
determined.
4.8.2.9 Safety
About two thirds of the total heat in steam is taken up in the change of state from
boiling water to steam, and hence when steam condenses, two thirds of its total
heat is given up to the body on which it condenses. This is what makes steam
such an effective heating fluid, and this is also what makes it very dangerous if it
condenses on the human body. Hence to get a part of the body in a jet of steam
is many times worse than in a corresponding flow of hot air at the same
temperature .
- When blowing steam lines make sure that everyone is clear of the area.
- Follow the guidelines laid down for air blowing operations (see paragraph
4.7.2.9).
- Personnel must always be adequately clothed when working in the
proximity of steam lines. Shorts and tee-shirts are forbidden.
- Close liaison with boiler house personnel is required.
Identical to 4.6.2.10.
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Initially steam should be slowly introduced into the system to allow a steady
temperature rise in the piping or equipment. Condensate must be drained from
all low points to avoid producing water slugs which could be propelled at high
velocity through the piping causing hydraulic shock and possible damage.
When steam blowing small diameter lines the normal block-valves may be used
for a limited time and should not be liable to damage.
When a steam blow has been completed, ensure the piping and equipment are
adequately vented to avoid pulling a vacuum during the cool down period. If
required, cool down can be accelerated by the injection of service air.
Additionally, target plates may be used if the steam line will feed a steam turbine.
- A polished aluminum or soft metal target plate is attached to the target plate
carrier on the tailpipe end (see the following figure)
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- If the exhaust steam appears to be clean install a target plate and steam
blow the system.
- If the plate has became eroded and pitted, easily seen by a matt gray
appearance and surface pitting, continue steam blowing.
- The target plate surfaces will become brighter after each subsequent
blowing.
- When the plate surface remains bright it will be possible to count the
number of impact pits per blow caused by large dirt or rust particles.
- When the plate remains unmarked it may be assumed that the piping is
clean.
In the case that target plates will be used, note that wet steam may produce a
"matting" effect on a polished target plate which can be misleading. In this case
look for pitting marks as a general guideline.
Reassemble the piping taking care not to reintroduce dirt into the equipment.
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- Field of application:
- Degreasing:
- Treatment:
- Solution handling:
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Calculate the amount of chemicals and water for treatment and rinsing.
During cleaning operation, the chemical solution velocity shall not reach
the high figures as given in chapters 4.6 to 4.8 to avoid erosion. For
chemical cleaning it is important that all surfaces to be cleaned are in
good contact with the solution, the high velocities are here not so
important as for mechanical cleaning.
Estimate the maximum head loss. With the velocity actual, estimate the
head loss for a flow going through the principal piping and add the static
head (if any). If the flow and the head loss are compatible with the pumps
available on the site, go ahead, otherwise reduced flow or external pump
has to be considered.
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Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Blinds used for chemical cleaning operations, if they are necessary they
will be indicated and numbered with a red color. Installation and removal
of blinds shall be followed up by commissioning by the mean of a blind list.
Installed blinds shall be tagged and equipped with a visible handle painted
red.
A site review shall be done to determine the possible solution and water
inlets and outlets, the water source, the pump(s) location, the additional
pipes or hose pipes layout from the source to the system.
The water disposal problem and the protection of the equipment and
people nearly shall be carefully studied.
The drawings for the additional pipes to be manufactured and erected may
be drawn if required. The required material (pipes, valves, gaskets, etc.)
and the means (monorails, cranes, pulleys blocks, etc.), tools, gaskets,
grease for bolts, nuts, etc. required to carry out the removal and
reassemble, the needs for the dummy spools (flanges, pipes, etc.) will be
determined.
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Good quality of fresh water and or demineralized water shall be used from
the beginning until the end.
The quality of the water shall comply with the specification for hydrostatic
test and the design basis for the plant respectively.
4.9.2.9 Safety
- Restricted area:
An area of at least 5 meters around the system will be roped off or closed
off during the cleaning operation.
- Work permit:
Any chemical cleaning operation shall be subject to specific work permits
according to the safety procedure.
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
- Environment protection:
Adequate protection of the devices in the vicinity of the system and water
outlet has to be installed in order not to damage equipment, electric
motors or instruments with chemical solution or water.
- Personal protection:
Protection of personnel carrying out the operation must be ensured by
suitable protective equipment, i.e. gloves, boots, coveralls, goggles, etc..
The flow / discharge pressure curve of the pump can also be used to
check the flow rate (make sure the pump runs at its normal speed).
When the complete system has been cleaned satisfactorily, the circuit
shall be emptied chemical solution.
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Then the system may be dried out with air or inert gas, if necessary, and
the removed devices shall be reassembled.
The duration of the cleaning is the time needed for the reaction of the
chemicals with the oil and greasy material in the whole system expressed
as retention time plus an additional safety margin. Test on side may be
carried out if necessary.
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries