Specification No 1652109-8.

0 Info No 300969

POWER PLANT SPECIFICATION

SUBJECT: CHEMICAL CLEANING OF CARBON STEEL PIPING SYSTEMS
Author : TMO Date: 950710 Approved: TKS Page: 1/8

General

This specification deals with the chemical cleaning of the carbon steel piping systems.

The piping systems mentioned in this specification are indicated in the Line List,
referring to this specification.

Prior to the chemical cleaning of the piping systems, pressure testing and mechanical
cleaning has to be executed. The piping systems have to be completely cleaned from
grease and oil.

When cleaning the piping systems chemically, the pipe section is exposed to an acid
solution. During the reaction between the acid and the surface of the pipe material, the
surface is cleaned from all remnants of rolling skin, oxidations etc. left over from the
mechanical cleaning. This treatment is also known as pickling. After the pickling the
pipe section is treated with a phosphate solution which provides the pipes with a
phosphate layer giving a short time protection against oxidation.

When the chemical cleaning is executed, the internal of the pipe section is completely
cleaned, and only the metallic surface of the base material must be visible.

The purpose of chemical cleaning is to protect the delicate components of the GenSet
from particles, which may cause damage or reduce the time of operation of the
components and the GenSet.

The chemical cleaning of the piping systems is normally used when the demand for
cleanliness is higher that it is possible to obtain by mechanical cleaning. Normally, the
chemical cleaning is followed by a flushing of the piping systems. (Flushing
specifications are not described in this specification).

The chemical cleaning of the piping systems has to be carried out in accordance with
the guidelines of the MBD-H supervisor. The chemical cleaning will not be accepted
without an approval from the MBD-H supervisor.
Specification No 1652109-8.0 Info No 300969

POWER PLANT SPECIFICATION

SUBJECT: CHEMICAL CLEANING OF CARBON STEEL PIPING SYSTEMS
Author : TMO Date: 950710 Approved: TKS Page: 2/8

Methods of Chemical Cleaning

The chemical cleaning of the piping systems can be executed according to:

A. a conventional treatment sequence of acid bath - water bath - lye

bath.

Short description:

Conventional and aggressive, but "easy to get" chemicals are used.

The execution of the treatment requires open baths for the chemical
solutions and heating-up facilities for the phosphate solution. Further,
the method requires a great deal of manual work, and therefore, there
must be paid great attention to the safety precautions.

B. an alternative treatment with simultaneously pickling and

phosphatizing.

Short description:

Sophisticated, but non-aggressive and non-polluting chemicals are

used. The execution of the treatment requires a vessel and a pump.
No heating-up facilities are necessary. Compared to method A the
need for manual workforce and safety precautions is very reduced.

With respect to the quality of the chemical cleaning, there should be no difference
whether method A or method B is executed.
Specification No 1652109-8.0 Info No 300969

POWER PLANT SPECIFICATION

SUBJECT: CHEMICAL CLEANING OF CARBON STEEL PIPING SYSTEMS
Author : TMO Date: 950710 Approved: TKS Page: 3/8

Execution of Work

Method A - Conventional Treatment

Preparation of the Piping System

The piping system in question has to be dismantled in each flange connection. All
components, valves, filters, pumps etc. are not to be included in this cleaning
operation, but have to be checked, and if necessary, carefully cleaned. All components
are to be sealed and preserved.

Preparation of the Hydrochloric Acid Bath

The hydrochloric acid (HCL) is commercially available with a concentration of 31-

33% and an arsenic content of less than 1%. The solution is prepared by mixing the
hydrochloride acid with clean potable water.

Mixing ration of the hydrochloric bath HCL : H2O = 3 : 2 (parts by weight).

CAUTION: Pour the acid into the water and never vice versa!

The temperature of the bath must not be below 20°C.

Preparation of the Water Bath

A bath with clean potable water must be prepared.

Preparation of the Lye Baths

The lye solution is prepared by mixing trisodium phosphate (Na3PO4) with clean
potable water.

Mixing ration of the lye bath Na3PO4 : H2O = 1 : 8 (parts by weight)

The treatment temperature must be 80°C. A heating-up device must be installed in the
lye bath.
Specification No 1652109-8.0 Info No 300969

POWER PLANT SPECIFICATION

SUBJECT: CHEMICAL CLEANING OF CARBON STEEL PIPING SYSTEMS
Author : TMO Date: 950710 Approved: TKS Page: 4/8

Method A - Conventional Treatment........(continued)

Safety Precautions

At hydrochloric acid baths and the lye baths, the fumes must be exhausted by
ventilators and led out into the open. Attention has to be paid to the local safety and
precaution regulations.

In compliance with the safety and precaution regulations on handling acids and lyes,
every person carrying out acid and lye treatment has to wear acid-resistant clothing,
rubber boots, rubber gloves and goggles. A connected water hose always has to be
kept ready for flushing and neutralizing in case of accidents.

Treatment of the Pipes

The dismantled pipe sections are put into the hydrochloric acid bath for the pickling
treatment. Attention has to be paid that no pockets of air inside the pipe section are
present. The duration of the treatment has to be determined by visual appraisal.

If any threads already have been made in the pipes, it is necessary to ensure that the tip
of the threads does not sustain damage. The duration of the treatment has to be
reduced accordingly.

After completion of the pickling process, the acid solution still adhering to the pipes
must be washed of in the water bath.

The pipes are then put into the lye bath. Any further remnants of the acid solution still
left in the scores and pores of the superficial structure will be neutralized in the lye
bath. In the lye bath the pipes are provided with a phosphate layer, giving a short time
protection against oxidation. As for the acid bath there must be no pockets of air
inside the pipe section during this operation.

The duration of the lye bath treatment is approximately 2 minutes.

After the lye bath treatment the pipe section are flushed with clean potable water to
remove any remnants of the lye. Hereafter, the pipe sections have to be dried, if
possible, by letting clean compressed air through the pipe section.

The chemical solutions can be used for several treatments of pipe sections. When the
solutions start to “run down”, the duration of the treatments has to be increased
accordingly.
Specification No 1652109-8.0 Info No 300969

POWER PLANT SPECIFICATION

SUBJECT: CHEMICAL CLEANING OF CARBON STEEL PIPING SYSTEMS
Author : TMO Date: 950710 Approved: TKS Page: 5/8

Method A - Conventional Treatment........(continued)

Sealing and Protection of Cleaned Pipe Sections

If quite some time elapses between the chemical cleaning and the mounting of the
piping system, the pipe section must be preserved, and the ends must be closed. For
this purpose plugs or caps in vivid colors are the most suitable as they will not be
overlooked, when mounting.

Disposal of Chemicals

Prior to disposal of the hydrochloride acid bath, the solution has to be neutralized. For
this purpose sodium hydroxide (NaOH) is suitable. By mixing the two chemicals in
the right quantities, the solution turns into salt water.

HCl + NaOH = NaCl + H2O

The solution is neutralized when the pH value is 7, or when the litmus paper does not
change color when dipped in the solution. When neutralized, the solution can be led to
the normal sewerage.

ATTENTION: Disposal of chemicals must be according to the local or national

safety and pre- caution regulations.

The trisodium phosphate solution is to be neutralized with liberally amounts of water.

At normal conditions the solution then can be led to the sewerage.

ATTENTION: Disposal of chemicals must be according to the local or national

safety and pre-caution regulations.
Specification No 1652109-8.0 Info No 300969

POWER PLANT SPECIFICATION

SUBJECT: CHEMICAL CLEANING OF CARBON STEEL PIPING SYSTEMS
Author : TMO Date: 950710 Approved: TKS Page: 6/8

Method B - Alternative Treatment

Preparation of the Piping System

The chemicals used for the alternative treatment are only aggressive to oxidations. On
normal conditions there is therefore no risk of corrosion or pitting of the painting,
rubber, packings, valve sealings etc. during the treatment.

The piping system in question is to be dismantled in each flange connection. All

components, valves, filters, pumps etc. are, if possible, not to be included in this
cleaning operation, but are to be checked, and if necessary, carefully cleaned. All
components are to be sealed and preserved.

The chemicals have to be circulated through the pipe sections by a pumping unit. A
suitable amount of pipe sections has to be assembled to form one single pipeline. As
absolutely no pockets of air are allowed during the treatment, it is of great importance
that the single pipeline is assembled in a way that ensures the escape of the air from
the inside of the piping. The best way to let the air escape, is to arrange the single
pipeline with continuously slope.

The pumping unit is consisting of an open vessel, with a volume capacity of

approximately 2 times the volume of the single pipeline. The vessel is connected to a
centrifugal pump. From here, the pump is connected to the lowest end of the single
pipeline. The other end of the single pipeline is connected to the top of the vessel. The
chemical is pumped from the vessel via the pump and through the single pipeline.
Hoses of plastic or similar are suitable for the connections between the pumping unit
and the single pipeline. A filter has to be installed between the vessel and the pump. In
front of the pump a non-return valve has to be installed. The vessel has to be equipped
with a drain and shut of valves at all connections.

Treatment of the Pipes, Degreasing

Prior to the pickling treatment, the piping system has to be completely cleaned from
oil and grease. For that purpose the chemical WS50 is used.

The chemical WS50 is poured into the open vessel and mixed with clean potable
water. All the shutoff valves on the vessel have to be closed.

The WS50 chemical is mixed with water to a 0.5% solution.

The temperature of the solution should not be below 10°C.

Specification No 1652109-8.0 Info No 300969

POWER PLANT SPECIFICATION

SUBJECT: CHEMICAL CLEANING OF CARBON STEEL PIPING SYSTEMS
Author : TMO Date: 950710 Approved: TKS Page: 7/8

Method B - Alternative Treatment........(continued)

The chemical solution is mixed in the vessel, the shutoff valves are opened, and the
pump is turned on. The solution is now circulated until the single pipeline is
completely filled and there are absolutely no air pockets in the system. Duration:
Approximately ½ hour.

The WS50 solution is drained from the piping system and the vessel. The system has
to be filled with clean potable water and flushed for about 10 minutes. When the water
flushing is executed, the water is drained from the system.

Treatment of the Pipes, Pickling

After the degreasing the pickling can begin. The chemical VH Deruster is poured into
the open vessel and mixed with clean potable water. All the shutoff valves on the
vessel have to be closed.

The VH Deruster chemical is mixed with water to a 5% solution.

The temperature of the solution should not be below 10oC.

When the chemical solution is mixed in the vessel, the shutoff valves are opened, and
the pump is turned on. The solution is now circulated until the single pipeline is
completely filled, and there are absolutely no air pockets in the system. Duration:
Approximately ½ hour.

The pump is turned off, and the shutoff valves on the vessel are closed. The chemical
solution has to rest in the piping for 5-6 hours. Then the shutoff valves are opened,
and the pump is turned on. The solution has to be circulated again for ½ hour. The
pump is turned off, and the shutoff valves closed. Again, the chemical solution has to
rest inside the piping for about 5-6 hours.

After the resting period the piping is inspected. If further treatment is necessary, the
above described procedure is repeated. If not, the chemical solution is drained from
the vessel and the single pipeline. The solution cannot be reused. The vessel is filled
with clean potable water, and the single pipeline is flushed by using the pump. If
necessary, the water flushing is repeated until all the chemical remnants have been
removed.

After completion of the treatment the single pipeline has to be dismantled and dried
by letting clean compressed air, or if possible, nitrogen through the pipe section.
Specification No 1652109-8.0 Info No 300969

POWER PLANT SPECIFICATION

SUBJECT: CHEMICAL CLEANING OF CARBON STEEL PIPING SYSTEMS
Author : TMO Date: 950710 Approved: TKS Page: 8/8

Method B - Alternative Treatment........(continued)

Sealing and Protection of Cleaned Pipe Sections

If quite some time elapses between the chemical cleaning and the mounting of the
piping system, the pipe section must be preserved and the ends must be closed. For
this purpose plugs or caps in vivid colors are the most suitable as they will not be
overlooked, when mounting.

Disposal of Chemicals

Both the chemical solutions of the WS50 and the VH Deruster pH neutral are non-
poisonous. The solutions can be led into the normal sewerage.

ATTENTION: Disposal of chemicals must be according to the local or national

safety and precaution regulations.