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Saep 388 PDF
Saep 388 PDF
Saep 388 PDF
1 Purpose...........................................................2
2 Scope………………………………………...…. 2
3 Applicable Documents.....…………………….. 2
4 Responsibilities………………………………… 3
5 Techniques for Cleaning Pipelines.….…….… 6
6 Surfactant Cleaning Procedure..……………... 8
7 Sampling and Acceptance Criteria..…….….. 19
8 Evaluating Chemical
Cleaning Performance..…………...…… 20
9 Wastewater Disposal……………..……..…… 20
1 Purpose
Cleaning contractors are chosen from the CSD-approved list to perform the cleaning
operations. A cleanliness criterion has been established as a minimum standard for
evaluating the performance of a chemical cleaning run. Cleaning is accomplished by
(not necessarily in the sequence listed below):
● Mechanical cleaning (scraping)
● Chemical cleaning
● Combination of listed above methods
2 Scope
This procedure defines the responsibilities of various departments involved in the pre
commission and operational cleaning of pipelines. It outlines methods to determine the
need for cleaning and the criteria for selecting specific cleaning procedure, and steps
involved in various cleaning procedure alternatives. Advice is available from
Consulting Services Department (CSD) and Pipelines Department (PD) to review
contractors’ detailed procedures for cleaning specific pipelines.
The procedures listed herein are applicable to clean undesirable deposits in pipelines.
For evaluation and recommendation of alternative cleaning procedures not listed herein,
contact CSD.
For cleaning pipelines containing valves, contact CSD, see Appendix IV.
3 Applicable Documents
The requirements contained in the following documents apply to the extent specified in
this procedure.
Page 2 of 24
Document Responsibility: Corrosion Control Standards Committee SAEP-388
Issue Date: 23 October 2013
Next Planned Update: 23 October 2018 Cleaning of Pipelines
4 Responsibilities
4.1 The Project Construction Agency is responsible for the overall cleaning activities
of new pipelines.
Page 3 of 24
Document Responsibility: Corrosion Control Standards Committee SAEP-388
Issue Date: 23 October 2013
Next Planned Update: 23 October 2018 Cleaning of Pipelines
4.5 Pipelines/Inspection
● Has the responsibility for inspection before and after cleaning.
● Is responsible to get and keep the cleaning activities records from the
cleaning contractor
● Maintains history of pipelines cleaning and incorporates relevant reports and
data into permanent pipelines records
Page 4 of 24
Document Responsibility: Corrosion Control Standards Committee SAEP-388
Issue Date: 23 October 2013
Next Planned Update: 23 October 2018 Cleaning of Pipelines
4.11 Design Review Requirements for Pipelines Projects and Major Pipelines Upgrade
The DBSP and Project Proposal packages submitted to CSD for review shall
specifically state the need for mechanical/chemical cleaning.
Detailed Design
Page 5 of 24
Document Responsibility: Corrosion Control Standards Committee SAEP-388
Issue Date: 23 October 2013
Next Planned Update: 23 October 2018 Cleaning of Pipelines
Pipelines are either pre-commission cleaned to remove mill scale, construction debris
and any form of solids, or post-commission cleaned to remove deposits which
accumulate while the line is in service.
Newly constructed pipelines are to be turned over to the proponent in a clean condition.
To accomplish this clean condition, these pipelines are typically
chemically/mechanically cleaned to remove construction debris and any form of solids.
Depending on the deposit present, scraper design can be hard rubber, silicon
carbide, hardened steel wire, or gel. Sometimes balls with scraper chains are
used. A series of scrapers, in larger sizes, is run through the line until all the
fouling is removed.
Page 6 of 24
Document Responsibility: Corrosion Control Standards Committee SAEP-388
Issue Date: 23 October 2013
Next Planned Update: 23 October 2018 Cleaning of Pipelines
For cleaning newly constructed pipelines and existing off stream pipelines, refer
to SABP-L-012 “Guidelines for On-Stream Scraping of Pipelines”. The scrapers
will be propelled by Nitrogen, dry gas or dry hydrocarbon medium using the
cleaning contractor equipment.
The chemical cleaning operation is typically done while the pipeline is in service
or out of service and will be specified by Pipelines Department. The chemical
cleaning methods typically fall under two methods: 1) use of chemicals with
diesel or 2) use of chemicals with gel. Water is not to be used as a mixing
medium when surfactants are used. The chemical cleaning train that contains
the chemicals compartment is typically propelled with dry air or nitrogen.
If air is used to propel the chemical cleaning train, a nitrogen buffer zone
between the chemical train and air is to be utilized. This nitrogen buffer zone
shall be placed immediately upstream and downstream of the chemical cleaning
train. The nitrogen length on each side shall be no less than 10% of the total
length of the pipeline section being chemically cleaned to ensure that diesel and
air do not mix.
Deposits normally include black powder, rust, scale, grease, weld spatter, stones,
etc. Scales and grease are chemically soluble but beads of weld metal are not,
although it is possible for a chemical cleaning operation to loosen these by
undercutting. In this state, they may become detached while the line is in service.
In practice, chemical cleaning should be used to remove soluble scale and grease
but should be followed by multiple scrapers. The line should also be dried as
specified under SAES-A-007 to prevent subsequent corrosion immediately after
cleaning. In the case of pipelines, these shall be filled with nitrogen, dry gas or
dry crude as soon as possible after cleaning. Due to the network length of
piping involved, communication between members of the cleaning crew can be
difficult, and shall be addressed prior to start of the job. Lines containing iron
sulfide will release H2S gas when contacted with acid and suitable precautions
have to be taken as per Chemical Hazard Bulletin (CHB) # 155.
Page 7 of 24
Document Responsibility: Corrosion Control Standards Committee SAEP-388
Issue Date: 23 October 2013
Next Planned Update: 23 October 2018 Cleaning of Pipelines
Cleaning Chemicals
There are mainly two chemical categories used for pipelines cleaning:
1. Acids
For detailed chemical cleaning procedure using acids, refer to
SAEP-1662 “Cleaning of Heat Exchangers and Unfired Plant
Equipment”.
2. Surfactants
Surfactants chemicals are non-corrosive compounds that lower the
surface tension of a liquid, the interfacial tension between two liquids,
or that between a liquid and a solid. Surfactants may act as detergents,
wetting agents, emulsifiers, foaming agents, and dispersants.
For the approved list of surfactants, or approval of new ones, refer to CSD.
The chemical cleaning procedure shall include the valve arrangements before, during, and
after each chemical cleaning run. It shall also include the detailed chemical train
launching procedure, the monitoring and tracking of the chemical train, and the receiving
procedure. The procedure shall also include the data monitoring such as upstream and
downstream pressure of the chemical train, its velocity, and any other important data.
Page 8 of 24
Document Responsibility: Corrosion Control Standards Committee SAEP-388
Issue Date: 23 October 2013
Next Planned Update: 23 October 2018 Cleaning of Pipelines
Equipment Layout:
VALVE DESCRIPTION:
VALVE DESCRIPTION
MIV Main Isolation Valve
A Chemical/Diesel Injection Valve
B N2/Air Main Injection Valve
C N2/Air Branch Injection Valve
D N2/Air Branch Injection Valve
V1 Launcher Vent
V2 Launcher Vent
Page 9 of 24
Document Responsibility: Corrosion Control Standards Committee SAEP-388
Issue Date: 23 October 2013
Next Planned Update: 23 October 2018 Cleaning of Pipelines
Surfactant cleaning of the pipeline shall be executed to ensure the removal of any sand,
corrosion products such as iron carbonate, iron oxides and iron sulfide, metallic iron, weld
spatter, salt and scale generated during the dewatering and swabbing.
Specific chemical cleaning train should be designed for the entire pipeline in the scope of
the procedure. The segment of pipeline from permanent launcher to permanent receiver
trap is to be chemically cleaned by two (2) cleaning train/runs with additional optional runs
if required. Refer to Figure 1 “Chemical Cleaning Train” for its configuration.
Pre-requisites:
Prior to start the surfactant cleaning train run, an initial back pressure of minimum 40 psig
shall be ensured in order to perform the run in controlled manner and within the required
velocity.
The medium to build up the back pressure and to propel the chemical cleaning train shall be
with nitrogen and dry air having a minimum dew point -1°C. Record log of the dry air dew
point shall be maintained during the back pressure build up and the train run. Dew point
reading shall be taken as the dry air entering into the pipeline every 4 hours.
A slug of nitrogen will be injected upstream and downstream of the cleaning train to create
a buffer zone between the dry air and the cleaning train.
Please refer to Table 1 “Chemical Train Composition and Run Duration” for its volume.
The specified gallons of nitrogen provided in Table 1 is equivalent to at least 20% of the
pipeline length that will be cleaned (10% before that cleaning train and 10% after the
cleaning train).
Whenever the surfactant cleaning is completed as per the approved chemical cleaning
procedure, then the pipeline as required shall be purged and pressurized to a minimum
pressure of 30 psig (Nitrogen) in preparation to the introduction of the transported media.
The planned cleaning run for the pipeline segment along with the expected amount of
chemicals and diluents are to be shown in Table 1.
Page 10 of 24
Document Responsibility: Corrosion Control Standards Committee SAEP-388
Issue Date: 23 October 2013
Next Planned Update: 23 October 2018 Cleaning of Pipelines
Pipeline
From To
Dry Air
High
First Scraper … Density N/A
Foam
1st Batch of
N2 Gallons XXX
Nitrogen
High
Second Scraper … Density N/A
Foam
Detergent Gallons XXX
st
1 and 2 nd 1st Batch
Diesel Gallons XXX
Surfactant
Cleaning Third Scraper Conical Scraper Brush
Runs** Detergent Gallons XXX
2nd Batch
Diesel Gallons XXX
Fourth Scraper … Scraper Brush
2nd Batch of
N2 Gallons Chemical
Nitrogen
High
Fifth Scraper … Density N/A
Foam
Dry Air
*Estimated run duration Hrs. XXX
* Estimated travel time is based on dry air velocity of 1.0 kilometer per hour. Velocity, volumes of
chemicals and diluents and type of chemicals may be adjusted depending on the gathered
results from the previous runs.
** Optional Run Only When Required.
Vacuum Truck will be used on a regular interval to empty the tanks and dispose
it to an approved waste disposal site/company.
Note: Refer to Appendix III for nitrogen amount calculation.
Page 11 of 24
Document Responsibility: Corrosion Control Standards Committee SAEP-388
Issue Date: 23 October 2013
Next Planned Update: 23 October 2018 Cleaning of Pipelines
Steps Description
1 Rig up equipment for both Launcher and Receiver
2 Deploy hoses supply line for connection
3 Pressurize hose against closed valve for 5 minutes to confirm connection leak test
Nitrogen purity entering the pipeline should be checked by the contractor using a hand held Nitrogen analyzer and as
4 per approved pureness of 95% minimum.
Volume and sequence will be as per Table 1 “Pipeline Chemical Train Composition and Run Duration”
Prepared the chemical required quantity base on Contractor concentration of diluents slug. Volume and sequence
5 will be as per Table 1 “Pipeline Chemical Train Composition and Run Duration”.
Collect one set of sample per batch as per Section 7.
As per pre-requisite, verify and confirm that the line is pack to a minimum 40 psig of nitrogen.
6
Re-packed when necessary.
Page 12 of 24
Document Responsibility: Corrosion Control Standards Committee SAEP-388
Issue Date: 23 October 2013
Next Planned Update: 23 October 2018 Cleaning of Pipelines
Steps Description
VALVE START-UP POSITION:
VALVE STATUS DESCRIPTION
MIV CLOSED Main Isolation Valve
A CLOSED Chemical/Diesel Injection Valve
B CLOSED N2/ Air Main Injection Valve
C CLOSED N2/Air Branch Injection Valve
D CLOSED N2/Air Branch Injection Valve
V1 CLOSED Launcher Vent
V2 CLOSED Launcher Vent
Page 13 of 24
Document Responsibility: Corrosion Control Standards Committee SAEP-388
Issue Date: 23 October 2013
Next Planned Update: 23 October 2018 Cleaning of Pipelines
Steps Description
Cleaning Train
Diesel and Surfactant Injection I Scraper Loading and Launching Sequence.
8
VALVE START-UP POSITION:
VALVE STATUS DESCRIPTION
MIV CLOSED Main Isolation Valve
A CLOSED Chemical/Diesel Injection Valve
B CLOSED N2/ Air Main Injection Valve
C CLOSED N2/Air Branch Injection Valve
D CLOSED N2/Air Branch Injection Valve
V1 CLOSED Launcher Vent
V2 CLOSED Launcher Vent
Page 14 of 24
Document Responsibility: Corrosion Control Standards Committee SAEP-388
Issue Date: 23 October 2013
Next Planned Update: 23 October 2018 Cleaning of Pipelines
Steps Description
Page 15 of 24
Document Responsibility: Corrosion Control Standards Committee SAEP-388
Issue Date: 23 October 2013
Next Planned Update: 23 October 2018 Cleaning of Pipelines
Steps Description
Open Valve A and inject the required amount of surfactant followed by the required amount of diesel.
Refer to Table 1 for the batch volume.
Once fully injected, close Valve A.
Page 16 of 24
Document Responsibility: Corrosion Control Standards Committee SAEP-388
Issue Date: 23 October 2013
Next Planned Update: 23 October 2018 Cleaning of Pipelines
Steps Description
5th Scraper
10
VALVE START-UP POSITION
VALVE STATUS DESCRIPTION
MIV CLOSED Main Isolation Valve
A CLOSED Chemical/Diesel Injection Valve
B OPENED N2/ Air Main Injection Valve
C CLOSED N2/Air Branch Injection Valve
D CLOSED N2/Air Branch Injection Valve
V1 CLOSED Launcher Vent
V2 CLOSED Launcher Vent
Page 17 of 24
Document Responsibility: Corrosion Control Standards Committee SAEP-388
Issue Date: 23 October 2013
Next Planned Update: 23 October 2018 Cleaning of Pipelines
Steps Description
After the scrapers have been received from the final cleaning run, the remaining collected sludge or waste
materials from the fractionation tanks will be transferred and disposed via vacuum tanker to an approved waste
disposal site/company.
Page 18 of 24
Document Responsibility: Corrosion Control Standards Committee SAEP-388
Issue Date: 23 October 2013
Next Planned Update: 23 October 2018 Cleaning of Pipelines
Sampling of cleaning batch (before injection) will be taken at the launching (from
tanks) and receiving locations (from scraper trap) in order to monitor the surfactant
cleaning run.
7.1 Clean containers will be used to collect the samples and they shall be clearly
identified with the following information:
o Pipeline Name, Date, Location (KM), and Batch Number
Page 19 of 24
Document Responsibility: Corrosion Control Standards Committee SAEP-388
Issue Date: 23 October 2013
Next Planned Update: 23 October 2018 Cleaning of Pipelines
Refer to SAES-L-388.
9 Wastewater Disposal
Disposal of all wastewater, and spent cleaning chemicals shall be in accordance with
SAEP-327, SAES-A-104 and Saudi Aramco Hazardous Waste Code (SAHWC).
The disposal of effluents outside Saudi Aramco facilities shall be sent to an approved
wastewater disposal facility provided by the Environmental Protection Department,
Dhahran. For the disposal of effluents outside Saudi Aramco facilities, the chemical
cleaning contractor shall submit a waste disposal manifest to Saudi Aramco Project
Construction Agency in case of new pipelines or Pipelines Department for existing
pipelines.
Revision Summary
23 October 2013 New Saudi Aramco Engineering Procedure.
Page 20 of 24
Document Responsibility: Corrosion Control Standards Committee SAEP-388
Issue Date: 23 October 2013
Next Planned Update: 23 October 2018 Cleaning of Pipelines
● All personnel shall be aware of emergency procedures and will attend contractor
safety/site introduction meetings on a daily basis before the start of any work or as
required to ensure that everyone understands his responsibility and what to do in case of
emergency.
● First aid and fire protection equipment shall be kept on the site (launcher and receiver)
Minimum of 2 dry powder fire extinguishers (30 lb) shall be available on both sites.
● All involved personnel on site shall wear proper protective equipment (PPE).
This includes fire resistance coveralls, Neoprene, PVC or NBR gloves or nitrile rubber,
Safety Glasses and Steel Toed Shoes/chemical resistant boot.
● Use of mobile phones and smoking within the scraper trap areas are prohibited.
● Any leaks and repairs identified shall only be corrected when the system under test has
been depressurized to zero.
● Provide an effective eye wash station and emergency shower per SAES-B-069 on both
launching and receiving station.
● If chemicals are needed, chemical Material Safety Data Sheets (MSDS) should be
attached with the chemical containers and fully understand by all personnel handling it.
● Job Safety Analysis (JSA) shall be performed by the proponent before starting the
cleaning activities of pipelines. For more chemical cleaning safety information, refer to
SAEP-1662.
Page 21 of 24
Document Responsibility: Corrosion Control Standards Committee SAEP-388
Issue Date: 23 October 2013
Next Planned Update: 23 October 2018 Cleaning of Pipelines
● For new pipelines cleaning, SAPMT to identify the overall responsible scraping and
cleaning activity coordinator. This coordinator shall ensure that all steps in this
procedure are followed. He should also ensure all safety measures are implemented.
The implementation of this procedure shall be under the direction and supervision of the
operation site coordinator. During the entire cleaning operations, Project inspection
shall be present at all times on site to ensure the monitoring of the chemical cleaning
operations and that it is going according to plan. Constant communications by
personnel on site on the conditions of the chemical cleaning operations shall be done.
● For existing pipelines cleaning, the above mentioned responsibilities will be under
Pipelines Department.
● The work shall be carried out in accordance with company Standards and General
Instructions. These will include, but not limited to the following:
● Check to ensure that all scraper traps' isolation valves and all pertinent branch valves
are not passing. If valves are passing, perform the necessary maintenance to stop the
passing valves.
Page 22 of 24
Document Responsibility: Corrosion Control Standards Committee SAEP-388
Issue Date: 23 October 2013
Next Planned Update: 23 October 2018 Cleaning of Pipelines
Example:
The volume of liquid nitrogen you need to fill 36” pipeline with a length of 1 km at pressure of 60 psi
and temperature of 40C:
r = 18 “= 0.4572 meters
l = 1000 meters
T2 = 40C = 313 K
Then: =
Page 23 of 24
Document Responsibility: Corrosion Control Standards Committee SAEP-388
Issue Date: 23 October 2013
Next Planned Update: 23 October 2018 Cleaning of Pipelines
● It is always recommended not to operate the valve in a dry condition since it can cause
damage to the seat area. In order to avoid such failure it always recommended to “top
up” the valve prior to any cycling: This will also help to push away any foreign debris
that may have become stuck in the grease from the seal face. Any abrasive
contaminants will do far less damage if well lubricated.
● The compatibility of the used chemical with valve soft insert to be checked and
confirmed.
● Avoid stroking the valve during the pipeline cleaning to avoid any exposure to the valve
seating area: In case the valve cavity filling is required, then a Jumper Hose Assembly
Method is recommended where jumpers hose assembly from the pipeline to the valve
body cavity through the body drain/vent valve.
● At the end of the cleaning process, selected valves might be removed for visual
inspection and seat testing if required. If this is not practical then an inside-out air seat
test to be performed on line to ensure that there was no damage to the valve due to the
commissioning activities.
Page 24 of 24